Applied Thermal Engineering 156 (2019) 91–98

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Applied Thermal Engineering

journal homepage: www.elsevier.com/locate/apthermeng

Research Paper

Thermo ecological optimization of shell and tube heat exchangers using T

NSGA II
⁎
Maida Bárbara Reyes Rodríguez, Jorge Laureano Moya Rodríguez ,
Cristiano Hora De Oliveira Fontes
Universidade Federal de Bahia, Salvador, Bahia, Brazil

H I GH L IG H T S G R A P H I C A L A B S T R A C T

• Aentransy
new ecological Function based on
dissipation is proposed.
• Shell and tubes heat exchangers are
optimized using NSGAII multicriteria
approach.
• There is carried out a case study from
literature with good results.

A R T I C LE I N FO A B S T R A C T

Keywords: Shell and tube heat exchangers are the most important equipment in chemical processes plants. The heat ex-
Optimization changer design from the thermodynamic point of view is based on two fundamental aspects, the global heat
Heat exchangers transfer coefficient and the pressure drop. In 2007 a new thermodynamic property denominated “Entransy” was
Ecological function defined, which expresses the capacity of a body to transfer heat. This property can totally characterize the
Entransy
capacity to transfer heat of a shell and tube heat exchanger. The loss of this capacity is denominated “Entransy
Genetic algorithm
Dissipation”. For evaluating the ecological impact of thermal machines, Angulo-Brown created in 1991 the
“ecological function”. In this paper the “entransy dissipation” and the ecological function were combined and a
new expression for evaluating the ecological impact of shell and tube heat exchangers is proposed. A multi-
objective optimization of shell and tube heat exchangers considering irreversibility is also carried out. The
ecological function and the cost were used as objective functions. For solving the of multi-objective optimization
problem, the method of the Genetic Algorithms is used.

1. Introduction
Primary energy consumption growth averaged 2.2% in 2017, up
from 1.2% last year and the fastest since 2013. This compares with the
10-year average of 1.7% per year. By fuel, natural gas accounted for the
largest increment in energy consumption, followed by renewables and
then oil [10]. Energy efficiency evaluation of heat exchangers are
crucial for energy saving in industrial applications, however, there is no
energy efficiency assessment method available for heat exchangers
[45].
Heat exchangers are present in most complex thermal systems in
industries and represent the most widely used device for heat transfer

⁎
Corresponding author.
E-mail addresses: jorge.moya@ufba.br (J.L. Moya Rodríguez), cfontes@ufba.br (C.H. De Oliveira Fontes).

