Energy 195 (2020) 116922

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Energy
journal homepage: www.elsevier.com/locate/energy

Synthesis and simultaneous MINLP optimization of heat exchanger

network, steam Rankine cycle, and organic Rankine cycle
Xiaojian Huang, Pei Lu, Xianglong Luo*, Jianyong Chen, Zhi Yang, Yingzong Liang,
Chao Wang, Ying Chen
School of Material and Energy, Guangdong Provincial Key Laboratory of Functional Soft Condensed Matter, Guangdong University of Technology,
Guangzhou, China

a r t i c l e i n f o a b s t r a c t

Article history: Process plants are typically energy intensive plants and pollutant emission contributors. Energy inte-
Received 21 April 2019 gration in process plants effectively reduces energy consumption and pollutant emission. In a traditional
Received in revised form energy integration concept, a heat exchanger network (HEN) is typically constructed for heat recovery
8 December 2019
between process streams. However, a large amount of medium-to-low-temperature surplus heat usually
Accepted 6 January 2020
Available online 11 January 2020
occurs in hot streams, where further internal heat integration is impossible, and is inevitably cooled by
external cold source. Integrating organic Rankine cycle (ORC) into the process HEN is an effect way in
further enhancing the energy recovery. However, the HEN, utility plant, and ORC are traditionally
Keywords:
HEN
designed and optimized separately or sequentially, resulting in local energy integration or optimization.
MINLP In the present study, ORC is integrated into a HEN to generate power energy from surplus heat. An
Organic Rankine cycle improved superstructure is constructed and a mixed integer non-linear programming model is devel-
Optimization oped for the synthesis and simultaneous optimization of the integration system containing process-
Heat recovery process HEN, hot utility-cold stream HEN, process hot stream-ORC HEN, steam utility plant, and cold
utility plant. Two case studies of different scale in complexity are elaborated to validate the proposed
methodology. Sensitivity analysis of carbon tax and fuel price are finally conducted.
© 2020 Elsevier Ltd. All rights reserved.

1. Introduction
The limited fossil fuel reserves and increasing concern on the
greenhouse effect push the industrial energy system toward a
sustainable direction. In process plants, heat and cold streams must
be cooled and heated, respectively, to their target temperatures.
Heat integration (HI) under certain rules between hot and cold
streams can be performed to maximize the heat recovery and
minimize the hot and cold utility requirements for process plants
[1]. Hot and cold streams compose a heat exchanger network
(HEN). The extra heat and cold demand after HI between hot and
cold streams in HENs are provided from the utility plants.
In the traditional HI concept, the utility plant is generally
designed separately from the HEN. Cerda et al. [2] presented a
transportation model for the minimization of the utility cost after
the HEN is designed. A transshipment model was developed by
* Corresponding author. School of Material and Energy, Guangdong University of
Technology, Guangzhou, 510006, China.
E-mail address: lxl-dte@gdut.edu.cn (X. Luo).
Papoulias and Grossmann [3] to minimize the utility cost for a
process system with a pre-defined HEN. Recently, the design of
utility plant together with a HEN has received significant attention,
and many innovative methods have been proposed. Zhang et al. [4]
presented a mixed-integer nonlinear programming (MINLP) model
that integrate the process plants and utility systems. Luo et al. [5]
presented a novel method for the simultaneous synthesis and
optimization of a HEN and utility system. Steam condensate and
boiler feed water (BFW) were incorporated to recover the surplus
heat in the HEN. These studies showed that integration or opti-
mization of HENs and utility systems saves remarkable energy or
cost compared with the conventional separate design concept.
However, previous research showed that a mass of low-
temperature surplus heat is available after HI in HENs, and must
be cooled by external cold utility. The use of external technology to
further recover surplus heat in HENs is significant in further
reducing fuel consumption and pollutant emission.
Recently, numerous studies have been conducted to integrate
HENs with energy systems (e.g., absorption cycle [6], heat pumps
and engines [7], thermal membrane distillation systems [8],

