Heat exchanger network synthesis with detailed exchanger designs—2. Hybrid optimization strategy for synthesis of heat exchanger networks

We propose a new strategy to synthesize heat exchanger networks with detailed designs of individual heat exchangers. The proposed strategy uses a multistep approach by first obtaining a heat exchanger network topology through solving a modified version of the mixed integer nonlinear programming (MINLP) stage-wise superstructure of Yee and Grossmann, which includes a smoothed LMTD approximation and pressure drops. In a second nonlinear programming (NLP) suboptimization step, we allow for nonisothermal mixing to solve problems with or without exchanger bypasses. The selected heat exchangers along with the mass and energy balances obtained are then used to design the network with detailed exchanger designs through solving a sequence of NLPs for individual heat exchanger designs. The NLPs are based on the detailed discretized optimization models of Kazi et al., which solve quickly and reliably to obtain heat exchangers based on rigorous, first-principles derived coupled differential equations. These models solve a differential algebraic equation system and do not rely on usual assumptions associated with other heuristic-based exchanger design methods, such as log mean temperature difference and F_T correction factors. These detailed exchanger designs are then used to update the network optimization model through sets of correction factors on heat exchanger area, number of shells, heat transfer coefficients, and pressure drops of each exchanger design, in a method based on that of Short et al. The method solves reliably, guaranteeing feasible exchangers for every potential network generated by the shortcut models, through validation with rigorous heat exchanger models at every iteration. In addition, the method does not increase the nonlinearity of the MINLP model, nor does it require any manual intervention or initialization from the user. Three examples are solved and the results are compared to those obtained in the literature.     

Bypass control of heat exchanger network under uncertainty

The dynamic control of the heat exchanger network is important for developing energy-efficient and safe industrial processes. In such a system, the control is achieved through the bypass stream around the heat exchanger. This work aims to track the setpoint temperature of the mixed stream by manipulating the bypass fraction of the cold stream around the heat exchanger. The implemented control is in a non-linear model predictive control (NMPC) framework. The first-principles model of a shell and a tube heat exchanger is used. The orthogonal collocation technique is used to discretize the first-principles model into the system of algebraic equations. In this work, uncertainty is also considered in the inlet temperature of the hot stream. The uncertain optimal control problem is dealt with by using a scenario tree-based approximation along with the affine policy-based method. The results show that, under different scenarios of uncertainty, the controlled variable efficiently tracks the setpoint. In comparison, considering the same scenarios of uncertainty used, the deterministic optimization approach shows significant deviation in the controlled variable from the setpoint as time passes.     

预测管壳式换热器温度分布的模型

基于微分法,提出了一种简单但精确的单相管壳式换热器温度分布计算模型.根据折流板数Nb和管程数n,将换热器划分成(Nb+1)个大单元,(Nb+1)n个子单元,管程流体顺次流过子单元,壳程流体平行流过大单元.以HTRI方法为基准,分别采用本模型和Cell模型对U型管式和浮头式换热器温度分布情况进行计算,通过与HTRI的计算...     

扭曲椭圆管换热的壳程强化传热特性

通过搭建扭曲椭圆管换热器壳程传热与压降性能测试平台,对扭曲椭圆管换热器壳程传热与压降性能进行了实验测试,以实验数据为基础对前人得到的壳程传热与压降性能计算准则关系式的应用范围进行了分析,同时拟合得到了测试用扭曲椭圆管换热器壳程传热与压降性能计算准则关系式,设计了与测试扭曲椭圆管换热器结构类似的折流板换热器以及折流杆换热器,采用相关计算方法对换热器的传热与压降性能进行了计算和比较,并分析了3台换热器的综合性能,结果显示扭曲椭圆管换热器传热效果好、压降低,具有很好的工业应用前景。     

单弓折流板管壳式换热器壳程局部传热及流阻研究

对半圆形单弓折流板管壳式换热器壳侧局部传热性能、局部流速及阻力进行了实验研究,测量结果表明,其壳侧局部传热膜系数的变化规律与相应点速率变化规律相一致。所取24个测量位置点分布较为合理,基本上反映了换热器局部相应换热及流场分布规律。同时归纳出换热器壳侧的平均努塞尔准数Nu与雷诺准数Re的关联式及流动阻力系数f与雷诺准数Re的关联式,为换热器的实际运用提供了参考依据。     

