夹点理论及其在换热网络中的优化分析

本文主要介绍了利用夹点技术设计换热网络的原则及需要注意的问题,并利用夹点技术对乙烯生产原有换热网络进行夹点分析,研究换热网络利用的瓶颈,找出换热网络不合理的环节和原因。经优化改造后新增4台换热设备,新增设备及改装费用约2 900万元,但每年节约公用工程费用2 949万元,回收期为一年,故改造合理,节能明显。     

一种新的换热网络改造方法探析——基于原有网络拓扑结构和换热器的最优应用

通过对原有换热网络的拓扑结构和换热器匹配进行分析,在有分流的分级超结构物理模型的基础上,提出了一种新的可满足一般技改要求的换热网络改造方法.该方法能够在对原有换热网络的拓扑结构和原有换热器面积充分利用并满足冷热流股进出口温度需求的同时,实现对原有换热网络的节能改造.同时建立了换热网络改造的数学模型,并应用混合遗传算法对其进行了求解.实例分析结果表明,该方法具有操作简单、节能潜力大以及投资回收期短等优点.     

基于AspenTech的分馏塔用能优化及换热网络夹点分析

炼油工艺过程中,分馏系统的用能优化是换热网络能量优化的必然要求。以荆门石化3．5Mt／a常减压蒸馏装置为例,利用AspenP1us和AsDenEnergyAnalyzer软件,对常压塔以及换热网络的用能情况进行分析,提出能量优化利用思路：变工况条件下．首先优化分馏系统操作参数,再以此为条件,优化换热网络结构,才能实现整个网络的能量优化。利用AspenPIus软件的模型分析功能,确定了常压塔底汽提蒸汽、常压炉出口温度、中段回流以及侧线的最佳操作参数,为换热网络的夹点分析提供基础数据;在分馏塔操作优化基础上,对现有换热网络进行夹点分析,找出最优夹点温差,求得现有换热网络最高理论换热终温（317．7℃）,为进一步优化换热网络提出了目标;通过建立现有换热网络的网格图,找出跨夹点换热的换热器（总共有5台）,为换热网络的改进提供了方向。     

多股流换热器的数学建模与精确数学控制

本文以平行流多股流换热器为研究对象,考虑了多股流换热器在换热过程中存在的多种影响因素,根据其复杂的传热机理建立了数学模型,并通过数值计算,获得了准确的结果.该模型的建立为多股流换热器的精确数学控制奠定了理论基础,同时为多股流换热器的性能分析,结构优化及运行优化提供了理论依据.     

土壤源热泵U型埋管换热器传热的非稳态数值模拟

本文基于能量平衡方程,建立了土壤源热泵U型埋管换热器周围土壤的非稳态传热模型,用所建立的传热模型对土壤源热泵冬季取热过程进行了动态模拟.研究了不同物性土壤温度及U型埋管出口流体温度的变化规律,分析了土壤物性对换热器换热性能的影响,采用间歇运行方式提高了换热器换热能力.通过建立数学模型得出的结果,可供设计参考.     

蚁群算法在换热网络优化中的应用

提出将蚁群算法应用于换热网络优化中,按照相等的能量份额将各股热流体分解成能量集合,热流体能量通过换热器在与冷流体换热的过程中得到分配,换热器单元面积得到相应地调整．能量分配过程中换热网络得到优化,从而使年综合费用减少的换热器面积不断积累,最终形成了一个最优的换热网络结构．通过具体算例验证了该方法的可行性和有效性,最终优化的结果证明该方法具有较强的全局搜索能力,能够应用于复杂换热网络的优化问题中．     

常减压装置换热网络优化应用

常减压装置是炼油能耗大户,其用能水平的高低对炼油厂综合能耗有较大影响。而在完成装置核心工艺的用能优化基础上再进行换热网络优化,是常减压装置的节能重点。应用AspenPlus流程模拟软件,建立某炼油厂常减压装置及换热网络流程模拟模型,并应用热集成技术及夹点技术对装置进行用能分析,对常减压及换热网络进行热集成优化,提出操作优化方案和改造优化方案,提高常减压装置的用能水平和热回收水平。操作优化实施后,装置每年产生的实际经济效益为476.5万元。另结合夹点技术对换热网络进行了三个层面的分析,首先应用夹点技术绘制过程负荷性能图,查看换热网络有无违背夹点换热原则;然后查找有无交叉换热的换热器;最后对可利用的低温余热进行有效利用。提出了相应的改造优化方案,改造方案实施后,预计每年为企业节省400万元的操作成本。     