https://doi.org/10.1016/j.energy.2020.116922
0360-5442/© 2020 Elsevier Ltd. All rights reserved.
2 X. Huang et al. / Energy 195 (2020) 116922
multiple-effect evaporation system [9] and organic Rankine cycle
(ORC) [10]) to recover surplus heat. In a variety of heat recovery
technologies, ORC has been regarded as one of the widely accepted
low-grade heat driven power generation technology [11]. In ORC,
organic fluids are used as working medium, different from the use
of water as the working fluid in Rankine cycle. The utilization of
ORC to recover waste heat from process plants has drawn consid-
erable attention in the past few years [12]. Yari et al. [13] conducted
a comparison of the thermodynamic and exergoeconomic perfor-
mances of ORC, Kalina cycle, and trilateral Rankine cycle. Their
findings showed that ORC is the most advantageous of the three
options in term of economic performance.
For the integration of HEN and ORC, some studies proposed
step-by-step methods. Gutie rrezeArriaga et al. [14] proposed a
two-stage HI approach. In the first stage, a grand composite curve
was established for the process streams to determine the HI targets,
waste heat available to drive ORC, cold utility load, and refrigeration
load. In the second stage, a genetic algorithm was used to deter-
mine the optimal ORC structure and operating conditions. Desai
and Bandyopadhyay [15] proposed a manual trial-and-error opti-
mization for the integration of ORC and HEN to recover surplus heat
of chemical processes. The operating conditions of ORC were
determined manually using pinch technology, and a heuristic
method was used to derive the HEN. Chen et al. [16] proposed a
two-step method for optimizing ORC and synthesizing HEN. In the
first step, a stand-alone HEN was synthesized to minimize the
demand for hot utility. In the second step, ORC was incorporated
into the surplus heat zone to maximize the power output below the
pinch point. The design parameters (e.g., condensation tempera-
ture and evaporation temperature) of ORC were fixed, and the
rigorous thermodynamic models of ORC were not included. Stije-
povic et al. [17] proposed a pinch analysis and mathematical pro-
gramming combined method to determine the optimum structure
of ORC and working mediums for various heat sources. The number
of ORC stages, HEN configuration, operating parameters, and the
working medium used in each cascade were considered to maxi-
mize the power output in ORC.
The step-by-step method mainly focused on the synthesis of
ORC with the surplus heat from the HEN. The simultaneous opti-
mization of HEN and ORC have drawn more and more attention.
HipolitoeValencia et al. [10] proposed a procedure for the inte-
gration of ORC and process plants. Their studies showed that the
proposed procedure is more cost-saving than an earlier developed
method using a sequential approach for discovering optimally in-
tegrated systems. Chen et al. [18] proposed a superstructure for
HEN synthesis; the superstructure contains ORCs which are used to
recover low-grade waste heat through a circulating heat transfer
fluid. And a unified MINLP model was developed for the synthesis
T (oC)
Cold utility system ORC system
Expander
Cooling
tower
C
Pump
Fig. 1. General relationship between HEN, ORC, and utility plants.
and optimization of the integration system. A case study of crude-
preheat train example demonstrated the effectiveness of the pro-
posed superstructure and MINLP formulation. Yu et al. [19e21]
presented several studies for the integration of ORC and HEN.
Integration of ORC and HEN was performed based on pinch tech-
nology in Yu et al. [19]. A mathematical programming model
integrating ORC into background process was proposed to maxi-
mize the net power output of ORC in Yu et al. [20]. In Yu et al. [21],
hot-water stream was proposed as an intermediate to recover
multiple waste heat streams. The hot water was considered a cold
stream in the HEN and as heat source in the ORC system.
Previous studies showed the considerable attention paid to the
integration of HEN and ORC to further improve the HI on the basis
of traditional HEN. Most of these studies applied the concept of
pinch integration and sequential method. The synthesis and design
of HEN and ORC were typically conducted with pre-specified ORC
structure, or the HEN and ORC were designed in sequence. Given
that the earning of ORC is power or electricity, and that of HENs is
heat recovery, the inconsistent objectives cause difficulty in eval-
uating the HENeORC integration system. Recently, the HI of HEN
and the utility plants has been substantially studied [22]. However,
the integration of HEN, utility plants and ORC was not reported
[23]. To fill the research gap, the present study proposes the inte-
gration of hot and cold utility plants, HENs, and ORC with various
working fluids. Fig. 1 shows the relationship among the HEN, ORC,
and utility plants. Heat recoveries of hot and cold streams are
determined according to pinch integration rules. The hot utility
plant provides hot utility energy for cold streams. ORC is integrated
into the HEN to absorb surplus heat and cogenerate power. Hot
stream is finally cooled to its target temperature using cold utility
provided by cold utility plant. Fig. 1 indicates the strong interlink-
age among the HEN, ORC, and utility plants. Appropriate modeling
and optimization method are required to maximize the global
performance of the integrated system.
Thus, an improved modelling framework and solution strategy
is proposed to integrate and simultaneous optimize the process
HEN, SRC, ORC and cold utility system. A MINLP model is con-
structed to synthesize and simultaneously optimize the proposed
integration system. The method incorporates rigorous thermody-
namic models of steam Rankine cycle (SRC)-based utility plant with
condensate heat recovery, ORC for the surplus heat recovery, and
cold utility plant for the cooling of hot streams. The objective is to
minimize the total annual cost (TAC) consists of capital investment
cost, operating cost, and environmental cost. The synthesis and
optimization aim to determine a design scheme for the HEN (the
number of heat exchangers, and heat exchange between hot and
cold streams), SRC (steam flow rate at all inlet/outlet of turbine, and
final temperature for hot utilities), and ORC (working fluid flow
Utility system
Boiler
Turbine
Pinch point C
Deaerator
H (kW)
 X. Huang et al. / Energy 195 (2020) 116922
rate, evaporating temperature, and condensing temperature). Two
case examples are elaborated to demonstrate the superiority of the
proposed methodology, and sensitivity analyses of carbon tax and
fuel price is also conducted. To the best of our knowledge, consid-
ering the system model for the efficient integration of HEN with
SRC, ORC and cold utility system which simultaneously exploits the
structural features, working fluids, and thermo-economic-
environmental objectives has not been found in the open literature.
2. Problem description
The entire problem can be described as follows: Presetting hot
streams which must be cooled and cold streams which must be
heated, with given properties (their inlet temperatures, outlet
temperatures, and heat-capacity flow rate). And the basic structure
of SRC and ORC are specified, including three types of working
mediums and their thermo-physical properties. Additional data
consists of investment cost for the utility components and heat
exchangers, unit price for fuel, electric power generated from SRC
and ORC, heat transfer coefficients for all streams, and minimum
allowable temperature differences (DTmin) of the entire HENs. Then
the integration problem contains in achieving the optimum
configuration of the sub-HENs; areas of all the heat exchangers;
design load and operation parameters of components in the utility
system; cold utilities requirement from the HEN, condensers of SRC
and ORC, and the minimum total annual cost (TAC).
Fig. 2 shows the superstructure of the proposed integration
system. The integration system comprises five sections: a HEN
consists of process hot and cold streams (PPHEN), a HEN consists of
cold streams leaves PPHEN and hot utility streams (PHUHEN), a
HEN consists of hot stream leaves PPHEN and ORC (PORCHEN), and
a HEN consists of hot streams leave PORCHEN and cold utility
streams (PCUHEN). The constructed PPHEN is a traditional HEN in
which process heat recovery is achieved by reasonably matching
hot and cold streams. In the PHUHEN, both latent and sensible heat
of steam are used as hot utilities. SRC-based utility plant [5] is used
to cogenerate steam and power [24e27]. The SRC-based utility
plant is easily extended to other types of utility plants when
necessary. In PORCHEN, an ORC is integrated to recover surplus
PHUHEN PPHEN
huk1 ... hukn pk1 ...
hui pi1
...
pin
Turbine
Fuel
Boiler Condenser
Pump
Deaerator
Fig. 2. Superstructure of the proposed integration system.
3
heat from hot streams. A general ORC comprises an evaporator, an
expander, a condenser, and a pump. After heat recovery in
PORCHEN, hot streams are cooled to their target temperatures by
cold utility. Fig. 3 displays the schematic and TeS diagram of a
simple ORC. In PCUHEN, the surplus heat of hot streams after
releasing heat in PORCHEN is cooled by cold utility. A cooling tower
is designed to provide cold utility for cooling the process hot
streams, steam leaves the turbine in the SRC, and vapor leaves the
ORC.
The aim of the present study is to model and solve the proposed
synthesis and optimization problem depicted in Fig. 2. Though the
integration system is decomposed into several sub-HENs from high
to low temperature in cascade, the simultaneous optimization of
four HENs, ORC, and SRC presents difficulty in solving the problem.
Traditional pinch technology is difficult to guarantee the optimal
solution when solving this kind of HI problem, thus requiring a
solution strategy. The following two sections will present a detailed
model and a strategy for solving the MINLP problem.
3. Model formulation
The models for process integration and optimization are
formulated based on the superstructure shown in Fig. 2. The entire
system can be divided into four subsystems, i.e., PPHEN, PHUHEN,
PORCHEN, and PCUHEN. Thus, the optimization model of the entire
integration system consists of four sub-HENs, SRC, ORC, cooling
tower, coupling constraints of these sub-systems, and objective
functions.
In the present study, PPHEN is a conventional HEN, whereas
PHUHEN and PORCHEN differ from the conventional HEN to a
certain extent. Both latent and sensible heat of steam generated
from the SRC are simultaneously used as hot utilities [5]. Thus, a
steam stream is divided into latent condensing stream and sensible
condensate stream. For the latent condensing stream, the temper-
ature remains unchanged. For the sensible condensate heat stream,
inlet temperature is the same as the saturate temperature, whereas
the outlet temperature varies. In PORCHEN, the working fluid is
heated in the evaporator from a subcooled liquid to saturation
liquid, saturation vapor, and finally superheating vapor. Thus, the
PORCHEN PCUHEN
pkn orck1 ... orckn
C
C
pj1 orcj
...
pjn
Cooling Makeup water
Expander tower
Condenser
Pump
4 X. Huang et al. / Energy 195 (2020) 116922

Fig. 3. Representation of a simple ORC: a) Schematic; b) TeS diagram.

working fluid stream should be divided into pre-heating, evapo-

Start
rating, and superheating sections. In preheating and superheating
stages, the heat exchange process is similar to that of hotecold
Model formulation and validation
streams. In the evaporating section, the working fluid tempera-
HEN, utility system and ORC model formulation and validation
ture shows no change. Generally, hot streams represent all the
streams that release heat and cold streams represent all the
Data input Input data
streams that absorb heat. In the present paper, i represents hot -Process streams properties
streams, which can be part of or consist the entire hot process -Thermophysical properties of working fluids
stream (pi) and hot utility stream (hui); and j represents cold -Film heat transfer coefficients
streams, which can be part of or make up the whole cold process -Minimum temperature difference
stream (pj) and ORC stream (orcj). Each subsystem is divided into
two heat transfer stages. pk, huk and orck denote stage in PHUHEN, Objective
PPHEN and PORCHEN, respectively. Nomenclature Section lists all Min =TAC
other subscripts, variables and parameters. The model is composed
of the HEN model, SRC model, cooling tower model, ORC model, Initial solution Solve relaxed model (RMINLP)
using solver CONOPT, MINOS
interlink constraints between sub-HENs, and objective functions.
and SNOPT in sequence
The HEN, SRC, and cooling tower models are commonly used
models and are described in detail in the previous study [5] and is Next solver
not repeated in this study. The ORC model, the entire energy system
integration model, constraints, and objective functions are formu- Is the solution of RMINLP No
“optimal ” or “locally optimal”
lated in this section. Notably, the proposed integration problem is
formulated into mathematical programming model and deter-
ministic optimization method is applied as shown in Fig. 4. YES
Local solution
Initialize original model and solve model
using solver DICOPT

3.1. Energy balances for process streams Global solution

Solve model using solver ANTIGONE
According to the proposed structure, hot streams enter from the
left side of each subsystem, whereas cold streams enter from the Final Solution
right side. Hot streams release heat, whereas cold streams absorb it.
Hot streams show a downward trend in temperature, whereas cold Fig. 4. Problem solution strategy and procedure.
streams exhibit an upward trend.
As shown in Fig. 2, process hot streams are cooled from their
supply temperatures to their target temperatures sequentially by
process cold streams, ORC working fluid, and cold utility. The heat
balances of process hotecold streams are formulated by Eq. (1), X X X X
qpi;pj;pk þ qpi;orcj;orck þ QCpi
where qpi,pj,pk denotes the quantity of heat transferred between hot
pj2PJ pk2PK orcj2ORCJ orck2ORCK
stream pi and cold stream pj at stage pk; qpi,orcj,orck denotes the  
quantity of heat transferred between hot stream pi and cold stream ¼ FHpi Tpi;in  Tpi;out cpi2PI (1)
orcj at stage orck; QCpi denotes the cold utility load used to cool hot
stream pi; FHpi, Tpi,in, and Tpi,out, represent the heat capacity flow
and inlet/outlet temperatures of hot stream pi, respectively. Simi- X X X X
larly, Eq. (2) indicates that process cold streams are heated by qpi;pj;pk þ qhui;pj;huk
process hot streams and/or hot utilities, where qhui,pj,huk denotes the pi2PI pk2PK hui2HUIhuk2HUK
quantity of heat transferred from stream hui to stream pj at stage  
¼ FCpj Tpj;in  Tpj;out (2)
huk; FCpi, Tpj,in, and Tpj,out, stand for the heat capacity flow and inlet/
out temperature of stream pj, respectively.
 X. Huang et al. / Energy 195 (2020) 116922 5