螺旋折流板换热器三角区漏流阻塞的实验研究

目前普遍使用的螺旋折流板换热器壳程的一个螺距主要采用4块平面折流板结构,但在相邻两块折流板的直边搭接处存在顶角相对的两个三角漏流区,使壳程流体偏离理想的螺旋流,严重影响了换热器的性能。采用折面折流板结构,可以封闭原始折流板之间的外侧三角漏流区,使壳程流体更接近连续的螺旋流动。实验结果表明,采用折面折流板代替原始的平面折流板后,换热器总传热系数增加6.7%～19.1%,平均增大16.9%,表明此折面折流板能有效提高螺旋折流板换热器的换热性能。虽然壳程压降也随之增大,但带来的泵耗功率增量非常有限。换热器的热性能因子均大于1.0,平均值为1.071,表明结构改进后的换热器,其综合性能平均提高7.1%。基于实验数据,拟合了结构改进前后的换热器壳程传热系数和阻力系数的相关实验关联式。研究结果对于换热器的节能优化具有重要的指导意义。     

Design of multiple shell and tube heat exchangers in series: E shell and F shell

Multiple shell and tube heat exchangers in the series are employed to handle the temperature cross in the chemical process industries. Depending on the degree of temperature cross, certain number of heat exchangers (either E or F shell type) need to be connected in series such that the temperature cross in each exchanger is within allowable limit. Determination of the number of exchangers for the given terminal temperatures is essential during heat exchanger design phase. In this paper, using finite difference calculus, modeling has been done to calculate the number of shells required for both E and F shell cases. In addition, equations are developed to determine hot and cold fluid temperature profiles across all heat exchangers. Design procedure is illustrated with the help of a case study and the capital cost of both cases is compared. Issues related to E shell and F shells are also discussed.     

曲面弓形折流板换热器壳程流体流动与传热

提出一种新型折流板--曲面弓形折流板,并构造曲面弓形折流板换热器,采用数值模拟和实验相结合的方法研究其壳程传热和流动阻力性能。在实验方面,设计了实验用曲面弓形折流板和普通弓形折流板换热器试样,其中换热器管束采用可拆连接形式,以考察不同折流板结构和板间距的影响。通过改变管程及壳程流量和管程流体进口温度,获得了大量对应于不同折流板结构的壳程压力降和传热系数实验数据。在模拟方面,利用Fluent软件建立了曲面弓形折流板换热器和普通弓形折流板换热器流体数值分析模型,得到了壳程流体流场分布及壳程压力降和传热系数。结果发现,在相同结构参数和流动条件下,曲面弓形折流板换热器壳程压力降比普通弓形折流板换热器降低9%～24%,而壳程传热系数比普通弓形折流板换热器提高3%～11%。     

平行流多流体板翅式换热器的动态数学模型

板翅式换热器动态特性的复杂性在于其通道间有翅片导热存在．本文从分析翅片的定态和非定态导热过程入手,建立了包括考虑隔板热容的通用平行流多流体板翅式换热器的动态数学模型．该数学模型能以热阻网络图形式加以描述,通过对热阻网络的变换,获得了可快速求解的三对角阵代数方程组．用此模型计算了两股流板翅式换热器和四股流板翅式换热器的动态响应过程,对流体流量（或进口温度）扰动,理论的预测结果与实验数据相当一致．     

一种扁管管翅式换热器的高效数值设计方法

传统的数值模拟方法计算量大，计算时间长，很难满足现代工业发展的需求。以扁管管翅式换热器为例，采用适体坐标与最佳正交分解（POD）相结合的方法构建了低阶模型，在等热流边界条件下对扁管管翅式换热器中流动与传热过程进行计算，并将POD计算结果与有限体积法（FVM）计算结果进行了对比。结果表明：POD方法能准确地捕捉到不同数量参数变化情况下的温度场及速度场信息。对于3变量工况重构速度场及温度场的相对偏差平均值的最大值分别为1.90%、0.308%。采用POD方法在保证计算精度的前提下将FVM计算速度最大能提高3093.4倍。研究对于提高扁管管翅式换热器数值设计效率、拓展POD方法的工程应用领域有一定的理论参考价值。     

