New method for automatic design of intensified shell and tube heat exchanger with twisted-tape insert

doi:10.16085/j.issn.1000-6613.2023-1410

Abstract

Abstract:

Shell and tube heat exchangers are the most widely used heat exchangers, and optimizing their design is a crucial research topic. Most existing design methods are based on heuristic methods or commercial solvers, which are slow in solving and can't guarantee the quality of design solutions. This paper applied set trimming to the automatic design of shell and tube heat exchangers. The outer diameter of tubes, the length of tubes, the diameter of the shell side, the number of tube sides, the pitch of twist-tapes, and the thickness of twist-tapes were defined as discrete variables and input into the program, which automatically output the design results and solutions. The automatic design optimization of shell and tube heat exchangers that intensified with twisted-tape insert was carried out by using single-objective optimization with the minimization heat exchange area, total annualized cost, and net present cost as optimization objectives. By comparison, we find that set trimming could ensure the global optimization of the design solution, and its solving time was very short. It could provide results within 0.5—2s. The results of minimizing the heat transfer area as the objective function showed that set trimming could obtain a smaller heat transfer area, which was reduced by 0.7% compared to the literature value. At the same time, the use of intensification techniques could reduce the heat transfer area. When the heat stream was distributed on the tube side, the technique reduced the heat transfer area by 7.7%, and the tube-side pressure drop increased by 16.9%. When the heat stream was distributed on the shell side, the heat transfer area was reduced by 14.6%, and the tube-side pressure drop increased by 98.7%. The optimization results with the objective of minimizing total annualized cost and net present cost showed that the cost of intensified conditions was lower than that of non-intensified states, and when the heat stream distribution was on the tube side, it was 13.1% lower. When distributed on the shell side, it was 0.57% lower. In addition, the cost of heat exchangers will also be affected by cost parameters.

Key words: heat exchanger, heat transfer enhancement, global optimization, set trimming

摘要：

管壳式换热器作为应用最广泛的换热器，对其进行优化设计是一个十分重要的研究主题。现有的设计方法多数是基于启发式方法求解或调用商业求解器，其运算速度较慢且不能保证设计解的质量。本文将集合修剪算法应用于管壳式换热器的自动设计，将管外径、管长、壳程直径、管程数、扭曲片节距、扭曲片厚度等定义为离散变量后输入，程序自动输出设计结果与方案。对采用扭曲片内插件的管壳式换热器进行自动设计优化，分别以最小化换热面积、年度总费用、净现值作为优化目标进行单目标优化。对比发现集合修剪算法可以保证设计解的全局最优，同时降低优化求解时间，可在0.5~2s内给出结果。以换热面积最小化为目标函数的优化结果显示，集合修剪算法可得到更小的换热面积，比文献值减少了0.7%，同时采用强化传热可减少换热面积。热流分配在管程时，强化技术降低了7.7%的换热面积，管程侧的压降则提高了16.9%；热流分配在壳程时，则降低14.6%的换热面积，管程压降提高了98.7%。以最小化年度总费用和净现值为目标的优化结果显示，强化传热的费用低于未强化情况，热流分配在管程时费用降低13.1%，分配在壳程时则降低0.57%。此外，换热器的费用也会受到成本参数的影响。

关键词: 换热器, 强化传热, 全局最优, 集合修剪

CLC Number:

TQ021

CUI Yi, LI Mengyuan, YANG Lu, LI Haidong, ZHANG Qiqi, CHANG Chenglin, WANG Yufei. New method for automatic design of intensified shell and tube heat exchanger with twisted-tape insert[J]. Chemical Industry and Engineering Progress, 2024, 43(9): 4824-4832.

崔祎, 李孟原, 杨路, 李海东, 张奇琪, 常承林, 王彧斐. 采用扭曲片内插件的管壳式换热器自动设计新方法[J]. 化工进展, 2024, 43(9): 4824-4832.