3.2. Modeling for ORC

WTorcj ¼ Morcj ðh4  h5 Þ (8)
ORC is a promising low-grade heat driven power generation
technology. ORC has also recently been a hot topic in energy-related QCorcj ¼ Morcj ðh5  h1 Þ (9)
fields; modeling a simple ORC is not a difficult task. However,
specific constraints and rules must be constructed when inte-
WTpump ¼ Morcj ðh2  h1 Þ (10)
grating ORC into HENs. In addition, working fluid properties are
typically extracted from a database, such as Refprop, or calculated  
from the equation of states. In the present study, to guarantee hORC ¼ WTorcj  WTpump QHorcj (11)
simultaneous optimization of the integrated system, regression
Eqs. 12e21 provide the fitting formula for the state points in
method is used to correlate the properties of working fluid as a
Fig. 3. Suppose that the working fluid entering the expander at
function of operating parameters.
saturate vapor state, all properties of working fluid can be formu-
lated as a function of evaporation temperature Te and/or
3.2.1. Energy balances of ORC
condensing temperature Tc. The specific enthalpy of saturated state
The energy balance of the internal stages for PORCHEN differs
points (i.e., points 1, 3, 4, and 6) are regressed as a formulation of
from that for PPHEN because the working fluid heating typically
one independent variable (e.g., Te or Tc) as shown by Eqs. (12), (15),
consists of preheating, evaporating and superheating processes. As
(16) and (19). The isentropic enthalpy rise in the pump Dh1-2s and
discussed in previous studies [28,29], superheating of working fluid
isentropic enthalpy drop in the expander Dh4-5s can be fitted as a
usually causes no improvement in the ORC performance; thus
function of Te and Tc as formulation by Eqs. (13) and (17). Then the
working medium superheating is not considered in the present
enthalpies of point 2 and 5 can be calculated from Eqs. (14) and
study. In this section, a working fluid stream is separated into
(18), where he and hp are the isentropic efficiencies of the
preheating and evaporating streams. Eq. (3) denotes the heat bal-
expander and pump, respectively. T2 is regressed as a function of Te
ance for hot process stream pi in PORCHEN. Eq. (4) provides the
and h2 while T5 is regressed as a function of Tc and h5 as given by
heat balance of working fluid preheating, and Eq. (5) calculates the
Eqs. (20) and (21). The fitting parameters are listed in Appendix A.
heat balance of evaporating working fluid, where Morcj is the mass
As shown in Appendix A, all of the determination coefficients (R2)
ratios of the working fluid, ORD and CARD represent the order and
of the regressed equations exceed 0.99, indicating the accuracy and
total element amount in a set respectively, and LHorcj indicates the
reliability of the formulated model.
evaporation latent heat. Eq. (6) constraints that the mass flow rate
of working medium is equal for preheating and evaporating
h1 ¼ cfaa þ cfbbTC þ cfccT 2C (12)
streams.
 
qpi;orcj;orck ¼ FHpi tpi;k  topi;orcj;orckþ1 Dh12s ¼ cfdd þ cfeeTE þ cfffT 2E þ cfggTC þ cfhhT 2C (13)
(3)
cpi2PI; corcj2ORCJ; orck2ORCK
Dh12s
h2 ¼ h1 þ (14)
  hp
qpi;orcj;orck ¼ FCorcj tipi;orcj;orck  torcj;orckþ1
.
cpi2PI; corcj2ORCJ; ORDðorcjÞ ¼ CARDðorcjÞ 2; orck2ORCK h3 ¼ cfaa þ cfbbTE þ cfccT 2E (15)

(4)
h4 ¼ cfii þ cfjjTE þ cfkkT 2E (16)
qpi;orcj;orck ¼ Morcj LHorcj cpi2PI; corcj2ORCJ; ORDðorcjÞ
(5) Dh45s ¼ cfll þ cfmmTE þ cfnnT 2E þ cfooTC þ cfppT 2C (17)
> CARDðorcjÞ=2; orck2ORCK

h5 ¼ h4  Dh45s he (18)

Morcj ¼ MorcjþCARDðorcjÞ=2 corcj2ORCJ; ORDðorcjÞ ¼ CARDðorcjÞ h6 ¼ cfii þ cfjjTC þ cfkkT 2C (19)

(6)
The working fluid in ORC (Fig. 3) is integrated in PORCHEN to T2 ¼ cfqq þ cfrrTE þ cfssh2 (20)
recover surplus heat of hot stream after process hotecold stream
integration. Eq. (7) expresses the energy balance in ORC evapora- T5 ¼ cftt þ cfuuTC þ cf vvh5 (21)
tors, and Eq. (8) yields the power generation of ORC. Eq. (9) cal-
culates the heat load of the cold utility for the ORC condenser, and
Eq. (10) expresses the power consumption of the pump in the ORC
system. h1, h2, h4 and h5 are enthalpies of the corresponding state
points. Eq. (11) shows the thermal efficiency of the ORC system. 3.2.2. Temperature feasibility constraints in ORC system
Eq. (22) guarantees that the temperature of streams orcj is
X X X
QHorcj ¼ qpi;orcj;orck ¼ Morcj ðh2  h4 Þ higher than or equal to the condensing temperature (Tc). Eq. (23)
pi2PI orcj2ORCJ orck2ORCK guarantees that the temperature of process cold streams orcj is
less than or equal to the evaporation temperature (Te). Notably, the
(7)
evaporation temperature (Te) should be higher than the
condensing temperature (Tc).
6 X. Huang et al. / Energy 195 (2020) 116922

torcj;orck  Tc corcj2ORCJ; orck2ORCK (22) CARDðhuiÞ

thui;huk ¼ Thui;in chui2HUI; ORDðhuiÞ  ; huk2HUK
2
tipi;orcj;orck  Te cpi2PI; corcj2ORCJ; orck2ORCK (23) (32)

CARDðhuiÞ
thui;huk¼1 ¼ Thui;in chui2HUI; ORDðhuiÞ > ; huk2HUK
2
3.3. Connection of HENs, SRC, and ORC as well as the border (33)
temperature setting for HENs
tpj;huk¼1 ¼ tpj;pk¼CARDðPKÞþ1 chui2HUI; ORDðhuiÞ
As demonstrated in Fig. 2, the superheating steams extracted CARDðhuiÞ (34)
from turbine are first de-superheated to saturated steams and then > ; huk2HUK
2
delivered to the HENs. After cooled by the cold stream, the satu-
rated steam become condensate water and returns to the SRC and Eq. (35) indicates that the inlet temperature of the first stream
enters the deaerator. Eqs. (24)e(27) express the mass balance and orcj (torcj¼1, orck¼CARD (ORCK)þ1) equals to the outlet tempera-
energy balance for medium pressure (MP) and intermediate pres- ture of working fluid from the pump (T2) in ORC. Eq. (36) denotes
sure (IP) extractions, where Mhui is the mass flow rate for hot that the temperature of the second stream orcj (tipi,orcj¼2,orck) and
stream, and MTMP,ext and MTIP,ext are the MP and IP steam extraction the evaporating temperature in the ORC system are equal. Eq. (37)
flow rates, respectively. MWMP and MWIP are the mass flow rates of expresses that the outlet temperature of the first stream orcj
water for cooling superheated MP and IP steam, respectively. HT1,out, (tipi,orcj¼1,orck¼1) and the temperature of the evaporating tempera-
HT2,out, and HWDEA are the steam enthalpies of subsection 1 outlet, ture in the ORC system are equal. Notably, all the inlet/outlet
subsection 2 outlet, and the enthalpy of BFW leaving the deaerator, temperatures of streams orcj are design variables.
respectively. Eqs. (28) and (29) indicate the mass and energy bal-
torcj¼1;orck¼CARDðORCKÞþ1 ¼ T2 corcj2ORCJ; orck2ORCK (35)
ances of deaerator, respectively, where MB is the boiler steam
generation flow rate, HCONDSz¼CARD(z),out is the enthalpy of turbine
condensing water, thui is the temperature of hot stream hui, and tipi;orcj¼2;orck ¼ Te cpi2PI; corcj2ORCJ; orck2ORCK (36)
HBGEN is the enthalpy of steam generated in the boiler.

