Research advances in heat exchanger fouling and heat exchanger network(HEN) overdesign method

doi:10.16085/j.issn.1000-6613.2016.02.003

Abstract

Abstract: Fouling resistance affects normal operation of heat exchanger network(HEN). The present paper introduced the HEN margin designs and the HEN optimal design by considering fouling resistance. Some methods on cleaning time or optimal cleaning cycles for heat exchangers or synthesis of heat exchanger networks with flexibility and controllability were summarized. However,these HEN designs were obtained when HEN was in the worst conditions,so it is generally not optimal. This paper proposes the synthesis of multi-pass heat exchanger network based on life cycle saving by considered the existing HEN design methods and the slow time-varying and continuous features of fouling. Finally,the optimal HEN results of accumulative total cost were obtained.

Key words: heat exchanger network, fouling, overdesign

摘要： 从结垢现象影响换热系统正常运行的角度出发,介绍了近几年换热网络裕量设计以及针对结垢问题不同学者研究出的换热网络优化设计。总结了在换热网络设计中对换热器清洗时序、清洗周期优化或者增加换热网络的裕量设计的不同换热网络设计最优方法,但这些方法都是在换热网络设计之初,考虑换热器结垢最严重的情况即换热网络在“最差”工况下进行的优化,因此优化得到的换热网络难以保证换热网络全运行周期的持续节能优化。本文结合现有换热网络设计方法的利弊,针对结垢过程的慢时变、持续特点,提出一种基于长周期持续节能的换热网络设计优化方法,在换热网络设计之初,定量分析结垢对网络结构的影响,以换热网络全周期累积总费用为目标函数,实现换热网络的最优综合。

关键词: 换热网络, 结垢, 裕量设计

CLC Number:

TQ021.8

CHANG Runxiu, SUN Lin, LUO Xionglin. Research advances in heat exchanger fouling and heat exchanger network(HEN) overdesign method[J]. Chemical Industry and Engineering Progree, 2016, 35(02): 358-363.

常润秀, 孙琳, 罗雄麟. 换热器结垢与换热网络裕量设计方法研究进展[J]. 化工进展, 2016, 35(02): 358-363.