https://doi.org/10.1016/j.applthermaleng.2019.04.044
Received 16 October 2018; Received in revised form 29 March 2019; Accepted 13 April 2019
Available online 15 April 2019
1359-4311/ © 2019 Elsevier Ltd. All rights reserved.
M.B. Reyes Rodríguez, et al.
applications in industrial processes [34]. Typical applications involve
heating or cooling of a fluid stream of concern, evaporation or con-
densation of a single or multicomponent fluid stream, and heat recovery
or heat rejection from a system. In other applications, the objective may
be to sterilize, pasteurize, fractionate, distill, concentrate, crystallize, or
control process fluid. In recent years, various researches have been
conducted on these devices [3,24,25].
The traditional design approach of this equipment involves the as-
sessment of different geometries to identify those that satisfy a given
heat capacity and a set of geometric and operating constraints. There
are few studies related to the environmental impact of heat exchangers
[20] developed a new physical quantity named entransy which has
been identified as a basis for optimizing heat transfer processes in terms
of the analogy between heat and electrical conduction. On the other
hand developed an ecological optimization criterion for finite‐time heat
engines called Ecological function. This criterion is based on the power
output and the rate of entropy generation. Analyzing both criteria
(entransy and ecological function), it is possible to optimize heat ex-
changers not only based on cost diminution but also based on reduction
of environmental impact using a new function based on Angulo Brown
and Guo criteria.
The aim of this paper is to develop a multi-objective optimization of
heat exchangers using as objective functions the cost and the ecological
function, with the particularity that this last one is a new function based
on entransy dissipation and ten mechanical constrains are considered in
the optimization process.
The paper is organized as follow: Section 2 refers to literature re-
view, in Section 3 named materials and methods, some concepts that
will be used and improved in the paper are analyzed, such as ecological
function of Angulo-Brown, entropy generation paradox, entransy, etc. It
is also developed a new ecological function according to the entransy
dissipation and it is evaluated the total cost of shell and tube heat ex-
changers. The multi-objective optimization problem using the ecolo-
gical function and the cost as objective functions together with me-
chanical constraints is presented and a case study from literature is
discussed. At the end of the paper the results are analyzed and some
conclusions are presented.
2. Literature review
Design-optimization of shell and tube heat exchangers (STHEs) re-
quires an integrated understanding of thermodynamics, fluid dynamics
and cost estimation [30,36,38].
According to [28], the optimization of heat exchangers is an im-
portant issue. The authors determined the optimum size of counter flow
surface condenser for Maral Overseas Ltd by entropy, exergy and en-
transy theories. In this work, effectiveness of heat exchanger, number of
transfer units, entropy generation, entransy dissipation, entransy dis-
sipation-based thermal resistance, entransy dissipation number and
entransy effectiveness for hot/cold fluid sides with outlet temperatures
of fluids are obtained for various 4L/D ratios. This work shows that
both entransy dissipation number and entransy-based thermal should
be as low as possible for proper design.
[2] Developed a very simple nomogram for evaluating the heat
transfer coefficient in shell and tube heat exchangers. This method al-
lows the heat transfer coefficient to be obtained only on the shell side
[42] developed a simplified model for studying shell and tube heat
exchangers. Despite its simplicity, the model proves to be useful for the
preliminary design of shell and tube heat exchangers working in cooling
systems.
[43] Conducted an experimental study to improve heat transfer in
shell and tube heat exchangers. In order to increase heat transfer, the
configuration of a shell and tube heat exchanger was improved through
the installation of seals on the shell side. The clearances between the
plates of the baffles and shell are blocked by seals, which effectively
reduces bypass in the shell side.
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Applied Thermal Engineering 156 (2019) 91–98
[19] Implemented a new concept called “field synergy number” for
optimizing shell and tube heat exchangers with segmental baffles. This
concept implies within itself several optimization criteria. The field
synergy number was defined as the indicator of the synergy between
the velocity field and the heat flow and it is considered as objective
function. The genetic algorithm is employed to solve the heat exchanger
optimization problems with multiple design variables. To analyze heat
transfer on the shell side the method of Bell Delaware was applied. This
work has the merit of introducing a new concept to optimize heat ex-
changers, it does not discuss other optimization criteria and applies one
of the oldest methods for calculating heat transfer on the shell side.
[7] Analyzed Crude oil fouling of a shell-and-tube heat exchanger
sized according to TEMA standard and compared it to a No-Foul design