Mhui¼1 ¼ MTMP;ext þ MWMP (24) tipi;orcj¼1;orck¼1 ¼ Te cpi2PI; corcj2ORCJ; orck2ORCK (37)

Mhui¼1 HSatMP ¼ MTMP;ext HT1;out þ MWMP HWDEA (25)

Mhui¼2 ¼ MTIP;ext þ MWIP (26) 3.4. Objective functions

In the present study, the aim of the proposed problem is to

Mhui¼2 HSatIP ¼ MTIP;ext HT2;out þ MWIP HWDEA
MTLP;ext þ MTz¼ORDðzÞ;out þ Mhui¼1 þ Mhui¼2
¼ MB þ MWMP þ MWIP
MTLP;ext HT1;out þ MTz¼CARDðzÞ;out HCONDSz¼CARDðzÞ;out
þ 4:2Mhui¼1 thui¼3;huk¼CARDðhukÞþ1
þ 4:2Mhui¼2 thui¼4;huk¼CARDðhukÞþ1
 ðMB þ MWMP þ MWIP Þ*HBGen
Eq. (30) shows the modelling rules for the starting inlet tem-
perature, outlet temperature, and interlink temperature for the
streams in PPHEN and PHUHEN, where thui,huk and Thui,in represent
the temperature of stream hui at stage huk and inlet temperature of
stream hui, respectively, tpj,huk is the temperature of stream pj at
stage huk.
tpi;pk¼1 ¼ Tpi;in cpi2PI; pk2PK
(27)
design an optimal integration system by minimizing the TAC. The
TAC comprises the investment costs of all components and the
operating cost derive from the fuel and water consumptions minus
(28) the profit achieved from power export [see Eq. (38)]. The invest-
ment cost is composed of the purchase cost of heat exchangers in
all the HENs [see Eq. (39)], components in the SRC-based utility
plant [see Eq. (40)] [30], components in the ORC [see Eq. (41)] [10],
and cooling tower [see Eq. (42)] [31]. The operating cost consists of
the boiler fuel cost [see Eq. (43)], pump power consumption cost in
the ORC system [see Eq. (44)], cooling utility cost (including pump
(29) power consumption cost, draft fan power consumption cost, make-
up water cost, and fixed cost) [see Eq. (45)]; and environmental cost
[see Eq. (47)]. Eq. (46) shows the CO2 emitted from a gas-fired
boiler, where CN refers to the carbon content of fuel, and Ccarbontax
represents the carbon emission charge [32]. Eq. (48) presents the
power export profit from the SRC and ORC.
minTAC ¼ INVHE þ INVUS þ INVORC þ INVCT þ OPFUEL
(30) þ OPORC þ OPCT þ TACcarbontax  WSELL (38)

tpj;pk¼CARDðPKÞþ1 ¼ Tpj;in cpj2PJ; pk2PK (31)

 X. Huang et al. / Energy 195 (2020) 116922 7

X X X h n .   .h  . i1=3 ob i
INVHE ¼ CF*zi;j;k þ Qi;j;k 1 htci þ 1 htcj dtii;j;k dtoi;j;kþ1 dtii;j;k þ dtoi;j;kþ1 2þd þ
i2PI∪HUIj2PJ∪ORCJ k2PK∪HUK∪ORCK
Xh n   .   1=3 ob i
CF*ZCpi þ QCpi 1 htcpi þ 1=htcCW dtcuipi dtcuopi dtcuipi þ dtcuopi 2 þ d
pi2PI
h n . ob i
CF þ QCconds =ð1=htcconds þ 1=hCW Þ ½ðTconds  TCWin ÞðTconds  TCWout Þð2Tconds  TCWin  TCWout Þ=2 þ d1=3
h n . . . . ob i
CF þ QCorcj 1 horcconds þ 1 htcCW ½ðT5  TCWin ÞððT1  TCWout ÞððT5  TCWin Þ þ ðT1  TCWout ÞÞ=2 þ d1=3
(39)

4.2. Solution procedure and strategy

INVUS ¼ CBCoeffa þ MB*CBCoeffb þ CTCoeffa þ WT*CTCoeffb
(40) The formulated model for the synthesis and optimization
problem contains continuous variables (e.g., heat exchange for each
 g  g heat exchanger, flow rate, enthalpy of extraction steam, and oper-
INVORC ¼ KF CV expander WTorcj þ KF CV pump WTpump (41)
ating parameters in ORC), binary variables (e.g., existence of all
candidate heat exchanger), and integer variables (e.g., heat
 
INVCT ¼ 3714  M 0:7 0:65 exchanger number in the HEN). Several discrete variables exist in
cw þ 3516  PW pump
 . the model of the proposed problem. Eqs. Eqn 1, 2, 3, 4, 5, 7, 8, 9, 10,
 1 þ 0:04 þ 0:05 L (42) 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21a, 24, 25, 26, 27, 28, 29, 39, 41, 42
and 45 are all non-linear equations. And, there are a large number
of non-linear equations which are undescribed in this paper. The
OPFUEL ¼ FB*cfuel AHour (43) formulated MINLP optimization model is non-convex. To ensure a
feasible solution, an extension of the previously developed solution
OPORC ¼ WTpump *cpower AHour (44) strategy [5] is used and demonstrated in Fig. 4. A relaxation model
of the original MINLP model is first solved using multiple solvers in
sequence to achieve an initial solution. Then, DICOPT [33], an
OPCT ¼ PWpump *cpower AHour þ PWdraft fans *cpower AHour effective local MINLP solver, is applied to achieve a local solution for
þ Mmakeup cwater AHourþ the original MINLP model. Finally, global solver ANTIGONE [34] is
used to obtain a global solution based on the local solution achieved
  from using DICOPT solver. The MINLP models were coded in the
3714  M 0:7 0:65
cw þ 3516  PW pump  0:01 (45) software GAMS [35] on a 3.0 GHz Intel(R) Core(TM) 2 PC.

Mco2 ¼ 3:667FBAHour*CN (46)

5. Case study

TACcarbontax ¼ Mco2 *Ccarbontax (47) 5.1. Case description

WSELL ¼ WT*cpower AHour þ WTorcj *cpower AHour
4. Model characteristics and solution strategy
4.1. Characteristics of the formulated model
The model of the proposed problem consists of the constraint
formulated by Eqs.(1)e(37) and the objective functions formulated
by. Eqs. (38)e(48) The optimization variables include the following:
existence of all candidate heat exchanger, heat load for each heat
exchanger, flow rate and enthalpy of extraction steam, operating
parameters in ORC, and the power generated from the turbine and
ORC. Among the optimization variables, the existence or absence of
candidate heat exchanger is 0/1 variable. Eqs. (1)e(5), (7)e(21),
(24)e(29), (39), (41), (42) and (45) are all non-linear equations.
At the same time, the undescribed models (e.g., HEN model, SRC
model and cooling tower model) in this paper also have a large
number of non-linear equations. Thus, the formulated optimized
model is a MINLP model.
(48) The cases in Luo et al. [5] are studied in this study to demon-
strate the superiority of the developed methodology. In a previous
work, the steam condensate and boiler feedwater were simulta-
neously integrated into the HENs. However, a remarkable amount
of surplus heat remains in the hot process streams. Therefore, an
integration of SRC, HENs, ORC with various working fluids, and cold
utility plant is proposed. In order to test the synthesis and opti-
mization method of the entire system, two scenarios are studied.
Four solutions (i.e., IHU, IHUO, OIHU, and OIHUO) are achieved (see
Table 1). Solutions IHU and OIHU have been studied in Luo et al. [5].
Then, the influences of carbon tax and fuel price on the optimiza-
tion results are conducted. In this case, three working fluids are
investigated and compared (i.e., R245fa, n-butane, and R123). These
working fluids possess the following properties: (1) dry fluid; (2)
high critical temperature (3) relatively low boiling point at the at-
mosphere pressure [15]. In addition, these working fluids exert
desirable effects on the temperature range of surplus heat from
HENs. Thus, these working fluids are widely used in studies
focusing on the integration of HEN with ORC. This paper aims not to
study the properties of working fluids but to present a simulta-
neous optimization of a novel integration process energy system.
Therefore, these three working fluids (i.e., R245fa, n-butane, and
8 X. Huang et al. / Energy 195 (2020) 116922

Table 1
Description of scenarios and solutions.

Scenario Solution Solution description

Scenario 1 IHU Latent heat of steam is used as hot utility. BFW is heated by the steam extracted from steam turbine.
IHUO ORC is integrated into the IHU to recover surplus heat from the HEN.
Scenario 2 OIHU Condensate heat and BFW are integrated into the system.
OIHUO The proposed integration system in the present study.

21852 kW 24102 kW TAC (k$)

hui1 263.9 oC pi1 195 oC 128.1 oC 13698 kW 90 oC 12151.8
C

11546 kW 11627 kW
14473 kW
hui2 198.3 oC pi2 155 oC 114.9 oC 65 oC
C
4373 kW

240 oC 173.2 oC 125 oC pj1

160 oC 146.3 oC 110 oC pj2

8.1 kg/s 198.3 oC 7.3 kg/s 3056 kJ/kg

13.3 kg/s 263.9 oC 10.7 kg/s 3309 kJ/kg
9.5 MPa 32.8 kg/s

5.0 MPa 1.5 MPa

Cooling Makeup water
Turbine 21054 kW tower
Fuel Boiler 0.008 MPa
2341 kJ/kg
0 kg/s 2945 kJ/kg
Pump C
673 kJ/kg Deaerator

Fig. 5. Design configuration of general integration of HEN and SRC for Case 1.