Figures/Tables 9

References 26

1	HE Yong, LIAO Nuo, LIN Kunrong. Can China’s industrial sector achieve energy conservation and emission reduction goals dominated by energy efficiency enhancement? A multi-objective optimization approach[J]. Energy Policy, 2021, 149: 112108.
2	王晓东. 管壳式换热器传热的模拟研究及其优化分析[D]. 沈阳: 东北大学, 2012.
	WANG Xiaodong. Analysis of simulation and optimization on heat transfer in shell-and-tube heat exchanger[D]. Shenyang: Northeastern University, 2012.
3	王志伟. 管壳式换热器壳程折流部件的传热性能研究[D]. 大庆: 东北石油大学, 2021.
	WANG Zhiwei. Study on the structural design and heat transfer performance of a new type of baffle unit[D]. Daqing: Northeast Petroleum University, 2021.
4	Philippe WILDI-TREMBLAY, GOSSELIN Louis. Minimizing shell-and-tube heat exchanger cost with genetic algorithms and considering maintenance[J]. International Journal of Energy Research, 2007, 31(9): 867-885.
5	Resat SELBAŞ, Önder KıZıLKAN, REPPICH Marcus. A new design approach for shell-and-tube heat exchangers using genetic algorithms from economic point of view[J]. Chemical Engineering and Processing: Process Intensification, 2006, 45(4): 268-275.
6	KHALFE Nadeem, LAHIRI Kumar, WADHWA Kumar. Simulated annealing technique to design minimum cost exchanger[J]. Chemical Industry and Chemical Engineering Quarterly, 2011, 17(4): 409-427.
7	RAVAGNANI Mauro A S S, SILVA Aline P, BISCAIA Evaristo C, et al. Optimal design of shell-and-tube heat exchangers using particle swarm optimization[J]. Industrial & Engineering Chemistry Research, 2009, 48(6): 2927-2935.
8	PATEL V K, RAO R V. Design optimization of shell-and-tube heat exchanger using particle swarm optimization technique[J]. Applied Thermal Engineering, 2010, 30(11/12): 1417-1425.
9	ŞENCAN ŞAHIN Arzu, Bayram KıLıÇ, Ulaş KıLıÇ. Design and economic optimization of shell and tube heat exchangers using Artificial Bee Colony (ABC) algorithm[J]. Energy Conversion and Management, 2011, 52(11): 3356-3362.
10	KHOSRAVI Rihanna, KHOSRAVI Abbas, NAHAVANDI Saeid. Assessing performance of genetic and firefly algorithms for optimal design of heat exchangers[C]//2014 IEEE International Conference on Systems, Man, and Cybernetics (SMC). San Diego, CA, USA. IEEE, 2014: 3296-3301.
11	ONISHI Viviani C, RAVAGNANI Mauro A S S, CABALLERO José A. Mathematical programming model for heat exchanger design through optimization of partial objectives[J]. Energy Conversion and Management, 2013, 74: 60-69.
12	GONÇALVES Caroline de O, COSTA André L H, BAGAJEWICZ Miguel J. Shell and tube heat exchanger design using mixed-integer linear programming[J]. AIChE Journal, 2017, 63(6): 1907-1922.
13	MANGLIK R M, BERGLES A E. Heat transfer and pressure drop correlations for twisted-tape inserts in isothermal tubes: Part I—Laminar flows[J]. Journal of Heat Transfer, 1993, 115(4): 881-889.
14	SARMA P K, KISHORE P S, RAO V Dharma, et al. A combined approach to predict friction coefficients and convective heat transfer characteristics in a tube with twisted tape inserts for a wide range of Re and Pr [J]. International Journal of Thermal Sciences, 2005, 44(4): 393-398.
15	SETHUMADHAVAN R, RAJA RAO M. Turbulent flow heat transfer and fluid friction in helical-wire-coil-inserted tubes[J]. International Journal of Heat and Mass Transfer, 1983, 26(12): 1833-1845.
16	RAVIGURURAJAN T S, BERGLES A E. Development and verification of general correlations for pressure drop and heat transfer in single-phase turbulent flow in enhanced tubes[J]. Experimental Thermal and Fluid Science, 1996, 13(1): 55-70.
17	Mafizul HUQ, AZIZ-UL HUQ A M, RAHMAN Muhammad Mustafizur. Experimental measurements of heat transfer in an internally finned tube[J]. International Communications in Heat and Mass Transfer, 1998, 25(5): 619-630.
18	JENSEN Michael K, VLAKANCIC Alex. Technical note experimental investigation of turbulent heat transfer and fluid flow in internally finned tubes[J]. International Journal of Heat and Mass Transfer, 1999, 42(7): 1343-1351.
19	STEHLÍK P, NĚMČANSKÝ J, KRAL D, et al. Comparison of correction factors for shell-and-tube heat exchangers with segmental or helical baffles[J]. Heat Transfer Engineering, 1994, 15(1): 55-65.
20	SERTH Robert W, LESTINA Thomas G. Process heat transfer principles, applications and rules of thumb[M]. 2nd ed. Oxford: Academic Press, 2014.
21	CHANG Chenglin, LIAO Zuwei, COSTA André L H, et al. Globally optimal design of intensified shell and tube heat exchangers using complete set trimming[J]. Computers & Chemical Engineering, 2022, 158: 107644.
22	COSTA André, BAGAJEWICZ Miguel J. 110th anniversary: On the departure from heuristics and simplified models toward globally optimal design of process equipment[J]. Industrial & Engineering Chemistry Research, 2019, 58(40): 18684-18702.
23	JIANG Ning, SHELLEY Jacob David, SMITH Robin. New models for conventional and heat exchangers enhanced with tube inserts for heat exchanger network retrofit[J]. Applied Thermal Engineering, 2014, 70(1): 944-956.
24	GONÇALVES Caroline de O, COSTA André L H, BAGAJEWICZ Miguel J. Alternative mixed-integer linear programming formulations for shell and tube heat exchanger optimal design[J]. Industrial & Engineering Chemistry Research, 2017, 56(20): 5970-5979.
25	HEWITT Geoffrey Frederick. Heat exchanger design handbook 2008[M]. New York: Begell house, 2008.
26	CHANG Chenglin, SHEN Weifeng. Global optimization of the design of intensified shell and tube heat exchanger using tube inserts[J]. The Canadian Journal of Chemical Engineering, 2024, 102（1）:350-365.