under industrial operating conditions. The authors concluded that for
similar operating conditions, TEMA and No-Foul heat exchangers have
the same behavior regarding fouling, and since the No-Foul one has less
tubes by design for the same heat duty, shear stress is increased.
[12] Used the method of global sensitivity analysis and harmony
search algorithm for optimizing shell and tube heat exchangers. This is
a Meta - heuristic method for searching problem solution. The Bell
Delaware method was used and both investment and operation costs
were optimized. The authors suggest that the optimization method is
more effective than genetic algorithms.
[31] Suggest that shell and tube heat exchangers (STHEs) are the
most common type in industrial processes. The authors mentioned that
the minimization of the cost of this equipment is a key goal for de-
signers and users. Due to the construction and operation of such
equipment, their design involves complex processes in the selection of
geometric and operating parameters.
[14] Performed a thermodynamic analysis of a gas power plant
using as functions entransy dissipation and entropy generation under
various operating conditions, namely, different specific heats of fluids,
different numbers of transfer units and different isentropic efficiencies
for the turbine and compressor. The author also developed a software
for this purpose which is used to analyze the effectiveness, entransy
dissipation, entropy generation, entransy dissipation ratio, and entropy
generation ratio for the cycle under different operating conditions.
[13] Presents an analysis of exergy destruction, entransy dissipation
and entransy-based thermal resistance for a heat exchanger. These
analyses are performed with various pipe materials such as steel, cast
iron, brass, aluminum, and copper. Various operating parameters are
selected for these analyses. The effectiveness of the heat exchanger is
also obtained for all conditions. The results were compared and the best
operating conditions associated with the heat exchanger performance
was obtained. This research can also be used to optimize the design of
heat exchangers. With these analyses, correct pipe material and correct
operating conditions can be selected.
One of the most ancient method for designing shell and tube heat
exchangers is the Kern method [15]. Designed a shell- and tube-type
heat exchanger by this method. To eliminate design problems, the au-
thors developed a software (DSTHE software) and calculated all design
parameters such as number of tubes, shell diameter, pipe pitch and
pitch ratio. The velocity of the tube side fluid, convective heat transfer
coefficients for tube and shell sides and overall heat transfer coefficient
are determined. The pressure drop in the tubes and shell, entropy
generation and entransy dissipation have also been found. A shell and
tube heat exchanger has been fabricated with the calculated para-
meters. These authors performed a certain number of experiments at
various operating conditions. For each condition, entropy generation
analysis, entransy dissipation analysis and entransy-based thermal re-
sistance analysis have been done. Maximum value of effectiveness,
minimum values of entropy generation, entransy dissipation and en-
transy-based thermal resistance have been found and that actual op-
erating conditions have been identified.
[34] Performed a rigorous investigation of multi-objective (four-
objective) optimization in shell and tube heat exchangers. The authors
M.B. Reyes Rodríguez, et al.
considered the maximization of effectiveness and minimization of total
cost, pressure drop and number of entropy generation units of heat
exchanger. The Multi-objective heat transfer search (MOHTS) was ap-
plied to obtain a set of Pareto-optimal points. Various objective opti-
mization results comprise a solution in a four dimensional hyper ob-
jective space and for visualization it is represented in a two-dimension
objective space. Thus, results of four-objective optimization are re-
presented by six Pareto fronts in two-dimension objective space. These
six Pareto fronts are compared with their corresponding two-objective
Pareto fronts.
3. Materials and methods
3.1. Ecological function of Angulo-Brown
The analysis and optimization of thermodynamic cycles has been
one of the most important and discussed issues in the theory of finite-
time thermodynamics. In addition to the power output and the rate of
entropy generation, a new criterion (ecological function) was in-
troduced for the first time to evaluate combustion engines:
E '= P − Tc ·σ (1)
P is the output engine power in kW, Tc is the temperature of the cold
reservoir in Kelvin degrees and σ is the entropy generation rate in kW
/K. Since the objective function E is similar in some sense to the en-
vironmental objective, this feature is also known as ecological objective
function. This function was perfected by [44], as it is showed in “Eq.
(2)”:
E = Ẇ − T0·Sġ (2)
whereẆ – Output engine power in kW, Sġ – Entropy generation rate in
kW/K, T0 - Environmental Temperature in K.
[8] Presented a function based on the Exergy and Ecology in a
unified way that is applicable to all thermodynamic cycles:
A T ΔS A
E" = − 0 = − T0 σ
τ τ τ (3)
where A represents the Exergy output, ΔS is the entropy generation, σ is