21852 kW 24117 kW 11799 kW 1884 kW

hui1 263.9 oC pi1 195 oC 128.0 oC 95.2 oC 90.0 oC
TAC (k$) 10579.0

11531 kW 4355kW 11645 kW 5688 kW o 8768 kw

hui2 198.3 oC pi2 155 oC 114.8 oC 95.2 C 65.0 oC

240.0 oC 196.3 oC 173.2 oC 125.0 oC pj1 93.2 oC 32.6 oC orcj1

160.0 oC 146.4 oC 110.0 oC pj2

93.2 orcj2
8.2 kg/s 198.3 oC 7.2 kg/s 3074.4 kJ/kg

13.3 kg/s 263.9 oC 10.7 kg/s 3315.4 kJ/kg

9.5 MPa 22.4 kg/s 5.0 MPa 1.5 MPa

8984.5 kW 3218 kW Cooling Makeup water
Turbine Expander tower
Fuel 2341kJ/kg 2341kJ/kg
2.0kg/s Boiler 0.008 MPa
0.8 MPa 2403.5 kJ/kg
0.0 kg/s 2993.9 kJ/kg 4.5 kg/s
C C
672.5 kJ/kg 32.0 oC Pump
Pump Deaerator

Fig. 6. Design configuration of general integration of HEN, SRC, and ORC using n-butane for Case 1.

Table 2
Comparative economic statistics of the integration system using various working fluids for Case 1.

IHU IHUO-R245fa IHUO-n-butane IHUO-R123

Investment cost of heat exchangers (k$) 1529.9 1383.1 1302.2 1372.6

Investment cost of utility plant components (k$) 2860.0 2039.7 2053.5 2041.4
Investment cost of cold utility components (k$) 40.8 89.7 90.3 89.8
Investment cost of ORC component (k$) e 450.6 456.5 415.5
Operating cost for cold utility (k$) 980.3 682.5 689.5 684.9
Operating cost for fuel (k$) 19541.6 13208.5 13316.6 13221.7
ORC operating cost (k$) e 62.6 89.4 34.5
Profit from selling electricity (k$) 12800.8 7306.9 7419.0 7241.6
Total annual cost (k$) 12151.8 10609.8 10579.0 10618.9
 X. Huang et al. / Energy 195 (2020) 116922 9

Table 3
Comparative statistics of various working fluids in ORC of Case 1.

Items IHUO-R245fa IHUO-n-butane IHUO-R123

Thermal efficiency (%) 10.9 10.9 10.6

Heat absorbed from process hot stream (kW) 27822.8 28138.3 27861.6
Heat removed in the ORC condenser (kW) 24788.5 25067.5 24901.3
Turbine power (kW) 3137.3 3217.9 3017.0
Pump power (kW) 103.0 147.1 56.8
Evaporation temperature ( C) 93.2 93.2 88.0
Condensing temperature ( C) 32.0 32.0 32.0

R123) are considered in this paper. The stream parameters of Case 1
and Case 2 can be found in Luo et al. [5]. Case 1 is a small case with
two hot streams and two cold streams. Case 2 is a relatively large
case with four hot streams and four cold streams. The hot utilities of
both cases are provided by SRC with two steam levels and the inlet
and outlet temperatures of cold utility is 20 and 28  C.
The basic parameters of SRC, process streams, and cold utility
can be found in Luo et al. [5].
5.2. Synthesis, integration, and optimization of case 1
5.2.1. Syntheses of HEN, SRC, and ORC
Two solutions are demonstrated. The first solution denotes the
IHU from a published article [5]. The second solution denotes the
IHUO. The two solutions aim to minimize the TAC and carbon tax is
excluded in the economic cost objective function. The numbers of
variables and equations of the proposed IHUO model are 426 and
729, respectively. The solution time is 22.88 s.
The design configuration of IHU presented in Fig. 5 is composed
of seven units (three heat exchangers in PHUHEN, two heat ex-
changers in PPHEN and two heat exchangers in PCUHEN). The
process-to-process heat recovery is 35729 kW, and the corre-
sponding cold utility is 28171 kW. For the SRC, the produced
electricity is 21054 kW. The TAC is 12151.8 k$.
Fig. 6 depicts the structure of IHUO using n-butane as working
fluid. Two heat exchangers are included in the PPHEN. The recov-
ered heat in process heat is 35762 kW. And pi1 and pi2 do not
require cold utility. Four heat exchangers are equipped between the
hot streams and ORC working fluid. The quantity of heat exchangers
of the integration system is two more than that of IHU. ORC pro-
duces 3218 kW of power. The TAC is 10579 k$, which is 12.94% lower
than that of IHU. Table 2 summarizes the optimization results for
Case 1. Table 3 summarizes the comparative statistics of various
working fluids in ORC. ORCs with different working fluids feature
different operating parameters, resulting in different thermal effi-
ciencies. The ORC with n-butane as working fluid demonstrates the
highest heat removed from process hot streams. The ORC with n-
butane as working fluid features the highest pump power con-
sumption and consequently, the highest operating cost as shown in
Table 2. However, the TACs of the three solutions with ORC inte-
gration are inconsistent with the performances of ORCs. IHUO-n-
butane holds the lowest TAC, followed by IHUO-R245fa and
IHUO-R123. These solutions are achieved from the tradeoff among
the four sub-HENs.
The results depicted in Fig. 6 show that the surplus heat from
the HEN is absorbed by ORC streams. Then, ORC can produce power
to yield profit and improve the entire system performance. The TAC
of IHUO can be reduced compared with the IHU. Therefore, the
economy of IHU can be effectively improved by integrating HEN
with ORC.
5.2.2. Integration and simultaneous optimization of HEN, SRC, and
ORC
In this scenario, two solutions are compared. The first solution
indicates the OIHU from the published article [5], and the second
solution indicates the OIHUO proposed in this paper. The two so-
lutions aim to minimize the TAC and carbon tax is excluded in the
economic cost objective functions.
Fig. 7 presents the optimization results of OIHU achieved from
Luo et al. [5]. There are two heat exchangers in PPHEN, five heat
exchangers in PHUHEN, one heat exchanger recovering heat from
process stream pi1 in PBFWHEN and two heat exchangers in
PCUHEN. The process-to-process heat recovery is 35654 kW. The
external cooling requirement is 27142 kW. For the utility plant, the

24069 TAC (k$)

hui1 19166 kW 263.9 oC pi1195 oC 128.1 oC 1103 kW 125.1 oC 12627 kW 90 oC 10951.3
kW C
3073 kW
hui3 201.3 oC
11191 kW o 11585 kW 14515 kW
hui2 198.3 oC pi2155 C 115.1 oC 65 oC
C

hui4 3114 kW 156.2 oC

1301 kW 112.1 oC
240 oC 195.5 oC 173.1 oC 125 oC pj1 bfwj

o
160 C 146.2 oC 110 oC pj2

o
7.4 kg/s 198.3 C 6.5 kg/s 3079 kJ/kg
11.7 kg/s 263.9 oC 9.4 kg/s 3318 kJ/kg
9.5 MPa 19.8 kg/s 1.5 MPa
5.0 MPa Makeup water
Cooling
tower
Turbine 7864 kW
Fuel Boiler 0.008 MPa
2416 kJ/kg
0 kg/s
3005 kJ/kg C
673 kJ/kg
Pump Deaerator

Fig. 7. Configuration of simultaneous and integration optimization of HEN and SRC for Case 1.
10 X. Huang et al. / Energy 195 (2020) 116922

19739 kW
hui1 263.9 oC pi1195 oC 24031 kW128.2 oC 2683 kW 120.8 oC 9271 kW
95.0 oC
1815 kW 90.0 oC TAC (k$) 9502.0

3144 kW o
hui3 2485 kW 214.8 oC 152.6 C
11245 kW 198.3 oC 9294 kW o 8094 kW 8712 kW
hui2 pi2155 oC 123.0 C 95.0 oC 65.0 oC
879 kW o
hui4 162.1 C
o
125 oC pj1 93.0 C
o
240.0 C 195.6 oC 173.1 oC 125.0 oC orcj1

160.0 oC 157.3 oC 147.4 oC 118.4 oC 110 oC pj2 93.0 oC orcj2

o
5.8 kg/s 198.3 C 5.1 kg/s 3018.4 kJ/kg
12.0 kg/s 263.9 oC 9.7 kg/s 3318.3 kJ/kg 1.5 MPa Expander

9.5 MPa 19.6 kg/s 3183kW

5.0 MPa
7815.9kW

Turbine

Fuel Boiler 0.008 MPa

2.0 kg/s 2410.6 kJ/kg
0.8 MPa 3.9 kg/s C Cooling
Makeup water
1.0 kg/s 2996.0 kJ/kg 32.0 oC
C tower
672.5 kJ/kg
Pump Deaerator 32.6 oC
Pump

Fig. 8. Configuration of simultaneous integration and optimization of HEN, SRC, and ORC using R123 as working fluid for Case 1.