折面螺旋折流板换热器的流动传热性能

针对现有平面螺旋折流板换热器的相邻折流板与壳体间存在的三角漏流区,提出了一种折面螺旋折流板换热器。基于实验研究分析了折面螺旋折流板换热器的螺旋角和搭接度对流动传热性能的影响,并拟合了壳程对流传热和阻力系数的实验关联式。结果表明,当壳程体积流量相同时,随着螺旋角的减小,折面螺旋折流板换热器的壳程总压降增加,壳程管束压降增加,壳程膜传热系数提升,综合性能增强;相同壳程体积流量下,随着搭接度的增加,壳程总压降也增加,壳程膜传热系数增加,综合性能提高。实验研究表明螺旋角18°、搭接度50%的折面螺旋折流板换热器流动传热性能最佳。将折面螺旋折流板换热器的螺旋角和搭接度作为修正因子拟合到了实验关联式中,对比发现实验值与Nu实验关联式计算值的平均相对误差为1.13%,与f实验关联式的平均相对误差为6.84%,说明了拟合的正确性和可靠性。研究结果为折面螺旋折流板换热器的设计提供了理论指导。     

Design and optimization of heat exchangers with helical baffles

The hydrodynamics and heat transfer characteristics of a heat exchanger with single-helical baffles are studied experimentally as well as numerically. A heat exchanger with two-layer helical baffles is designed by using computational fluid dynamics (CFD) method. The comparisons of the performance of three heat exchangers with single-segment baffles, single-helical baffles and two-layer helical baffles, respectively, are presented in the paper. The experiment is carried out in counter-current flow pattern with hot oil in shell side and cold water in tube side. Overall heat transfer coefficients are calculated and heat transfer coefficients of shell side are determined by Wilson plots technique. It shows that the heat exchangers with helical baffles have higher heat transfer coefficient to the same pressure drop than that of the heat exchanger with segmental baffles based on the present numerical results, and the configuration of the two-layer helical baffles has better integrated performance than that of the single-helical baffles.     

Simultaneous MINLP synthesis of heat and power integrated heat exchanger networks

This paper describes the simultaneous MINLP synthesis of heat and power integrated heat exchanger networks. The objective of this work is to obtain feasible networks with optimal tradeoffs between investment, utility and power consumption caused by pressure drops in heat exchangers, and to use a detailed design model for exchangers in the synthesis in order to represent pressure drops and heat transfer coefficients as functions of exchanger design variables. In this way, the simultaneous synthesis of HEN and the detailed exchanger design become completely consistent and optimal.     

换热器结构优化与换热性能评价指标研究

某运载器中冷却器存在若干问题：壳侧压力损失较大；采用的弓形折流板结构使得壳侧工质呈现出Z字形流动，在折流板后易形成流动死区，促使壳侧结垢，使得换热器总传热性能降低。提出了两种针对壳侧结构的强化换热设计方案。方案一为减少弓形折流板数量、增加折流板间距；方案二为采用螺旋折流板替换原有的弓形折流板。为验证文中采用的热力设计方法的准确性，根据文献中的实验结果针对弓形折流板和螺旋折流板管壳式换热器热力设计方法进行了验证，结果表明文中采用的热力设计方法得到的计算数据与实验结果的偏差在37%以内，满足工程设计需求。优化方案根据优化参数不同，其优化结果有所不同，基本存在以下规律：优化设计可使换热器管壳两侧总压降减小，但同时其换热性能也下降。因此，需要一个综合指标来进行评价。文中提出以换热量Q与换热器流动阻力引起功耗的比值作为综合性能评价指标。该指标表示换热系统克服换热器流动阻力消耗单位泵功下的换热量，其值越大，单位泵功下换热量越高，经济性越好。经过计算发现最优方案相对原始方案，综合评价指标提高了约22.2%。     

采用换热器负荷图指导换热网络改造的新方法

目前大部分图形工具仅适用于以节能为目标的换热网络（HEN）设计或者改造。能量回收量的增加往往伴随换热单元数的增多，而换热单元数对设备投资费有较大影响。采用换热器负荷图（HELD）提出一种系统化的换热网络改造新方法。新方法基于夹点分析，在改造区间中选择匹配目标，重新构建改造用HELD，从而简化问题；通过在水平方向上平移热流股曲线实现跨夹点负荷的重新分配，完成节能目标，并结合经验规则，尽可能减少改造后换热网络的换热器数目。以一个工业造纸厂为例，对其进行节能改造方案设计，相较于文献报道结果，得到两个节能目标值相近且换热器改动数目更少的新方案，验证了新方法的有效性。     