变量	取值
管外径/m	0.019，0.025，0.032，0.038，0.051
管长/m	1.220，1.829，2.439，3.049，3.659，4.877，6.098
间径比	1.25，1.33，1.50
管束布局方式	1表示正方形布局，2表示三角形布局
管程	1，2，4，6
挡板数	1，2，3，…，20
壳程直径/m	0.787，0.838，0.889，0.940，0.991，1.067，1.143，1.219，1.372，1.524
扭曲片节距/m	0.074700，0.103275，0.131850
扭曲片厚/m	0.002，0.003，0.004

变量	取值
管外径/m	0.019，0.025，0.032，0.038，0.051
管长/m	1.220，1.829，2.439，3.049，3.659，4.877，6.098
间径比	1.25，1.33，1.50
管束布局方式	1表示正方形布局，2表示三角形布局
管程	1，2，4，6
挡板数	1，2，3，…，20
壳程直径/m	0.787，0.838，0.889，0.940，0.991，1.067，1.143，1.219，1.372，1.524
扭曲片节距/m	0.074700，0.103275，0.131850
扭曲片厚/m	0.002，0.003，0.004

物流	质量流量 /kg·s^-1	进口温度 /℃	出口温度 /℃	污垢系数 /m²·K·W^-1	密度 /kg·m^-3	比热容 /J·kg^-1·K^-1	黏度 /Pa·s	热导率 /W·m^-1·K^-1	允许压降 /Pa	流速范围 /m·s^-1
热流乙醇	55.6	150	60	0.00020	789.0	2470.0	0.00067	0.170	100000	[1.0,3.0]
冷流冷却水	295.0	30	40	0.00040	995.0	4186.8	0.00080	0.590	100000	[0.5,2.0]

物流	质量流量 /kg·s^-1	进口温度 /℃	出口温度 /℃	污垢系数 /m²·K·W^-1	密度 /kg·m^-3	比热容 /J·kg^-1·K^-1	黏度 /Pa·s	热导率 /W·m^-1·K^-1	允许压降 /Pa	流速范围 /m·s^-1
热流乙醇	55.6	150	60	0.00020	789.0	2470.0	0.00067	0.170	100000	[1.0,3.0]
冷流冷却水	295.0	30	40	0.00040	995.0	4186.8	0.00080	0.590	100000	[0.5,2.0]

设计参数	ST	SS	ST-TI	SS-TI
管外径/m	0.019	0.019	0.025	0.019
管长/m	4.877	6.098	6.098	4.877
间径比	1.25	1.25	1.25	1.25
管束布局方式	正方形	正方形	正方形	三角形
管程	6	1	4	1
挡板数	4	15	6	11
壳程直径/m	0.991	0.838	0.940	0.838
扭曲片节距/m	—	—	0.074700	0.074700
扭曲片厚/ m	—	—	0.004	0.002