References

[1] MARSELLE D F,MORARI M,RUDD D F. Design of resilient processing plants-II:design and control of energy management systems[J]. Chemical Engineering Science,1982,37(2):259-270.
[2] KOTJABASAKIS E,LINNHOFF B. Sensitivity tables for the design of flexible processes (1)—How much contingency in heat exchanger networks is costeffective[J]. Chemical Engineering Research and Design,1986,64(3):197-211.
[3] UZTURK D,AKMAN U. Centralized and decentralized control of retrofit heat exchanger network[J]. Computer Chemical Engineering,1997,21:373-378.
[4] 汪旭,冯霄. 基于启发式方法的弹性换热网络的合成[J]. 计算机与应用化学,2010,27(10):1349-1352.
[5] 倪锦,崔国民,姜慧,等. 换热网络的柔性识别及基于旁路调节的运行优化[J]. 化工进展,2010,29(1):17-24.
[6] SABOO A K,MORARI M,WOODCOCK D C. Design of resilient processing plants-Ⅷ,a resilience index for heat exchanger networks[J]. Chemical Engineering Science,1985,40(8):1553-1565.
[7] SWANEY R E,GROSSMANN I E. An index for operational flexibility in chemical process design Part I:Formulation and theory[J]. AIChE J.,1985,31:621.
[8] GROSSMANN I E,CALFA B A,GARCIAHERREROS P. Evolution of concepts and models for quantifying resiliency and flexibility of chemical process[J]. Computers and Chemical Engineering,2014,70:22-34.
[9] 胡山鹰,陈丙珍,沈静珠. 柔性换热网络综合方法研究[J]. 计算机与应用化学,1991,8(4):296-301.
[10] 胡山鹰,陈丙珍,沈静珠. 热回收网络结构柔性的改进方法研究[J]. 化工学报,1993,44(6):700-707.
[11] 肖丰,姚平经. 多周期换热网络柔性综合与维护同步优化[J]. 华东理工大学学报,2009,35(5):783-787.
[12] ZHENG K,LOU H H,WANG J,et al. A method for flexible heat exchanger network design under severe operation uncertainty[J]. Chemical Engineering and Technology,2013,36(5):757-765.
[13] MATHISEN K W,SKOGESTAD S,WOLF E A. Controllability of heat exchanger networks[C]//LA,USA:AIChE Annual Meeting,1991,152.
[14] MATHISEN K W,SKOGESTAD S,WOLF E A. Bypass selection for control of heat exchanger networks[J]. Computers and Chemical Engineering,1992,5:263-272.
[15] KONUKMAN A E S,AKMAN U,CAMURDAN M C. Optimal design of controllable heatexchanger networks under multidirectional resiliencytarget constraints[J]. Computers and Chemical Engineering,1995,19(1):149-154.
[16] 罗雄麟,孙琳,王传芳,等. 换热网络操作夹点分析与旁路优化控制[J]. 化工学报,2008,59(5):1200-1206.
[17] 侯本权,孙琳,罗雄麟. 基于结构可控性分析的换热网络旁路优化设计[J]. 化工学报,2011,62(5):1326-1338.
[18] 孙琳,迟进浩,罗雄麟. 换热器裕量设计与旁路设计分析[J]. 计算机与应用化学,2008,25(11):1369-1373.
[19] 夏车奎,罗雄麟,孙琳. 基于全周期节能的有旁路换热网络裕量优化设计[J]. 化工学报,2012,63(5):1449-1458.
[20] AZAD A V,G.HAEBI H,AMIDPOUR M. Novel graphical approach as fouling pinch for increasing fouling formation period in heat exchanger network (HEN) state of the art[J]. Energy Conversion and Management,2011,52:117-124.
[21] SHILLING R L. Fouling and uncertainty margins in tubular heat exchanger design:an alternative[J]. Heat Transfer Engineering,2012,33(13):1094-1104.
[22] PAN M,BULATOV I,SMITH R. Exploiting tube inserts to intensify heat transfer for the retrofit of heat exchanger networks considering fouling mitigation[J]. Industrial and Engineering Chemistry Research,2013,52(8):2925-2943.
[23] 陈鹏鹏. 基于污垢生长的换热网络综合与清洗时序优化[D]. 大连:大连理工大学,2013.
[24] SIKOS L,KLEMES J. Reliability availability and maintenance optimisation of heat exchanger networks[J]. Applied Thermal Engineering,2010,30(1):63-69.
[25] ISHIYAMA E M,PATERSON W R,WILSON D I. Optimum cleaning cycles for heat transfer equipment undergoing fouling and ageing[J]. Chemical Engineering Science,2011,66:604-612.
[26] POGIATZIS T,ISHIYAMA E M,PATERSON W R,et al. Identifying optimal cleaning cycles for heat exchangers subject to fouling and ageing[J]. Applied Energy,2012,89:60-66.
[27] 樊婕,李继龙,刘琳琳,等. 换热器网络设备面积与清洗时序同步优化[J]. 化工学报,2014,65(11):4484-4489.
[28] SMAILI F,ANGADI D K,HATCH C M,et al. Optimization of scheduling of cleaning in heat exchanger networks subject to fouling:sugar industry case study[J]. Food and Bioproducts Process,1999,77(2):159-164.
[29] SMAILI F,VASSILIADIS V S,WILSON D I. Mitigation of fouling in refinery heat exchanger networks by optimal management of cleaning[J]. Energy and Fuels,2001,15:1038-1056.
[30] JIN Z,CHEN X,DONG Q. Planning the optimum cleaning schedule based on simulation of heat exchangers under fouling[J]. Heat Transfer Asian Research,2012,41(1):33-42.
[31] CAPUTO A C,PELAGAGGE P M,SALINI P. Joint economic optimization of heat exchanger design and maintenance policy[J]. Applied Thermal Engineering,2011,31(8):1381-1392.
[32] RODRIGUEZ C,SMITH R. Optimization of operating conditions for mitigating fouling in heat exchanger networks[J]. Chemical Engineering Research and Design,2007,85(A6):839-851.
[33] MARKOWSKI M,URBANIEC K. Optimal cleaning schedule for heat exchangers in a heat exchanger network[J]. Applied Thermal Engineering,2005,25:1019-1032.
[34] 王大成,赵晶英. 石化行业换热设备清洗周期优化建模及求解[J]. 化工机械,2014,41(4):496-500.
[35] ESCOBAR M,TRIERWERLER J O,GROSSMANN I E. A heuristic Lagrangean approach for the synthesis of multiperiod heat exchanger networks[J]. Applied Thermal Engineering,2014,63:177-191.
[36] NEMET A,KLEMES J J,KRAVANJA Z. Optimising entire lifetime economy of heat exchanger networks[J]. Energy,2013,57:222-235.
[37] COLETTI F,MACCHIETTOA S,POLLEY G T. Effects of fouling on performance of retrofitted heat exchanger networks:a thermo-hydraulic based analysis[J]. Computers and Chemical Engineering,2011,35:907-917.
[38] 李绍军,姚平经. 最小年度化费用换热网络综合的匹配规则研究[J]. 高校化学工程学报,2000,14(1):59-64.