Table 4
Comparative economic statistics of the integration system using various working fluids for Case 1.

Items OIHU OIHUO-R245fa OIHUO-n-butane OIHUO-R123

Investment cost of heat exchangers (k$) 1472.6 1497.0 1358.6 1339.0

Investment cost of utility plant components (k$) 1858.3 1833.8 1846.7 1857.5
Investment cost of cold utility components (k$) 28.6 82.9 83.5 84.1
Investment cost of ORC component (k$) e 447.0 453.7 441.3
Operating cost for cold utility (k$) 586.1 654.7 662.0 669.2
Operating cost for fuel (k$) 11787.1 11594.7 11696.4 11780.7
ORC operating cost (k$) e 61.7 88.2 34.9
Profit from selling electricity (k$) 4781.4 6606.0 6687.2 6652.5
Total annual cost (k$) 10951.3 9565.7 9502.0 9554.3

Table 5
Comparative statistics of various working fluids used in the ORC for Case 1.

Items ORC-R245fa ORC-n-butane ORC-R123

Thermal efficiency (%) 10.9 10.9 10.6

Heat absorbed from process hot stream (kW) 27547.9 27891.7 28138.3
Heat removed in the ORC condenser (kW) 24550.4 24853.9 25148.7
Turbine power (kW) 3098.9 3182.9 3047.0
Pump power (kW) 101.4 145.1 57.4
Evaporation temperature ( C) 93.0 93.0 88.0
Condensing temperature ( C) 32.0 32.0 32.0

power output is 7864 kW and the recovered heat from pi1 for BFW
preheating is 1103 kW. The solution yields the TAC of 10951.3 k$.
Fig. 8 shows the optimum results of OIHUO with ORC using n-
butane as working fluid. Three heat exchangers exist in PPHEN. The
process-to-process heat recovery is 36008 kW and the external
cold utility for pi1 and pi2 is zero. Four heat exchangers exist be-
tween the hot streams and ORC working fluid. The surplus heat
recovered by ORC measures 27892 kW, and the quantity of heat
exchangers of the integration system is two more than that in OIHU.
ORC produces 3183 kW of power, and the TAC is 9502.0 k$, which is
13.23% lower than that of OIHU. Table 4 summarizes the optimi-
zation results for the case. As shown in Table 4, the TAC of OIHUO in
different working fluids remarkably reduces compared with that of
OIHU. Table 5 summarizes the comparative statistics of various
working fluids in ORC. As shown in Table 5, the ORC using different
working fluids features different operating parameters. The ORC
using R245fa and n-butane as working fluid holds the same and
highest thermal efficiency and the highest heat recovered from hot
process streams. Consequently, the ORC using n-butane as working
fluid features the highest power generation. The ORC using R123 as
working fluid holds the lowest pump power consumption and
consequently, the lowest operating cost. Among the three solutions
using different working fluids, OIHUO- n-butane yields the lowest
TAC, followed by OIHUO-R123 and OIHUO-R245fa.
The comparison between OIHUO and OIHU shows that TAC can
also be reduced. OIHU exhibits the optimal results achieved from
 X. Huang et al. / Energy 195 (2020) 116922 11

3221 kW
4943 kW 7993 kW
hui1
16604 kW 263.9 oC pi1195.0 oC 29964 kW 104.2 oC 89.2 oC 65.0 oC
11948 kW
C TAC (k$) 16763.0

2933 kW 9920 kW
263.9 oCpi2 150.0 C 102.0 oC 102.0 oC 70.0 oC
o
hui3
C
13109 kW 12763 kW 198.3 oC pi3 130.0 oC 9637 kw 4863 kW
hui2 96.8 oC 80.0 oC
9890 kW C
15379 kW 10360 kW 2761 kW
198.3 oC pi4 190.0 C 138.7 oC 104.2 oC 95.0 oC
o
hui4
C
o o
210.0 C 173.1 oC 100.0 C pj1

170.0 oC o
170.0 C 124.4 oC 90.0 oC pj2
o
136.3 C 136.3 oC 96.5 Co
80.0 oC pj3

205.0 oC 196.3 oC 169.6 oC 128.0 oC 100.0 oC pj4

o
18.4 kg/s 198.3 C 16.3 kg/s 3055.6 kJ/kg
12.1 kg/s 263.9 oC 9.7 kg/s 3308.8 kJ/kg 1.5 MPa
Cooling Makeup water
9.5 MPa 32.6 kg/s tower
5.0 MPa
15088.1 kW

Turbine

Fuel Boiler 0.008 MPa

3.0 kg/s 2369.2 kJ/kg
0.8 MPa 6.5 kg/s
0.0 kg/s 2962.8 kJ/kg
C
672.5 kJ/kg
Pump Deaerator

Fig. 9. Configuration of simultaneous and integration optimization of HEN and SRC for Case 2.

19679 kW 24314 kW
6801 kW 5925 kW 5046 kW 9480 kW 4060 kW 65.0 oC
hui1 263.9 oC pi1195.0 oC 106.0 oC 106.0 oC 77.3 oC 77.3 oC
C TAC (k$) 14919.0

11784 kW 12992 kW 5686kW 6122 kW

pi2 150.0 oC 108.1 oC 89.7 Co
89.7 Co
70.0 oC
hui3 122.0 oC C
12107 kW 7387kW 2613 kW o 4500 kW
hui2 198.3 C pi3 130.0 oC
o
130.0 oC 104.5 oC 95.5 C 80.0 oC 80.0 oC
1361 kW o pi4 25546 kW o 2123kw 831 kW
hui4
o
146.2 C 190.0 C 104.8 C 97.8 C o
97.8 Co
95.0 oC
o o
C
210.0 C 194.9 oC 168.0 C 100.0 oC pj1

170.0 oC 170.0 C o 144.0 oC 97.6 C o 90.0 oC pj2

o
180.0 C 180.0 Co
99.0 oC 80.0 oC pj3 74.4 oC orcj1

205.0 oC 151.8 oC 120.0 oC 100.0 oC pj4 74.4 oC orcj2

o
6.2 kg/s 198.3 C 5.5 kg/s 3073.9 kJ/kg
19.8 kg/s 263.9 oC 15.9 kg/s 3312.0 kJ/kg 1.5 MPa Expander

9.5 MPa 26.7 kg/s 1433 kW

5.0 MPa
10102.1 kW

Turbine

Fuel Boiler 0.008 MPa

2.4 kg/s 2391.4 kJ/kg
0.8 MPa 5.3 kg/s C Cooling
Makeup water
32.0 oC
0.0kg/s 2986.0 kJ/kg
C tower
672.5 kJ/kg
Pump Deaerator 32.2 oC
Pump

Fig. 10. Configuration of simultaneous and integration optimization of HEN, SRC, and ORC using R245fa as working fluid for Case 2.