管壳式换热器强化传热研究进展

管壳式换热器作为工程中应用广泛的换热器,具有结构坚固、适应性强、能够利用和回收热能等优点。在追求高能源利用效率的背景下,换热器的强化传热得到广泛关注。本文重点阐述了管壳式换热器的强化传热相关研究进展,包括换热器本身几何结构的优化、换热流体的热物性改善以及多种强化传热技术结合的复合强化传热方法。其中几何结构优化主要包括改变换热管管型、增加管内插入物以及壳程中的隔板优化研究等。换热流体热物性改善包括纳米流体提高热导率、潜热型热流体提高比热容等。复合强化传热是将多种强化方法结合,可弥补单一方法的不足,以获得更高强化传热效果。最后指出管壳式换热器强化传热未来的研究方向在于持续开发强化传热管、制备稳定的纳米流体及潜热型流体以及多种强化方式复合提高强化效果。     

Heat exchanger system boundary regulation

The boundary feedback regulator design for heat exchangers with delayed feedback is developed. Counter-flow/parallel-flow heat exchanger systems described by a pair of coupled transport hyperbolic partial differential equations (PDEs) with delayed boundary feedback loop modeled by the boundary time lag are considered. The coupled transport hyperbolic PDEs and boundary delay by application of boundary transformation are transformed in the corresponding linear infinite-dimensional system utilized in the regulator design. The regulator design initially addresses a full state feedback controller realization augmented by the observer design to achieve simultaneously output exponential stabilization as well as tracking and disturbance rejection of polynomial and/or harmonic type of reference signals. The simulations studies demonstrate the proposed design for counter-flow and parallel-flow heat exchangers, two common configurations present in industrial practice.     

Numerical simulation and structure optimization of spiral wound heat exchanger with novel spacing bars

Spiral wound heat exchangers are widely used in industrial production for their advantages, such as large heat transfer areas and compact structures. However, their compact design also poses significant difficulties for numerical simulation and experimental research. The spacing bar between tube bundles has an essential impact on the performance of wound tube heat exchangers. This paper presents a new type of spacing bar vertically installed on the core barrel of the spiral wound heat exchanger to enhance the comprehensive heat transfer performance. A numerical model of a new type of wrapped tube heat exchanger has been constructed, which agrees with experimental results. Under the same working conditions, the comprehensive heat transfer performance on the shell side of the spiral wound heat exchanger with new spacing bars is increased by 7.4%–10.5% compared with the traditional structure. On this basis, the influence of the new spacing bar's structural parameters on the heat exchanger's performance was studied, and the empirical correlation between the structural parameters and operating conditions of the new spacing bar and the performance of the heat exchanger was fitted. The research results have guiding significance for the design of spiral wound heat exchangers.     

转化过程气体换热器的副线调节性能——温度的影响

对转化过程采用圆缺形折流板和双圆缺形管束排列的气体换热器 ,推导出操作气量负荷率、管壳程副线率以及换热面积富裕系数与换热器管壳程进出口温度变化值之间的定量解析关系式 ,它们仅是换热器管壳程进出口温度设计值的函数。管壳程进出口温度变化共有 58种组合形式。最小换热面积富裕系数为温度变化引起换热量变化及换热器平均温差变化两部分的乘积。     

三螺旋折流板换热器多流路通道流动与传热数值模拟

为了增加大螺旋角下单位长度换热管上螺旋折流板数量提高换热,提出三螺旋折流板导流结构,对设置三螺旋折流板后壳程流体的流动与传热进行了数值模拟,重点考察了Reynolds数Re=1391～4174时的壳程压降及对流传热系数,与设置单螺旋折流板的对比结果表明：三螺旋折流板换热器壳程对流传热系数高27.9%,JF因子高13.67%,综合传热性能更好。在此基础上运用耗散理论分析了三螺旋折流板采取不同螺旋角时对换热效率的影响,发现由传热引起的耗散率随Reynolds数变化规律与壳程对流传热系数随Reynolds数的变化规律类似,相同流量条件下螺旋角为64.8°的换热器耗散率最小。另外,中心换热管与壳壁附近换热管的传热系数比较结果显示,中心管热交换量均低于壳壁附近换热管热交换量。