COMPUTER AIDED OPTIMAL HEAT EXCHANGER NETWORK SYNTHESIS BY A TWO-STAGE METHOD

This paper presents a two-stage method for the optimal heat exchanger network synthesis.In the firststage based on the study of the pinch point properties,a network minimizing the utility consumption and thenumber of exchangers is developed.Usually,this network is close to the optimal.In the second stage,anonlinear programming formulation is developed,and its solution with features of minimum capital andannual operating costs provides an improvement on the network obtained in the first stage.An integratedsoftware package for heat exchanger network synthesis has been developed.This package consists of a sp-readsheet,a graphics program,a data base management system,a menu program,an application networksynthesis program,a network simulation program and a data base of standard size exchangers.The appli-cation of this method is illustrated with several examples which include a complex crude oil preheating heatexchanger network.     

基于流股虚拟温度综合大规模多流股换热器网络

Effective temperature level of stream, namely stream pseudo temperature, is determined by its actual temperature and heat transfer temperature difference contribution value. Heat transfer temperature difference contribution value of a stream depends on its heat transfer film coefficient, cost per unit heat transfer area, actual temperature, and so on. In the determination of the suitable heat transfer temperature difference contribution values of the stream, the total annual cost of multistream heat exchanger network （MSHEN） is regarded as an objective function, and genetic/simulated annealing algorithm （GA/SA） is adopted for optimizing the heat transfer temperature difference contribution values of the stream. The stream pseudo temperatures are subsequently obtained. On the basis of stream pseudo temperature, optimized MSHEN can be attained by the temperature-enthalpy （T-H） diagram method. This approach is characterized with fewer decision variables and higher feasibility of solutions. The calculation efficiency of GA/SA can be remarkably enhanced by this approach and more probability is shown in searching the global optimum solution. Hence this approach is presented for solving industrial-sized MSHEN which is difficult to deal by traditional algorithm. Moreover, in the optimization of stream heat transfer temperature difference contribution values, the effects of the stream temperature, the heat transfer film coefficient, and the construction material of heat exchangers are considered, therefore this approach can be used to optimize and design heat exchanger network （HEN） with unequal heat transfer film coefficients and different of construction materials. The performance of the proposed approach has been demonstrated with three examples and the obtained solutions are compared with those available in literatures. The results show that the large-scale MSHEN synthesis problems can be solved to obtain good solutions with the modest computational effort.     

用伪并行遗传/模拟退火算法进行多流股换热器网络综合的研究

The multi-stream heat exchanger network synthesis (HENS) problem can be formulated as a mixed integer nonlinear programming model according to Yee et al. Its nonconvexity nature leads to existence of more than one optimum and computational difficulty for traditional algorithms to find the global optimum. Compared with deterministic algorithms, evolutionary computation provides a promising approach to tackle this problem. In this paper, a mathematical model of multi-stream heat exchangers network synthesis problem is setup. Different from the assumption of isothermal mixing of stream splits and thus linearity constraints of Yee et al., non-isothermal mixing is supported. As a consequence, nonlinear constraints are resulted and nonconvexity of the objective function is added. To solve the mathematical model, an algorithm named GA/SA (parallel genetic/simulated annealing algorithm) is detailed for application to the multi-stream heat exchanger network synthesis problem. The performance of the proposed approach is demonstrated with three examples and the obtained solutions indicate the presented approach is effective for multi-stream HENS.     

基于专家系统和遗传算法的换热网络的建模和优化

A new superstructure from of heat exchanger networks(HEN) is proposed based on expert system (ES). The new superstructure from is combined with the practical engineering.The different investment cost formula for different heat exchanger is also presented based on ES.The mathematical model for the simultaneous optimization of network configuration is established and solved by a genetic algorithm.This method can deal with larger scale HEN synthesis and the optimal HEN configuration is obtained automatically.Finally,a case study is presented to demonstrate the effectiveness of the method.     