Luo et al. [5]. Therefore, more potential or optimization freedom for effectiveness of the proposed integration system and technology
energy and cost reduction can be achieved by using the design has been well demonstrated. In this section, Case 2 is studied to
configuration of OIHUO proposed in this paper. apply the proposed method to relatively large-scale problem. For
simplification, two scenarios, IHU and OIHUO, are demonstrated
and compared. The two solutions aim to minimize the TAC and
5.3. Synthesis, integration, and simultaneous optimization of HEN,
carbon tax is excluded in the economic cost objective functions. The
SRC, and ORC for case 2
numbers of variables and equations of the proposed IHUO model
are 739 and 1216, respectively. The solution time is 46.92 s.
As shown in the results of Case 1, the superiority and
12 X. Huang et al. / Energy 195 (2020) 116922
Table 6
Comparative economic statistics of the integration system using various working fluids for Case 2.
Items
Investment cost of heat exchangers (k$)
Investment cost of utility plant components (k$)
Investment cost of cold utility components (k$)
Investment cost of ORC component (k$)
Operating cost for cold utility (k$)
Operating cost for fuel (k$)
ORC operating cost (k$)
Profit from selling electricity (k$)
Total annual cost (k$)
Table 7
Comparative statistics of various working fluids in ORC for Case 2.
Items IHUO-R245fa IHUO-n-butane
Thermal efficiency (%) 8.4 8.6
Heat added (kW) 16593.0 17098.9
Heat removed (kW) 15195.1 15634.6
Turbine power (kW) 1433.2 1519.3
Pump power (kW) 35.2 55.0
Evaporation temperature ( C) 74.4 75.3
Condensing temperature ( C) 32.0 32.0
Fig. 9 presents the optimization and results of IHU for Case 2.
There are seven heat exchangers in PPHEN, five heat exchangers in
PHUHEN, four heat exchangers in PCUHEN. The process-to-process
heat recovery is 85163 kW. The cold utility requirement is
25537 kW. For the utility plant, the power output is 15088 kW. The
solution yields the TAC of 16763.0 k$.
Fig. 10 shows the optimum results of OIHUO using R245fa as
working fluid in the ORC. Seven heat exchangers exist in PPHEN.
The process-to-process heat recovery is 83094 kW. Three heat ex-
changers exist between the hot streams and ORC working fluid. The
surplus heat recovered by ORC measures 16593 kW, and the
quantity of heat exchangers in the integration system is three more
than that in IHU. ORC produces 1433 kW of power, and the TAC is
14919.0 k$, which is 11.1% lower than that of IHU. Table 6 sum-
marizes the optimization results for the case. As shown in Table 6,
the TAC of OIHUO in different working fluids remarkably reduces
compared with that of IHU. Table 7 summarizes the comparative
statistics of various working fluids in ORC. As shown in Table 7, the
ORC using different working fluids features different operating
parameters. The ORC using R123 as working fluid holds the highest
thermal efficiency and the highest heat recovered from hot process
streams. Consequently, the ORC using R123 as working fluid fea-
tures the highest power generation. Among the three solutions
using different working fluids, OIHUO-R245fa yields the lowest
TAC, followed by OIHUO-R123 and OIHUO-n-butane. These solu-
tions are achieved from the trade-off among the four sub-HENs,
SRC, and cold utility plant.
The comparison between OIHUO and IHU shows that TAC can be
remarkably reduced by integrating HEN with ORC for a large-scale
problem. Noting that the saving ratio of TAC of Case 2 is lower than
that of Case 1 because the available surplus heat and the temper-
ature level of the hot stream are lower in Case 2. The result for Case
2 show that the proposed model and solution strategy is also
effective in solving large-scale complex problem.
5.4. Influence of carbon tax on the synthesis and optimization
results
In the proposed design configuration, ORC is used to recover
surplus heat for energy conservation and cost reduction. Another
IHU IHUO-R245fa IHUO-n-butane IHUO-R123
2696.3 2444.9 2086.3 1914.7
2831.8 2382.4 2576.4 2743.9
231.4 162.0 180.6 165.2
e 270.6 279.0 355.6
783.7 748.6 856.9 870.2
19393.3 15902.3 17417.8 18713.2
e 21.4 33.5 20.0
9173.6 7013.4 7964.3 9713.4
16762.9 14918.7 15466.1 15069.3
feature of ORC is its environmental friendliness. Therefore, the
environmental performance of the proposed system is considered.
IHUO-R123
In this section, carbon tax is added to the objective function. To
investigate the influence of carbon tax on the proposed system,
8.8
three different kinds of carbon emission charge standards [36] in
23486.8
21409.0 China are considered. The first carbon emission charge standard
2044.8 based on China’s standard was established in 2003 [37]. The second
33.0 carbon emission charge standard is derived from the cost of
75.7
reducing pollution based on mature technologies [38]. The third
32.0
carbon emission charge standard is based on the cost of total
pollution damage in Shandong Province and is carried out through
ExternE project [39,40]. The three emission charge costs of CO2 are 0,
3.3, and 50 $/t. To demonstrate the influence of carbon tax on the
synthesis and optimization results, Case 1 is re-studied by incor-
porating different carbon tax in the objective function.
Fig. 11 shows the influence of carbon tax on the investment cost
of HEN, surplus heat recovered by ORC, fuel cost, carbon tax, and
TAC. For n-butane and R123, the investment cost of HEN increases
with the increase of carbon tax to increase the heat integration in
the PHEN and thus reduce the fuel consumption. As the fuel cost
and environment cost are directly related to the fuel consumption,
the fuel cost decreases and the environmental cost increment rate
decreases. The surplus heat recovered by ORC decreases with the
increase in carbon tax because the available surplus heat decreases
with the intensification of process-process integration. For R245fa,
the investment cost of HEN first decreases then increases with the
increase of carbon tax. Unsurprisingly, the fuel cost first increases
and then decreases with the increase of carbon tax. Also, the sur-
plus heat recovered by ORC first increases and then decreases with
the carbon tax. Correspondingly, the fuel cost of scenarios with
carbon tax of 3.3 and 50$/t are lower than that of 0$/t. Among the
solutions with three working fluids, the solution with n-butane
features the maximum increment in investment cost of HEN
(34.6%). It is easy to understand that both environmental cost and
TAC increase as carbon tax increases. Among the solutions with
three working fluids, the solution with working fluid n-butane
holds the maximum increment in TAC (75.6%).
5.5. Sensitivity analysis of fuel price
Natural gas prices vary widely across regions and time. Fuel
price significantly affects the results of the proposed system. Thus,
performing sensitivity analysis of the fuel price on the proposed
system is necessary. To demonstrate the effect of fuel price on the
synthesis and optimization results, Case 1 is re-studied by incor-
porating different fuel price in the objective function. In the anal-
ysis, natural gas prices vary from 227 $/t to 694.6 $/t with a fixed
carbon charge of 3.3 $/t (the second carbon emission charge stan-
dard proposed in Wei and Zhou [38]).
Fig. 12 presents the influence of natural gas price on the in-
vestment cost of HEN, waste heat recovered by ORC, fuel cost,
 X. Huang et al. / Energy 195 (2020) 116922 13

1600 11900
R245fa n-butane R123 R245fa n-butane R123
1400
11800

1200
Investment cost of HEN (k$)

11700

Fuel cost (k$)

1000
11600
800
11500
600

11400
400

200 11300

0 11200
0 3.3 50 0 3.3 50
Carbon tax ($/t) Carbon tax ($/t)
28000 800
R245fa n-butane R123 R245fa n-butane R123
Surplus heat recovered by ORC (kW)

700
27800

Environmental cost (k$)

600
27600
500

27400 400

300
27200
200
27000
100

26800 0
0 3.3 50 0 3.3 50
Carbon tax ($/t) Carbon tax ($/t)

18000
R245fa n-butane R123
16000

14000
Total annual cost (k$)

12000

10000

8000

6000

4000

2000

0
0 3.3 50
Carbon tax ($/t)

Fig. 11. Influence of carbon tax on: a) investment cost of HEN; b) surplus heat recovered by ORC; c) fuel cost; d) environmental cost; and e) TAC.

environmental cost, and TAC for working fluids n-butane, R245fa, heat recovery by ORC decreases with the increase of fuel price. The
and R123. Usually, to minimize the TAC, the fuel consumption reason is that the available surplus heat in the PPHEN decreases
should be minimized, the heat integration between process hot with the further heat integration intensification compare to the
streams and cold streams should be maximized, and the heat re- scheme based on the base fuel price. It is unsurprising that the fuel
covery by ORC should be maximized. As shown in Fig. 12, the in- cost increase monotonously with the increase of fuel price for all
vestment cost of PPHEN increases with the increase of fuel price for working fluids. From Tables 2, 4 and 6, we can see that the fuel cost
three working fluids. This indicates that the heat integration be- occupies largest proportion among the total cost, thus, the TAC also
tween process hot-cold streams is further intensified with the in- increases monotonously with the increase of fuel price for all
crease of fuel price. As a result, the hot utility demand decreases working fluids.
and the fuel consumption decreases. Subsequently, the environ- Though the ORC with different working fluids feature similar
mental cost decreases with the increase of fuel price. However, the change trends in costs and surplus heat recovery by ORC, the
14 X. Huang et al. / Energy 195 (2020) 116922

Fuel cost (k$) Investment of HEN (k$)

Total annual cost (k$) Environmental cost (k$)
(a) Surplus heat recovered by ORC(kW)
35000 30000

Surplus heat recovered by ORC (kW)

30000
28000

25000
26000

20000
Cost (k$)

24000
15000

22000
10000

20000
5000

0 18000
227 340.5 454 567.5 681
(b)
35000 30000

30000
28000

25000

Surplus heat recovered by ORC (kW)

26000

20000
Cost (k$)

24000

15000

22000
10000

20000
5000

0 18000
227 340.5 454 567.5 681
(c)
35000 30000

30000
28000
Surplus heat recovered by ORC (kW)

25000
26000

20000

24000
Cost (k$)

15000

22000
10000

20000
5000

0 18000
227 340.5 454 567.5 681
Unit price of fuel ($/t)

