CCB 4313

Heat Integration
Automated Design of Heat Exchanger Networks
Dr. Rajashekhar Pendyala
Chemical Engineering Department
University Teknologi PETRONAS

Automated Design of HEN

Given a problem

Tmin = 10 C, QHmin = 960 kW

How can we automate the design process?

Automated Design of HEN

First set up a reducible structure

Incorporating all feasible options

Automated Design of HEN

Then, optimize

Initial Design
(Superstructure)

Final Design

Automated Design of HEN

BUT

This is a difficult non-linear optimization!

Automated Design of HEN

Starting with a simpler superstructure removes many
structural options (some of which might be desirable)

BUT makes the optimization linear

Automated Design of HEN

Problem with simplified superstructure
This
Parallel Configuration

12 Parallel Configurations

Cannot evolve to all

possibilities
Series Configuration

Series-Parallel Configurations

Parallel-Series Configurations

Automated Design of HEN

SO, if this is a feature of solution from
(linear) optimization of simplified superstructure:

THEN, substitute this (add features):

Any parallel,
series-parallel or
parallel-series
arrangement
AND re-optimize (non-linear)

Automated Design of HEN

Automated Design of HEN

Should we base the initial superstructure
on the pinch decomposition?

Works for small problems

but not for practical problems!

Automated Design of HEN

Rather than just divide at the pinch

Divide into enthalpy intervals

Automated Design of HEN

AND

Create simplified superstructure for each enthalpy interval.

Automated Design of HEN

PROBLEM

The superstructure (even simplified) becomes

too large to solve for practical problems

BLOCK DECOMPOSITION

Automated Design of HEN

Block Decomposition

Combine enthalpy intervals into Blocks

Automated Design of HEN

How are blocks determined?
Try to combine as many intervals into one block as
possible
TS, HOT > TT, COLD & TT, HOT > TS, COLD should be satisfied
within each block

In other words, temperature

differences always feasible

Automated Design of HEN

Initial Design
Has design options across block boundaries

Mixing junctions especially create many options

Automated Design of HEN

Design Comments

Generate only an initial design

Tends to use excessive stream splitting
Further evolution required to merge
exchangers and simplify structure
Evolution by optimization

Automated Design of HEN

What would happen if utilities could be varied ?

Minimum Energy Cost

Minimum Total Cost

Utility cost increases

Lower capital cost due to higher
driving forces

Automated Design of HEN

If utilities are allowed to vary,
need to provide additional matches to exploit utilities

Every utility in every block

Automated Design of HEN

Constrained matches
Initial design is not unique for given heat transfer area,
so user can remove or enforce various structural
features

Imposed matches
Forbidden matches
Constraints for area or heat duty (max or min)
Constrain number of branches for stream splits

Note: after a constraint is placed, there might be a

heat transfer area penalty there might be no feasible
solution to the problem

Automated Design of HEN

Summary
Automated heat exchanger network design can be
achieved through the optimization of a superstructure
Difficult non-linear optimization problem
Practical problems require a two-stage approach using
linear and then non-linear optimization
A wide range of constraints can be included

Thank You

REFERENCES
1. Smith R., Chemical Process Design, Mc Graw Hill, New York,
1995.
2. Linnhoff, B. et al, User Guide on Energy Efficiency through
Process Integration, IchemE Rugby, England, 1994.