多管程换热器换热网络的合成

Many methods have been proposed for synthesis of heat exchanger networks in recent years, most of which consider single pass exchangers. In this study some evolutionary rules have been proposed for synthesis of multipass exchanger networks. The method is based on the heuristic that optimal networks should feature maximum energy recovery and have the minimum number of shells. The effectiveness of the developed evolutionary rules is demonstrated through some literature examples.     

A numerical study on heat transfer enhancement and design of a heat exchanger with porous media in continuous hydrothermal flow synthesis system

The aim of this study is to use a new configuration of porous media in a heat exchanger in continuous hydrothermal flow synthesis (CHFS) system to enhance the heat transfer and minimize the required length of the heat exchanger.For this purpose,numerous numerical simulations are performed to investigate performance of the system with porons media.First,the numerical simulation for the heat exchanger in CHFS system is validated by experimental data.Then,porous media is added to the system and six different thicknesses for the porous media are examined to obtain the optimum thickness,based on the minimum required length of the heat exchanger.Finally,by changing the flow rate and inlet temperature of the product as well as the cooling water flow rate,the minimum required length of the heat exchanger with porous media for various inlet conditions is assessed.The investigations indicate that using porous media with the proper thickness in the heat exchanger increases the cooling rate of the product by almost 40％and reduces the required length of the heat exchanger by approximately 35％.The results also illustrate that the most proper thickness of the porous media is approximately equal to 90％ of the product tube's thickness.Results of this study lead to design a porous heat exchanger in CHFS system for various inlet conditions.     

A systematic approach for synthesizing a low-temperature distillation system

In this paper, by combining a stochastic optimization method with a refrigeration shaft work targeting method, an approach for the synthesis of a heat integrated complex distillation system in a low-temperature process is presented. The synthesis problem is formulated as a mixed-integer nonlinear programming (MINLP) problem, which is solved by simulated annealing algorithm under a random procedure to explore the optimal operating parameters and the distillation sequence structure. The shaft work targeting method is used to evaluate the minimum energy cost of the corresponding separation system during the optimization without any need for a detailed design for the heat exchanger network (HEN) and the refrigeration system (RS). The method presented in the paper can dramatical y reduce the scale and complexity of the problem. A case study of ethylene cold-end separation is used to il ustrate the application of the approach. Compared with the original industrial scheme, the result is encouraging.     

基于温度和热容流率同时变化的有分流换热网络弹性设计的研究

A new superstructure model of heat exchanger networks (HEN) with stream splits based on rangers of streams supply temperatures and heat capacity flow rates is presented. The simultaneous optimal mathematical model of flexible HEN synthesis is established too. Firstly, the streams with rangers of supply temperatures and/or the streams with the rangers of heat capacity flow rates are pretreated; Secondly, several rules are proposed to establish the superstructure model of HEN with splits and the simultaneous optimal mathematical model of flexible HEN; Thirdly, the improving genetic algorithm is applied to solve the mathematical model established at the second step effectively, and the original optimal structure of HEN based on the maximum operation limiting condition can be obtained easily; Finally, the rules of heat exchange unit merged and the heat load of heat exchanger relaxed are presented, the flexible configuration of HEN satisfied the operation condition between the upper and down bounds of supply temperature and heat capacity flow rates can be obtained based on the original optimal structure of HEN by means of these rules. A case study demonstrates the method presented in this paper is effective     

Combined mass and heat exchange network synthesis based on stage-wise superstructure model☆

Integrating multiple systems into one has become an important trend in Process Systems Engineering research field since there is strong demand from the modern industries. In this study, a stage-wise superstructure-based method is proposed to synthesize a combined mass and heat exchange network (CM&HEN) which has two parts as the mass exchange network (MEN) and heat exchange network (HEN) involved. To express the pos-sible heat exchange requirements resulted from mass exchange operations, a so cal ed“indistinct HEN super-structure (IHS)”, which can contain the all potential matches between streams, is constructed at first. Then, a non-linear programming (NLP) mathematical model is established for the simultaneous synthesis and optimiza-tion of networks. Therein, the interaction between mass exchange and heat exchange is modeling formulated. The NLP model has later been examined using an example from literature, and the effectiveness of the proposed method has been demonstrated with the results.     