基于耗散理论的螺旋板式换热器多目标优化设计

在理论的基础上,分析了螺旋板式换热器运行过程中,传热和压降引起的耗散数与冷流体出口温度和冷、热流体的流速的关系。利用多目标遗传算法,以传热和压降引起的耗散数最小为目标,对流体出口温度和冷、热流体的流速的组合进行了优化。给出了优化实例,根据优化解对优化效果进行了评价,指出采用优化解对换热器进行设计,可以减少流体流动的压降减少水泵用能,而且可以减少传热单元数、降低设备的投资和运行费用,提高换热器的经济性。     

圆柱阵列换热器底部壁面对流换热的初步研究

圆柱阵列换热器是最具潜力的太阳能电站换热器。该文分析了圆柱阵列换热器底部壁面对流换热特性。编制了基于最小二乘法的计算程序，并据此利用现有实验数据拟合出具有普遍意义的圆柱阵列换热器底部壁面对流换热的无量纲换热参数的表达式，对比分析表明，该表达式真实地反映了圆柱阵列的存在及其尺度的变化对底部壁面换热的影响。这一结果为优化换热器结构和建立研究太阳能换热器的多区域连续数值模型奠定了基础。     

换热管内插开圆孔扭带提高传热效率

文章简述传热设备的强化传热的节能技术;通过自制不同规格自旋开孔扭带置入换热管进行冷态实验和热态实验,分析换热管内插扭带后传热效果的改变;用实验数据解析扭带转速、压力降、传热系数与流速的内在关系,验证出开孔扭带比光滑扭带的强化传热效果更好,为企业在节能降耗改造现有换热器设备中提高其传热效率提供理论依据。     

Studies on the retrofit of heat exchanger network based on the hybrid genetic algorithm

The retrofit of heat exchanger networks (HENs) is an important branch of investigation for systematic heat integration. The studies on the economical and efficient retrofit techniques are very important for the high energy-consumption enterprises to save energy, protect environment and improve their market competitiveness. Because the retrofit of HEN is an optimization problem normally solved by a mixed integer nonlinear program (MINLP) which requires enormous solution space, it is very difficult to solve it with the traditional optimization methods. In this paper, by the analysis of an existing heat exchanger network, the hybrid genetic algorithm is applied to obtain the optimal retrofitted HEN with full utilization of the existing heat exchangers and structures. Two examples are taken to show the better effect of the retrofit method with the optimal new heat exchangers and re-piping cost and energy saving.     

Economic optimization of shell and tube heat exchanger based on constructal theory

In this paper, the new approach of constructal theory has been employed to design shell and tube heat exchangers. Constructal theory is a new method for optimal design in engineering applications. The purpose of this paper is optimization of shell and tube heat exchangers by reduction of total cost of the exchanger using the constructal theory. The total cost of the heat exchanger is the sum of operational costs and capital costs. The overall heat transfer coefficient of the shell and tube heat exchanger is increased by the use of constructal theory. Therefore, the capital cost required for making the heat transfer surface is reduced. Moreover, the operational energy costs involving pumping in order to overcome frictional pressure loss are minimized in this method. Genetic algorithm is used to optimize the objective function which is a mathematical model for the cost of the shell and tube heat exchanger and is based on constructal theory. The results of this research represent more than 50% reduction in costs of the heat exchanger.     

Design optimization of shell-and-tube heat exchanger using particle swarm optimization technique

Shell-and-tube heat exchangers (STHEs) are the most common type of heat exchangers that find widespread use in numerous industrial applications. Cost minimization of these heat exchangers is a key objective for both designer and users. Heat exchanger design involves complex processes, including selection of geometrical parameters and operating parameters. The traditional design approach for shell-and-tube heat exchangers involves rating a large number of different exchanger geometries to identify those that satisfy a given heat duty and a set of geometric and operational constraints. However, this approach is time-consuming and does not assure an optimal solution. Hence the present study explores the use of a non-traditional optimization technique; called particle swarm optimization (PSO), for design optimization of shell-and-tube heat exchangers from economic view point. Minimization of total annual cost is considered as an objective function. Three design variables such as shell internal diameter, outer tube diameter and baffle spacing are considered for optimization. Two tube layouts viz. triangle and square are also considered for optimization. Four different case studies are presented to demonstrate the effectiveness and accuracy of the proposed algorithm. The results of optimization using PSO technique are compared with those obtained by using genetic algorithm (GA).     

