Automated retrofit targeting of heat exchanger networks

doi:10.1007/s11705-018-1747-2

Front. Chem. Sci. Eng.

2018, Vol. 12

Issue (4) : 630-642 https://doi.org/10.1007/s11705-018-1747-2

RESEARCH ARTICLE

Automated retrofit targeting of heat exchanger networks

Timothy G. Walmsley¹(

), Nathan S. Lal², Petar S. Varbanov¹, Jiří J. Klemeš¹

¹. Sustainable Process Integration Laboratory – SPIL, NETME Centre, Faculty of Mechanical Engineering, Brno University of Technology, Brno 60190, Czech Republic
². Energy Research Centre, School of Engineering, University of Waikato, Hamilton 3240, New Zealand

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Abstract

The aim of this paper is to develop a novel heat exchanger network (HEN) retrofit method based on a new automated retrofit targeting (ART) algorithm. ART uses the heat surplus-deficit table (HSDT) in combination with the Bridge Retrofit concepts to generate retrofit bridges option, from which a retrofit design may be formulated. The HSDT is a tabular tool that shows potential for improved re-integration of heat source and sink streams within a HEN. Using the HSDT, retrofit bridges—a set of modifications that links a cooler to a heater to save energy—may be identified, quantified, and compared. The novel retrofit method including the ART algorithm has been successfully implemented in Microsoft Excel^TM to enable analysis of large-scale HENs. A refinery case study with 27 streams and 46 existing heat exchangers demonstrated the retrofit method’s potential. For the case study, the ART algorithm found 68903 feasible unique retrofit opportunities with a minimum 400 kW·unit⁻¹ threshold for heat recovery divided by the number of new units. The most promising retrofit project required 3 new heat exchanger units to achieve a heat savings of 4.24 MW with a favorable annualised profit and a reasonable payback period.

Keywords process retrofit pinch analysis heat exchanger network heat recovery

Corresponding Author(s): Timothy G. Walmsley

Just Accepted Date: 18 May 2018 Online First Date: 31 October 2018 Issue Date: 03 January 2019

Cite this article:

Timothy G. Walmsley,Nathan S. Lal,Petar S. Varbanov, et al. Automated retrofit targeting of heat exchanger networks[J]. Front. Chem. Sci. Eng., 2018, 12(4): 630-642.

URL:

https://academic.hep.com.cn/fcse/EN/10.1007/s11705-018-1747-2
https://academic.hep.com.cn/fcse/EN/Y2018/V12/I4/630

Fig.1 The relationship between (a) heat exchanger T-DH plot, (b) EGCC, and (c) E-PTA

Fig.2 Using the HSTD for retrofit bridge identification and quantification from Lal et al. [²⁷]

Fig.3 Novel HEN retrofit targeting method incorporating the ART algorithm and the HSDT

Tab.1 E-PTA

Tab.2 HSDT

Fig.4 HEN grid diagram for the refinery case study

Fig.5 (a) SCC and (b) GCC of the refinery, using PA

Fig.6 METD (a) with and (b) without recovery exchangers

Fig.7 Simplified HSDT. C: coolers; R: recovery exchangers; H: heaters; Red shade: heat surplus; Blue shade: heat deficit.

Tab.3 Automated retrofit bridge search statistics

Fig.8 Retrofit bridge search results evaluated based on (a) energy savings and exchanger area, (b) the new performance metrics, and (c) total retrofit profit and payback.

Fig.9 HEN grid diagram representing the network after applying the retrofit bridge

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[1]	Andreja NEMET, Jiří Jaromír KLEMEŠ, Petar Sabev VARBANOV, Valter MANTELLI. Heat Integration retrofit analysis—an oil refinery case study by Retrofit Tracing Grid Diagram[J]. Front. Chem. Sci. Eng., 2015, 9(2): 163-182.

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