Devise of a W serpentine shape tube heat exchanger in a hard chromium electroplating process

In a hard chromium electroplating process, a heat exchanger is employed to remove the heat produced from the high current intensity in an electroplating bath.Normally, a conventional U shape heat exchanger is installed in the bath, but it provides low heat removal.Thus, this study designs a novel W serpentine shape heat exchanger with identical heat transfer area to the conventional one for increasing heat removal performance.The performance of the heat exchange is tested with various flow velocities in a cross-section in range of 1.6 to 2.4 m·s~(-1).Mathematical models of this process have been formulated in order to simulate and evaluate the heat exchanger performance.The results show that the developed models give a good prediction of the plating solution and cooling water temperature, and the novel heat exchanger provides better results at any flow velocity.In addition, the W serpentine shape heat exchanger has been implemented in a real hard chromium electroplating plant.Actual data collected have shown that the new design gives higher heat removal performance compared with the U shape heat exchanger with identical heat transfer area; it removes more heat out of the process than the conventional one of about 23%.     

A monogenetic algorithm for optimal design of large-scale heat exchanger networks

The optimal design of large-scale heat exchanger networks is a quite difficult task not only due to its non-linear characteristics but also due to a great number of local optima in its solution space. An explicit analytical solution of stream temperatures for the superstructure heat exchanger networks was developed, which reduces number of decision variables significantly. Based on this solution, a mathematical model for synthesis of heat exchanger networks was formulated for searching the optimal configuration of a heat recovery system by a hybrid genetic algorithm. For large-scale heat exchanger networks, a monogenetic algorithm based on the optimization of sub-networks is proposed. In the first step of the optimization, the hybrid genetic algorithm is applied to the synthesis of the whole heat exchanger network for finding the functional groups (sub-networks) rather than the chromosomes (positions of the heat exchangers and splits of the streams) and genes (areas and heat capacity flow rates). Then the monogenetic algorithm for evolution of the functional groups is carried out to improve the HEN. This procedure was applied to examples taken from literature and better results were obtained.     

有分流换热网络的弹性设计-基于温度波动情形

提出了基于温度波动的有分流换热网络的超结构模型和同步优化的弹性设计方法。首先对于起始温度在一定范围内波动的物流进行预处理。即分段处理。然后建立换热网络同步优化的数学模型,最后对分段物流进行合并,并通过能量松弛方法得取满意一定弹性要求的换热网络结构。     

无分流换热网络的弹性设计(Ⅰ)基于温度波动情形

提出了基于温度波动的无分流换热网络的超结构模型和同步优化的弹性设计方法。对于起始温度在一定范围内波动的物流进行预处理即分段处理,并提出了分段原则;提出了基于规则的网络超结构模型并建立了弹性换热网络同步优化的数学模型;采用遗传算法求解了所提出的优化数学模型;提出了分段物流的合并及能量松弛的原则,对分段物流进行合并,并通过能量松弛方法得到优化的弹性换热网络结构。通过几个换热网络的弹性设计,说明了本方法的有效性和应用前景。     

用遗传算法进行多流股换热器网络综合的研究

建立了多流股换热器网络综合数学模型，该模型改进了文献中等温混合的不合理假设。多流股换热器网络综合问题本质上是一个混合整数非线性规划问题(MINLP)，这类问题的非凸非线性的特性使得目标函数存在多个局部最优解。传统的基于梯度的搜索方法在处理这类问题时由于计算规模庞大且极易陷于局部最优解而不再适用，而遗传算法却为解决这类问题提供了很有希望的一个方向。因而对遗传算法求解多流股换热器网络综合问题进行了研究，提出了可以自动产生可行的多流股换热器网络的方法策略，最后通过两个例题说明所提方法是可行的。     