the Entropy generation rate and τ is the time period of the cycle. For the
particular case of engines, the Exergy production rate of the cycle is the
Power Output (A/τ = P) and the ecological function becomes the
function developed by [44]:
E '= P − T0·σ (4)
This feature complements the aspects of classical thermodynamics
related to the output power, efficiency and entropy generation.
Therefore, the above expression might be applied to the case of heat
exchangers, replacing P by the heat transfer rate:
E '= Q − Tc ·σ (5)
The application of entropy generation in heat exchangers has been
questioned in recent years and, in this way, this work proposes a new
ecological function based on the entransy dissipation.
3.2. Entropy generation paradox
According to [26] various metrics of heat exchanger thermal per-
formance has been widely studied and used. The entropy generation
minimization method (EGM) proposed by [5], was characterized by
irreversibility caused by flow friction, finite temperature difference and
imbalanced flow [37]. Investigated the entropy generation (irreversi-
bility) concept and applied it in heat exchanger analysis. The author
used the enthalpy exchange irreversibility norm (EEIN) as a measure of
the internal heat exchanger irreversibility [22]. Performed an exergy-
based analysis using NSGAII.
Confusion about second law-based metrics still exists. In order to
93
Applied Thermal Engineering 156 (2019) 91–98
eliminate the entropy generation paradox [23], proposed the approach
by non dimensionalizing entropy generation number in heat exchanger
in different way based on the Bejan‘s approach. [39], studied over 100
heat exchangers flow-arrangements and revealed deviations between
minimized irreversibility and maximized number of transfer unit
(NTU). He claimed that the heat exchanger performance is associated
with both irreversibility and flow-arrangement [40]. Reported the un-
expected deviation by using minimized entropy generation unit and
maximized load in a refrigerant-to-air two phase heat exchanger. Be-
sides the paradox, the rightness of using EGM as an indicator in heat
transfer was also questioned [4] has shown that the generation of en-
tropy corresponding to heat loss by work through an EGM-optimized
heat exchanger and heat load in single-phase countercurrent heat ex-
changers has always been lower than those obtained through another
method.
3.3. Entransy
In order to solve the difficulty related to the entropy generation
paradox [18,20], proposed a new concept (entransy) and applied it in
studies involving the improvement of heat transfers. Entransy is a
property to measure the heat transfer potential, which is calculated as:
1 1
Evh = Q vh·Uh = Q vh·T
(6)
2 2
where Q vh = M·c v·T is the thermal energy of the heat stored in an object
with constant volume, which can be referred as the thermal load. Uh or
T represents the thermal potential.
Together with the concept of Entransy, arose the concept of
“Entransy dissipation”. Entransy dissipation is the lost in heat transfer
capability during a heat transfer process, which is similar to viscous
dissipation in viscous flow and is associated with the heat transfer ir-
reversibility [21]. Presented the extremum principle for entransy dis-
sipation in both conduction and convection, which is equivalent to the
entransy dissipation based on the thermal resistance minimization
principle. The pressure drop is neglected in this approach. To date,
work based on interactions is still in the preliminary phase and no work
involving two-phase is reported. There are aspects involving different
metrics based on the entransy: entransy dissipation, entransy dissipa-
tion-based thermal resistance and dimensionless expression [21] and
non-dimensional entransy dissipation number [18], which accounts for
friction term but lacks theoretical validation.
An optimization strategy combined the entransy theory and genetic
algorithm was proposed by [17]. The applicability of entransy theory
on shell-and-tube heat exchanger with helical baffles (STHXsHB) was
firstly proved by the consistency of performance evaluation criteria
(PEC) and entransy dissipation theory based on experimental data. The
effects of helix angle, overlapped degree and shell-side velocity on
thermal resistance (optimization objective) were discussed based on the
minimum thermal resistance principle. The results showed that the
entransy dissipation thermal resistance decreased with the shell-side
velocity but increased with the helix angle. According to the sensitivity
study, the thermal resistance was considered to be mostly affected by
the shell-side velocity and then the helix angle. Three optimum con-
figurations were obtained by the genetic algorithm, for which the
thermal resistance decreased by 7%. The combination of entransy
theory and genetic algorithm can provide some theoretical guidance to
optimize the configuration of shell-and-tube heat exchanger with he-
lical baffles [17].
3.4. Ecological function according to the entransy dissipation
Considering that the Entransy dissipation is a more appropriate
concept than entropy generation for evaluating the irreversibility in
heat exchangers, as mentioned in the previous section, and in ac-
cordance with the principles on which the ecological function [1] is
M.B. Reyes Rodríguez, et al. Applied Thermal Engineering 156 (2019) 91–98

