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Article history: In this study, a new shell and tube heat exchanger optimization design approach is developed. Artificial
Received 8 September 2009 Bee Colony (ABC) has been applied to minimize the total cost of the equipment including capital invest-
Received in revised form 12 July 2011 ment and the sum of discounted annual energy expenditures related to pumping of shell and tube heat
Accepted 13 July 2011
exchanger by varying various design variables such as tube length, tube outer diameter, pitch size, baffle
Available online 11 August 2011
spacing, etc. Finally, the results are compared to those obtained by literature approaches. The obtained
results indicate that Artificial Bee Colony (ABC) algorithm can be successfully applied for optimal design
Keywords:
of shell and tube heat exchangers.
Heat exchangers
Shell and tube heat exchanger
Ó 2011 Elsevier Ltd. All rights reserved.
Economic optimization
Artificial Bee Colony (ABC) algorithm
0196-8904/$ - see front matter Ó 2011 Elsevier Ltd. All rights reserved.
doi:10.1016/j.enconman.2011.07.003
A. Sßencan Sßahin et al. / Energy Conversion and Management 52 (2011) 3356–3362 3357
Nomenclature
are feasible with respect to traditionally designed exchangers. In DE are applied over a wide range of the key parameter combina-
particular, in the examined cases a reduction of total costs up to tions considered. The performance of DE and GA is compared with
more than 50% was observed [5]. Özçelik has carried out exergetic respect to some criteria identified and defined in this study. It is
optimization of shell and tube heat exchangers using a genetic found that DE, an exceptionally simple evolution strategy is signif-
based algorithm. Genetic based algorithm was developed, pro- icantly faster compared to GA, yields the global optimum over a
grammed, and applied to estimate the optimum values of discrete wide range of the key parameters and proves to be a potential
and continuous variables of the MINLP (mixed integer nonlinear source for accurate and faster optimization [7]. Optimization of
programming) test problems. The genetic based algorithm was ex- shell and tube heat exchangers using global sensitivity analysis
tended to make parametric studies and to find optimum configura- (GSA) and harmony search algorithm (HSA) by Fesanghary et al.
tion of heat exchangers by minimizing the sum of the annual were carried out. To reduce the size of the optimization problem,
capital cost and exergetic cost of the shell and tube heat exchang- non-influential geometrical parameters which have the least effect
ers. The results of the example problems show that the proposed on total cost of shell and tube heat exchangers are identified using
algorithm is applicable to find optimum and near optimum alter- GSA. The HSA which is a meta-heuristic based algorithm is then ap-
natives of the shell and tube heat exchanger configurations [6]. plied to optimize the influential geometrical parameters. To dem-
Babu and Munawar have used differential evolution (DE) and ge- onstrate the effectiveness and accuracy of the proposed
netic algorithm (GA) strategies for the optimal design of shell- algorithm, an illustrative example is studied. Comparing the HSA
and-tube heat exchangers. Bell’s method is used to find the heat results with those obtained using genetic algorithm (GA) reveals
transfer area for a given design configuration along with the that the HSA can converge to optimum solution with higher accu-
pressure drop constraint. The 10 different working strategies of racy [8]. Genetic algorithm has been applied for the optimal design
of shell-and-tube heat exchanger by Selbas et al. The design vari- constraints of arbor strength, arbor deflection, and cutting power.
ables as outer tube diameter, tube layout, number of tube passes, Various cutting strategies are considered to determine the optimal
outer shell diameter, baffle spacing and baffle cut for the optimal process parameters like the number of passes, depth of cut for each
design were used. LMTD method is used to determine the heat pass, cutting speed, and feed. The upper and lower bounds of the
transfer area for a given design configuration. A case study has process parameters are also considered in the study. An application
been made for examination of the performance of genetic algo- example is presented and solved to illustrate the effectiveness of
rithm. From this study they concluded that the combinatorial algo- the presented algorithms. The results of the presented algorithms
rithms such as genetic algorithm provided significant are compared with the previously published results obtained by
improvement in the optimal designs compared to the traditional using other optimization techniques [15]. Further details on ABC
designs [9]. algorithm and its application can be found in Ref. [16].
Artificial Bee Colony (ABC) is a relatively new member of swarm As seen above, studies on optimization of energy systems with
intelligence. The foraging behavior, learning, memorizing and ABC algorithm in the literature was not found. In this paper, ABC
information sharing characteristics of bees have recently been algorithm was applied to the new field. The application of the
one of the most interesting research areas in swarm intelligence. ABC algorithm in the shell and tube heat exchanger optimization
Studies on honey bees are in an increasing trend in the literature design as different from artificial intelligence methods available
during the last few years. ABC algorithm is applied in the fields in the literature is investigated. This algorithm was successfully
as biological simulation, continuous optimization, salesman prob- applied for design and economic optimization of shell and tube
lems, optimization of neural networks. Karaboga analyzes the for- heat exchangers. This study has provided new methodology in
aging behavior of honey bee swarm and proposes a new algorithm the optimization of shell and tube heat exchangers.
simulating this behavior for solving multi-dimensional and multi-
modal optimization problems, called Artificial Bee Colony (ABC).