特殊换热网络算例优化与分析

换热网络综合属于混合整数非线性规划问题,具有严重的非凸、非线性特性。为探讨某些换热网络算例可能存在内部公用工程且年综合费用极低的特殊换热网络结构,本文采用了允许公用工程内置的无分流分级超结构模型。基于布谷鸟搜索算法,通过设置最小换热量阀值及以较小概率接受较差结构来指导换热网络结构进化,建立适用于求解换热网络综合问题的优化算法,并对特殊算例的优化结果进行分析。本文列举3个特殊算例,具有热流体的初始温度高于热公用工程的入口温度或热公用工程的进出口温差较大的特征,改进的布谷鸟搜索算法能够搜索到带有内部公用工程的换热网络结构,且年综合费用得到明显下降。结果表明：对于特殊算例,公用工程内置能够优化换热网络的热量分布,节约换热器面积,有效降低换热网络的年综合费用。     

基于热损失的换热网络夹点设计法

现行的换热网络目标方法,在进行换热网络价格估算时,未考虑热物流的热损失。在真实的设计中,换热器壳体保温后仍与环境温度相差较大,则其热损失不可忽略。文章提出了一个新的基于热损失的换热网络夹点设计法,该方法首先以综合费用最小为目标确定出最小温差,然后建立问题表格确定出夹点位置及最小公用工程消耗,最后再进行换热网络设计。文中采用某石油常减压换热网络系统为典型算例对该方法的前两步进行了分析研究,论证了该方法的必要性及可行性。结果表明:该方法与基本Linnhoff夹点技术法估算的投资费用有较大的差距之外,在一定的最小温差下,其与基本Linnhoff夹点技术法确定的夹点位置不同,公用工程消耗也有较大的差距。     

Bypass Selection for Control of Heat Exchanger Network

Considering the flexibility and controllability of heat exchanger networks (HENs), bypasses are widely used for effective control of process stream target temperatures. However, the optimal location for the bypass is generally difficult to design with the trade-off between controllability and capital investments. In this paper, based on the steady-state model of heat exchanger networks the optimal bypass location was firstly selected by iteratively calculating the non-square Relative Gain Array (ns-RGA). To simplify the calculation process, rules of bypass selection were also proposed. In order to evaluate this method, then, the structural controllability of heat exchanger networks was analyzed. With both the consideration of the controllability and capital investments, the bypasses locations were finally selected. A case study on the HEN in Crude Distillation Unit was presented in which the ns-RGA and structural controllability were used to select bypasses and also to evaluate the results.     

SYNTHESIS OF FLEXIBLE HEAT EXCHANGER NETWORKS WITH STREAM NO - SPLITTING(Ⅰ) BASED ON RANGES OF STREAM SUPPLY TEMPERATURES

提出了基于温度波动的无分流换热网络的超结构模型和同步优化的弹性设计方法。对于起始温度在一定范围内波动的物流进行预处理即分段处理,并提出了分段原则;提出了基于规则的网络超结构模型并建立了弹性换热网络同步优化的数学模型;采用遗传算法求解了所提出的优化数学模型;提出了分段物流的合并及能量松弛的原则,对分段物流进行合并,并通过能量松弛方法得到优化的弹性换热网络结构。通过几个换热网络的弹性设计,说明了本方法的有效性和应用前景。     

Interval based MINLP superstructure synthesis of combined heat and mass exchanger networks

An interval based superstructure approach for combining the synthesis of heat and mass exchanger networks is presented in this paper. The technique involves combining the interval based MINLP superstructure (IBMS) for the synthesis of heat exchanger networks (HENs) with that of mass exchanger networks (MENs). The two networks are made to interact through the lean stream in the mass exchange network. The new approach involves the use of the lean substream concept to explore potential mass exchange temperatures. An example which involves a one-lean stream mass exchange problem alongside regeneration and hot and cold utilities is presented.