遗传算法优化氢气网络的应用

采用遗传算法,对炼油厂氢气网络进行优化。运用超结构建立氢气网络模型,以最小年度总费用为优化目标,考虑PSA氢气提纯装置的运行费用,以及氢气网络系统中产生的燃料气价值。该算法不易陷入局部最优解,能迅速得到氢气网络的结构与参数,具有获得全局最优解的能力。实例计算验证了方法的有效性。     

Heat Transfer Enhancement for Heat Exchanger Network Retrofit

Heat exchanger networks (HEN) play important roles in a chemical plant. In a plant lifetime, it may be required to retrofit a HEN several times in order to improve the energy efficiency or to accommodate the increase in throughput. The network pinch method developed by Asante and Zhu [1] can identify bottlenecks, which limit the increase in heat recovery for an existing HEN and also indicate promising structure changes to overcome the bottlenecks. As a result of HEN retrofit, additional surface area is required for some heat exchangers. There are a number of options to provide additional area, such as installing new shells or new units, adding new tubes to an existing bundle, etc. If heat transfer enhancement (HTE) is applied, additional area can be reduced significantly. This can result in a great reduction in capital cost and implementation time for modifications. However, in practice, heat transfer enhancement techniques have not been applied extensively, particularly in the petroleum refining industry. Several main aspects need to be addressed when HTE is taken into consideration for HEN retrofit. The first is how to determine which heat exchangers are suitable to apply HTE in the network and the second issue is to determine what level of augmentation of heat transfer performances is required. The last is about how to select a particular enhancement technique that can fulfil the enhancement requirement. A new strategy for applying HTE in HEN retrofit at the conceptual design stage has been developed. The above issues can be addressed properly by this new method. The new procedure is demonstrated using a case study.     

Effectively designed shell‐tube heat exchangers considering cost minimization and energy management

Cost optimization, which is expressed as a set of analytical variables, is a key objective in economic design approaches of shell‐and‐tube heat exchangers. This study has provided new design techniques based on tube bundle effect on the economic optimization design of shell‐and‐tube heat exchangers. Also the objective of this paper is to develop the cost estimating for the new modified shell‐and‐tube heat exchangers by introducing new objective functions. According to the results the best configuration choice will obviously be the one with the least irreversibility, that is, with the lowest exergy destruction rate and lower annual capital cost. Also, the combined reduction of annual capital investment and operating cost by the new design technique led to a decrease in the overall costs of about 10% to 24% in comparison with original design. So the proposed design technique shows potential for improvement and economic optimization of shell‐and‐tube heat exchangers.     

Detailed equipment design in heat exchanger networks synthesis and optimisation

In heat exchanger network synthesis, important features like pressure drop and fouling effects are usually neglected. In this work a new methodology is proposed to include these effects in grassroots as in retrofit designs. Heat exchangers are detailed designed during the heat exchanger network synthesis. Pinch analysis is used to obtain the heat exchangers network with the maximum energy recovery, and a new systematic procedure is proposed to the identification and loop breaking. Bell–Delaware method for the shell side is used to design the heat exchangers. An example of the literature was studied and the results show differences between heat exchangers, with and without the detailed design, relative to heat transfer area, fouling and pressure drop. The great contribution of this work is that individual and global heat transfer coefficients are always calculated, in despite of the current literature, where these value are assumed in the design step. Moreover, the methodology proposed to the heat exchangers design assures the minor heat exchanger according to TEMA standards, contributing to the minimisation of the heat exchanger network global annual cost. Finely, the new heat exchanger network considering pressure drops and fouling effects presents values more realistic then those one neglecting the equipment detailed design.     

Application of intensified heat transfer for the retrofit of heat exchanger network

A number of design methods have been proposed for the retrofit of heat exchanger networks (HEN) during the last three decades. Although considerable potential for energy savings can be identified from conventional retrofit approaches, the proposed solutions have rarely been adopted in practice, due to significant topology modifications required and resulting engineering complexities during implementation. The intensification of heat transfer for conventional shell-and-tube heat exchangers can eliminate the difficulties of implementing retrofit in HEN which are commonly restricted by topology, safety and maintenance constraints, and includes high capital costs for replacing equipment and pipelines. This paper presents a novel design approach to solve HEN retrofit problems based on heat transfer enhancement. A mathematical model has been developed to evaluate shell-and-tube heat exchanger performances, with which heat-transfer coefficients and pressure drops for both fluids in tube and shell sides are obtained. The developed models have been compared with the Bell-Delaware, simplified Tinker and Wills-Johnston methods and tested with the HTRI® and HEXTRAN® software packages. This demonstrates that the new model is much simpler but can give reliable results in most cases. For the debottlenecking of HEN, four heuristic rules are proposed to identify the most appropriate heat exchangers requiring heat transfer enhancements in the HEN. The application of this new design approach allows a significant improvement in energy recovery without fundamental structural modifications to the network.