The algorithm is tested on three well known test functions. From 2. Artificial Bee Colony (ABC) algorithm
the simulation results, it is concluded that the proposed algorithm
can be used for solving uni-modal and multimodal numerical opti- The foraging behavior, learning, memorizing and information
mization problems [10]. Basturk and Karaboga presented another sharing characteristics of honeybees have recently been one of
ABC algorithm and expanded the experimental results of Karaboga the most interesting research areas in swarm intelligence. ABC
(2005). The performance of the algorithm is tested on five multi- algorithm is a swarm intelligent optimization algorithm inspired
dimensional benchmark functions and the results were compared by honey bee foraging [17]. Recently, there are some studies about
with genetic algorithms. It is pointed out that ABC algorithm out- ABC algorithm. ABC as an optimization tool provides a population-
performs genetic algorithm for functions having multi-modality based search procedure in which individuals called foods positions
and uni-modality [11]. Pham et al. optimized the weights of Mul- are modified by the artificial bees with time and the bee’s aim is to
ti-Layered Perceptions (MLP) using the bees algorithm. The train- discover the places of food sources with high nectar amount and
ing of a MLP network can be regarded as the minimization of an finally the one with the highest nectar. In ABC system, artificial
error function. The error function defines the total difference be- bees fly around in a multidimensional search space and some (em-
tween the actual output and the desired output of the network ployed and onlooker bees) choose food sources depending on the
over a set of training patterns. In terms of the bees algorithm, each experience of themselves and their nest mates, and adjust their
bee represents a MLP network with a particular set of weight vec- positions. Some (scouts) fly and choose the food sources randomly
tors. The aim of the algorithm was to find the bee with the set of without using experience. If the nectar amount of a new source is
weight vectors producing the smallest value of the error function. higher than that of the previous one in their memory, they memo-
Despite the high dimensionality of the problem, the algorithm suc- rize the new position and forget the previous one. Thus, ABC sys-
ceeded to train more accurate classifiers than back propagation tem combines local search methods, carried out by employed
algorithm [12]. Pham et al. presented optimization of neural net- and onlooker bees, with global search methods, managed by
works for the identification of defects in wood veneer sheets. The onlookers and scouts, attempting to balance exploration and
bees algorithm was used instead of a back propagation algorithm exploitation process [18].
to optimize the weights of the neural network. The optimization This model that leads to the emergence of collective intelligence
using the bees algorithm involves the bees searching for the opti- of honeybee swarms consists of three essential components: food
mal values of the weights assigned to the connections between sources, employed foragers, and unemployed foragers, and defines
the neurons within the network where each bee represents a neu- two leading modes of the honeybee colony behavior: requirement
ral network with a particular set of weights. The aim of the Bees to a food source and abandonment of a source. The main compo-
Algorithm was to find the bee producing the smallest value of nents of this model as below [18]:
the error function. The experimental results show that the Bees
Algorithm was able to achieve an accuracy that was comparable 1. Food Sources: In order to select a food source, a forager bee
to the back propagation method. However, the Bees Algorithm evaluates several properties related with the food source such
proved to be considerably faster [13]. Quijano and Passino devel- as its closeness to the hive, richness of the energy, taste of its
oped an algorithm, based on the foraging behavior of honey bees, nectar, and the ease or difficulty of extracting this energy. For
to solve resource allocation problem. The primary sources for con- the simplicity, the quality of a food source can be represented
structing components of the proposed model were: dance strength by only one quantity although it depends on various parameters
determination, dance threshold, unloading area, dance floor and mentioned above.
recruitment rates, explorer allocation and its relation to recruit- 2. Employed foragers: An employed forager is employed at a spe-
ment. They also proposed an engineering application on dynamic cific food source which she is currently exploiting. She carries
resource allocation for multi-zone temperature control, to high- information about this specific source and shares it with other
light the main features of the dynamical operation of the honey bees waiting in the hive. The information includes the distance,
bee social foraging algorithm [14]. Venkata Rao and Pawar pre- the direction and the profitability of the food source.
sented optimization aspects of a multi-pass milling operation 3. Unemployed foragers: A forager bee that looks for a food source
using ABC. The objective considered is minimization of production to exploit is called unemployed. It can be either a scout who
time (i.e. maximization of production rate) subjected to various searches the environment randomly or an onlooker who tries
A. Sßencan Sßahin et al. / Energy Conversion and Management 52 (2011) 3356–3362 3359
to find a food source by means of the information given by the food sources and calculating the nectar amounts; and determining
employed bee. the scout bees and placing them onto the randomly determined
food sources [19].