Fig. 12. Influence of natural gas price on surplus heat recovery and costs for integration solution using different working fluids: (a) n-butane; (b) R245fa; (c) R123.
 X. Huang et al. / Energy 195 (2020) 116922 15

change rates are different. The surplus heat recovered by ORC using that of OIHU. The TAC of OIHUO is 21.28e21.81% lower than that
n-butane decreases slightly with fuel price while those of ORC us- of IHU. In the large-scale Case 2, the TAC of OIHUO is 7.74e11.00%
ing R245fa and R123 decreases first sharply and then slowly with lower than that of IHU. The optimization schemes are quite
fuel price. The comparison between the ORCs using different different when using different working fluid. However, the TACs
working fluids shows that the ORC using n-butane features lower of the optimization schemes do not deviate significantly from
surplus heat recovery than those of ORCs using R245fa and R123. each other because the TAC is minimized under the best trade-
The surplus heat recovered in ORC using n-butane is 21.6e25.1% off among all the sub-HENs using the proposed simultaneous
and 22.2e25.1% lower than those of ORCs using R245fa and R123 optimization method. These comparison results indicated that
under the same fuel price. However, the TACs of three integration the integration and optimization of ORC, SRC, and HEN using the
systems using different working fluids do not deviate significantly proposed method are effective in improving the performance of
from each other. For the studied scenarios shown in Fig. 12, the industrial energy system.
maximum deviation of TAC over the average TAC under the same The sensitivity analysis showed that carbon tax exerts remark-
fuel price condition is 1.04%. able influence on the optimization results. For n-butane and
The sensitivity analysis results shown in Fig. 12 indicates that R123, the fuel consumption reduces with the increase of carbon
the optimal results of the proposed system are influenced signifi- tax to minimize the TAC and the surplus heat recovered by ORC
cantly by fuel price. The heat recovered from process hot-process decreases with carbon tax. For R245fa, the change trends of fuel
cold stream integration increases with increasing fuel price. The cost, surplus heat, and investment cost of HEN are different to
surplus heat recovered by ORC and hot utility demand decreases those of n-butane and R123. However, the TACs of integration
with the increase in fuel price. This finding reflects that the pro- system using three working fluids do not deviate from each
posed system features a better advantage in the lower fuel prices other due to the simultaneous optimization and best trade-off of
compared with OIHU. Though the integration schemes are different the integration system. The sensitivity analysis of fuel price
for different working fluids due to their different thermo-physical showed that minimizing the fuel consumption is the direction of
properties, the TAC does not deviate significant from each other minimize the TAC as the fuel price increase. The fuel cost and
as the TAC is determined from the trade-off among PPHEN, PHU- TAC unsurprisingly increase with the increase of fuel price;
HEN, PPORC, SRC, and PCUHEN. however, the increase rate of the former is lower than that of the
latter as minimizing the fuel consumption is attributed to the
6. Conclusion increase of other costs. The surplus heat recovered by the ORC
decreases with the increase of fuel price because the available
This paper developed a superstructure containing PHEN, PHU- surplus heat decreases with the decrease of fuel consumption.
HEN, PORCHEN, PCUHEN, SRC, and cold utility system. Different to
the previous sequential optimization method, a MINLP optimiza-
Acknowledgment
tion model was formulated for the synthesis and simultaneous
optimization of the proposed integration system. Two cases with
The authors gratefully acknowledge the financial support from
different scale in complexity were investigated and compared with
the State Key Program of National Natural Science Foundation of
the schemes without integrating ORC. The influence of carbon tax
China (Grant No. 51736005), National Natural Science Foundation
and fuel price on the integration scheme were conducted.
of China (Grant No. 51876043), and Science and Technology Pro-
Following conclusions were drawn.
gram of Guangzhou (201704030108).

In the small-scale Case 1, the optimization scheme IHUO and

OIHUO were achieved using the proposed method. The com- Appendix A. Regression correlations of ORC working fluids
parison showed that the TAC of IHUO is 12.61e12.94 lower than
that of IHU and the TAC of OIHUO is 12.65e13.23% lower than

Table A1
Fitting correlations of the properties of working fluids

Items Coefficients R2

R245fa
cfaa, cfbb, cfcc for h1 and h3 202.1920, 1.1723, 0.0021 0.9999
cfdd, cfee, cfff, cfgg, cfhh for Dh1e2s 0.4083, 0.0132, 1.7542E-04, 0.0014, 7.6094E-05 0.9994
cfii, cfjj, cfkk for h4 and h6 400.9362, 0.8925, 0.0017 0.9994
cfll, cfmm, cfnn, cfoo, cfpp for Dh4e5s 0.3191, 0.7336, 0.0016, 0.7679, 0.0019 0.9999
cfqq, cfrr, cfss for T2 146.4921, 0.0054, 0.7392 0.9999
cftt, cfuu, cfvv for T5 408.1944, 0.2126, 1.0135 0.9996
n-butane
cfaa, cfbb, cfcc for h1 and h3 204.7597, 2.0933, 0.0050 0.9999
cfdd, cfee, cfff, cfgg, cfhh for Dh1e2s 0.8567, 0.0248, 3.9495-E04, 0.0007, 1.8693E-04 0.9994
cfii, cfjj, cfkk for h4 and h6 577.9352, 1.7568, 0.0034 0.9993
cfll, cfmm, cfnn, cfoo, cfpp for Dh4e5s 1.5775, 1.4493, 0.0033, 1.4605, 0.0035 0.9999
cfqq, cfrr, cfss for T2 77.4780, 0.0072, 0.3967 0.9998
cftt, cfuu, cfvv for T5 303.0088, 0.2065, 0.5213 0.9996
R123
cfaa, cfbb, cfcc for h1 and h3 200.7101, 0.9582, 0.0009 1
cfdd, cfee, cfff, cfgg, cfhh for Dh1e2s 0.2302, 0.0074, 9.9283E-05, 0.0007, 4.4291E-05 0.9996
cfii, cfjj, cfkk for h4 and h6 379.9826, 0.6722, 0.0008 0.9999
cfll, cfmm, cfnn, cfoo, cfpp for Dh4e5s 1.3876, 0.6173, 0.0011, 0.6715, 0.0015 0.9999
cfqq, cfrr, cfss for T2 191.9116, 0.0051, 0.9649 1
cftt, cfuu, cfvv for T5 522.1370, 0.1399, 1.3725 0.9998
16 X. Huang et al. / Energy 195 (2020) 116922

Nomenclature dtcuo ¼ temperature difference between the cold sede of hot

stream-cold utility, oC
dti ¼ temperature difference between the hot side of hot-
Subscripts cold stream, oC
CW ¼ index for cooling water dto ¼ temperature difference between the cold side of hot-
conds ¼ index for condenser cold stream, oC
DEA ¼ index for deaerator FB ¼ fuel consumption of boiler, kg/s
draftfans ¼ index for daft fans in cooling tower h ¼ enthalpy of state point in the ORC, kJ/kg
ext ¼ index for extraction steam from tribune htc ¼ film heat transfer coefficient, kW/(m2∙oC)
MP ¼ index for MP steam INVCT ¼ investment of cold utility components, $
hui ¼ index for process streams from steam turbine INVHE ¼ heat exchanger investment cost, $
HUI ¼ index for process streams from steam turbine hui INVUS ¼ utility component investment cost, $
huk ¼ index for the stages of process cold stream that INVORC ¼ ORC component investment cost, $
matches process stream from steam turbine M ¼ flow rate, kg/s
HUK ¼ index for stages of process cold stream that matches MT ¼ turbine inlet or extraction steam flow rate, kg/s
process stream from steam turbine MW ¼ water for cooling superheat steam, kg/s
i ¼ index for hot streams and process streams from steam OPCU ¼ cold utility operating cost, $
turbine OPORC ¼ ORC operating cost, $
in ¼ index for inlet OPFUEL ¼ operating cost for fuel, $
IP ¼ index for IP steam q ¼ heat exchanging quantity, kW
out ¼ index for outlet QC ¼ cold utility requirement, kW
j ¼ index for cold streams and ORC working fluid stream PW ¼ power consumption in cooling tower, kW
k ¼ index for all stages, including HUK, ORCK, and PK and TAC ¼ total annual cost, $
temperature locations T ¼ inlet or outlet temperature, oC
orcj ¼ index for process streams from ORC Tc ¼ condensing temperature, oC
ORCK ¼ index for stages for cold process stream from ORC that Te ¼ evaporation temperature, oC
matches the hot stream t ¼ temperature of stream at temperature location, oC
pump ¼ index for pump ti ¼ outlet temperature of cold stream split after exchange
Pi ¼index of process hot streams heat with hot stream, oC
PI ¼ index of hot streams pi to ¼ outlet temperature of hot stream split after exchange
Pj ¼index of process cold streams heat with cold stream, oC
PJ ¼ index of hot streams pj WT ¼ power generation or consumption, kW
Pk ¼ index of stages in matching of hot and cold process WSELL ¼ profit of selling electricity, $
PK ¼ index of stages in matching of hot and cold process pk
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