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An engineering target-oriented multi-scenario heat exchanger network retrofit methodology with consideration of exergoeconomic assessment

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Abstract

Energy efficiency in process systems has attracted increasing attention due to the benefits of decreased greenhouse gas emissions and improvements in sustainability. As a vital solution, the retrofit of heat exchanger networks (HENs) mainly focuses on recombining the existing heat exchangers or modifying the HEN topology by adding/removing heat exchangers. Yet, there are still challenges that need to be addressed for HENs retrofit problems. In this paper, a systematic HENs retrofit methodology with exergoeconomic assessment is proposed. To be consistent with the actual industrial application, three retrofit scenarios, namely heat transfer area distribution retrofit, topology retrofit without additional heat exchangers, and topology retrofit with additional heat exchangers, are considered in the retrofit optimization model. A typical HEN retrofit case in the crude distillation unit is tested. The comparative results indicate that the Scenarios 2 and 3 outperform the Scenario 2 since they have a relatively high annual profit ($3.42MM and $3.47MM) and a low exergy destruction coefficient (0.321 and 0.303). This study is helpful to address the engineering target-oriented HENs retrofit problems by considering different practical retrofit levels.

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Abbreviations

i :

Hot process stream

j :

Cold process stream

n :

Heat exchangers stage on i

m :

Heat exchangers stage on j

k :

Total number index

ADC:

Atmospheric distillation column

TINA:

Outlet temperature of heat exchangers on i, °C

TINB:

Inlet temperature of heat exchangers on i, °C

TJMA:

Inlet temperature of heat exchangers on j, °C

TJMB:

Outlet temperature of heat exchangers on j, °C

T HS, i :

Supply temperature of stream i, °C

T HE, i :

Target temperature of stream i, °C

T CS, j :

Supply temperature of stream j, °C

T CE , j :

Target temperature of stream j, °C

T H :

Hot side arithmetic mean temperature of heat exchangers

T C :

Cold side arithmetic mean temperature of heat exchangers

T K :

Kelvin temperature

T 0 :

Ambient temperature

T temp :

Integral intermediate variable, °C

T MH :

Hot streams mixed temperature, °C

T MC :

Cold streams mixed temperature, °C

△T min :

Minimum heat transfer temperature difference, °C

△TA:

Cold end temperature difference of heat exchangers, °C

△TB:

Hot end temperature difference of heat exchangers, °C

LMT:

Logarithmic mean temperature

D :

Difference, °C

c p :

Heat capacity, kW/(ton °C)

CP:

Heat flow, kW/°C

M :

Mass flowrate, tonne/hr

η EXRC :

Exergy recovery coefficient

η EDRC :

Exergy destruction coefficient

ExO :

Recoverable exergy, kW

ExR :

Recovered exergy, kW

D JR :

Rejected exergy, kW

D KR :

Exergy destruction, kW

Q i :

Enthalpy of stream i, kW

Q O :

Recoverable energy, kW

Q i, n, m, Q i, n, Q j, m :

Heat duty of exchangers, kW

Q HU :

Hot utility, kW

Q CU :

Cold utility, kW

f :

Stream split fraction

S :

Heat transfer area, m2

C :

Capital cost, $

O d :

Total capital cost of new heat exchangers, $

O e :

Recovered exergy profit per year, $

c O :

Recoverable exergy price, $/GJ

P :

Operating time per year

O :

Annual profit, $

VDC:

Vacuum distillation column (VDC)

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Acknowledgements

This work is supported by the National Natural Science Foundation of China (22078373).

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Authors and Affiliations

  1. School of Chemical Engineering and Technology, Guangdong Engineering Center for Petrochemical Energy Conservation, Sun Yat-Sen University, Zhuhai, 519082, Guangdong, China

    Kan Wang, Chang He & Qinglin Chen

  2. School of Materials Science and Engineering, Sun Yat-Sen University, Guangzhou , 510275, Guangdong, China

    Jianqing Hu, Qiaoqiao Tang, Chang He, Bingjian Zhang & Qinglin Chen

Authors
  1. Kan Wang
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  2. Jianqing Hu
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  3. Qiaoqiao Tang
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  4. Chang He
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  5. Bingjian Zhang
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  6. Qinglin Chen
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Correspondence to Chang He or Qinglin Chen.

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Appendices

Appendix

See Table 7.

Table 7 ASTM D86 (American Society Testing Materials) of crude oil
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Appendix B

See Figs. 10 and 11 ; Tables 8, 9 and 10.

Fig. 10
figure 10

Process simulation model in Aspen Plus V10.0

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Fig. 11
figure 11

Simulation model of current HEN in Aspen Plus V10.0

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Table 8 Input and simulation data of pre-fractionator
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Table 9 Input and simulation data of atmospheric distillation column
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Table 10 Input and simulation data of vacuum distillation column
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Appendix C

See Table 11.

Table 11 ASTM D86 of distillate products (95% liquid volume)
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Appendix D

See Tables 12 , 13 , and 14 .

Table 12 Updated heat exchangers ID for L–1 retrofit scheme
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Table 13 Updated heat exchangers ID for L–2 retrofit scheme
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Table 14 Updated heat exchangers ID for L–3 retrofit scheme
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Wang, K., Hu, J., Tang, Q. et al. An engineering target-oriented multi-scenario heat exchanger network retrofit methodology with consideration of exergoeconomic assessment. Environ Dev Sustain 25, 375–399 (2023). https://doi.org/10.1007/s10668-021-02058-9

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