The main steps of the algorithm are as below [18]:
3. Heat exchanger design formulations
1. Initialize population
2. Repeat The area for a heat exchanger is calculated by [20,21]:
3. Place the employed bees on their food sources
Q
4. Place the onlooker bees on the food sources depending on their S¼ ð1Þ
nectar amounts U DT LM F
5. Send the scouts to the search area for discovering new food where Q is the heat load, U is the overall heat transfer coefficient,
sources DTLM is the logarithmic mean temperature difference for the coun-
6. Memorize the best food source found so far ter flow arrangement and F is its correction factor.
7. Until requirements are met Overall heat transfer coefficient [22,23]:
1
The flowchart of the Artificial Bee Colony algorithm is given in U¼ ð2Þ
1 do
Fig. 2. Each cycle of the search consists of three steps after initial- hs
þ Rfs þ di
Rft þ h1t
ization stage: placing the employed bees onto the food sources and
calculating their nectar amounts; placing the onlookers onto the di ¼ 0:8do ð3Þ
Table 1
Design specifications for different case studies [5].
Reynolds number is determined as follows: 4. Optimization design of heat exchanger design and objective
v t di function
Re ¼ ð4Þ
t
The tube sheet patterns and pitch, the fouling resistances and
The tube side heat transfer coefficient ht can be determined the thermophysical properties of fluids were accepted as fixed
from the equation of Nusselt number [22,23]: parameters in the optimization design of heat exchanger design.
ht di The optimization variables are the shell inside diameter, tube out-
Nu ¼ ¼ 0:023 Re0:8 0:4
t Pr t ð5Þ side diameter, the number of tube side passages and baffles spac-
k
ing. Based on the actual values of the design specifications and
Nu k the fixed parameters, and on the current values of the optimization
ht ¼ ð6Þ variables, the exchanger design routine determines the values of
di
the shell side and tube side heat transfer coefficients, the heat ex-
where ft is the Darcy friction factor given as [1]: changer area, the number of tubes, the shell and tube length and
ft ¼ ð1:82log10 Ret 1:64Þ2 ð7Þ the tube side and shell side flow velocities and, thus defining all
constructive details of the exchanger satisfying the assigned ther-
The shell side heat transfer coefficient hs can be found as [20]: mal duty specifications. The computed values of flow velocities
0:14 and the constructive details of the exchanger structure are then
k 1 lt
hs ¼ 36 Re0:55
s Pr3s ð8Þ used to evaluate the objective function. The optimization algo-
De lw rithm, based on the value of the objective function, updates the
The equivalent shell diameter can be computed as follows trial values of the optimization variables which are then passed
[20,21]: onto the design routine to define a new architecture of the heat ex-
For square tube pitch: changer. The process is iterated until a minimum of the objective
2
function is found or a prescribed convergence criterion is met.
4 Pt 2 p4do The objective function has been assumed as the total present
De ¼ ð9Þ cost C tot [5]:
pdo
and for triangular tube pitch:
2
4 ð0:43 Pt 2 0:5 p do Þ
De ¼ ð10Þ Table 2
0:5 p do
Comparison of other results with the results of this study for Case study-1.
Flow velocity for the tube side can be obtained from [20,21]: Case study-1
mt n
vt ¼ pdo ð11Þ The results of Ref. The results of Ref. The results of this
4
qt N t [21] [5] study
Ds (m) 0.894 0.83 1.3905
Flow velocity for the shell side can be obtained from [20,21]: B (m) 0.356 0.5 0.4669
ms do (m) 0.02 0.016 0.0104
vs ¼ ð12Þ S (m2) 278.6 262.8 230.109
as qs
Nt 918 1567 1528
The shell side passes area and clearance [20,21]: vt (m/s) 0.75 0.69 0.36
vs (m/s) 0.58 0.44 0.118
Ds B Cl ht (W/ 3812 3762 3818
as ¼ Cl ¼ Pt do ð13Þ m2 K)
Pt
hs (W/ 1573 1740 3396
The number of tube is calculated as [21]: m2 K)
n1 U (W/ 615 660 832
Ds m2 K)
Nt ¼ K 1 ; ð14Þ L (m) 4.83 3.379 3.963
do
DPt (Pa) 6251 4298 3043
where constants K 1 and n1 are defined according to the number of DPs (Pa) 35,789 13,267 8390
passes and tubes arrangement. Ci (€) 51,507 49,259 44,559
Co (€/ 2111 947 1014.5
The necessary tube length L follows as: year)
S CoD (€) 12,973 5818 6233.8
L¼ ð15Þ Ctot (€) 64,480 55,077 50,793
p do Nt
A. Sßencan Sßahin et al. / Energy Conversion and Management 52 (2011) 3356–3362 3361
Table 3 Table 4
Comparison of other results with the results of this study for Case study-2. Comparison of other results with the results of this study for Case study-3.
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