Fig. 1. Flow chart of the NSGA II Algorithm.

Source: [16]

based, the following new ecological function is proposed to evaluate the According to [41], the capital investment Ci is calculated based on
environmental impact of heat exchangers: the surface area of the heat exchanger:
ΔG T Ci = a1 + a2At a3 (10)
EE '= Q −
AMTD (7)
Where a1 = 8000, a2 = 259.2 and a3 = 0.91 for exchangers made
where: with stainless steel for both shells and tubes. The total discounted op-
erating cost related to the pumping power is given as follows:
Q – Heat transfer rate or thermal load ΔG T – Total Entransy dissipation in the Co = PCE H (11)
in kW. exchanger in kW K.
AMTD – Arithmetic mean temperature EE Ấ – New Ecological Function in kW ny
Co
difference K. Cod = ∑ (1 + i) k
k=1 (12)
1
ΔG T = Uocal ∗ At ∗ F ∗ LMTD[(Thi − Tho) + (Tci − Tco)] 1 ⎛ ṁ t ṁ
2 P= ⎜ ΔPt + s ΔPs ⎞⎟
ΔP (Th,o − Th,i) ΔP (Tc,o − Tc,i) η ⎝ ρt ρs ⎠ (13)
+ ṁ t t T
+ ṁ s s T
ρt ln h,o ρs ln c,o
T h,i Tc,i (8)
Cod is the total discounted operating cost related to pumping power to overcome fric-
tion in $
Uocal – Overall heat transfer coefficient in At – Total heat transfer area in m .
2
Co is the annual operating cost in $/yr Ce is the electric energy cost in $/kW h.
W/m2 K H is the annual operating time in h/yr. i is the annual discount rate
Thi – Inlet temperature of hot fluid in K Tho – Outlet temperature of hot fluid in P is the pumping power in kW η is the overall pumping efficiency
K
Tci – Inlet temperature of cold fluid in K Tco – Outlet temperature of cold fluid
in K
3.6. Multi-objective optimization using the ecological function and the cost
ṁ t – Mass flow on tube side in Kg/s. ṁ s – Mass Flow on Shell side in Kg/s.
ΔPt – Pressure drop on the tube-side in Pa. ΔPs – Pressure drop on the shell-side in as objective functions
Pa.
ρt – Fluid density on the tube side in Kg/m3. ρc – Fluid density on the shell side in To perform the multi-objective optimization of shell and tube heat
Kg/m3. exchangers, the method of Bell-Delaware was applied. The objective
LMTD – Logarithm mean temperature dif- F – Correction factor
functions comprised the total cost and the ecological function. The
ference K.
entire procedure was performed using non-dominated sorting genetic
algorithm II (NSGAII), implemented in MATLAB. Fig. 1 presents the
3.5. Total cost of shell and tube heat exchangers flow chart of the NSGA II Algorithm.
An initial population of 50 individuals and a total of 100 genera-
The total cost of shell and tube heat exchangers (Ctotal) is calculated tions were used.
in an approximately way including the capital investment (Ci), energy The two criteria (two objective functions) are:
costs (Ce), annual operating cost (Co) and total discounted cost of op- ΔG T
eration (Cod) [6]. Maximize: EE '= Q − , Minimize: Ctotal = Ci + Cod
AMTD
Ctotal = Ci + Cod (9)
The tube length, tube diameter, number of tubes and the spacing

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M.B. Reyes Rodríguez, et al. Applied Thermal Engineering 156 (2019) 91–98

between baffles are the decision variables.

t: Minimal thickness of the shell (inches) Do: Outside shell diameter (inches)
Ten mechanical constraints are considered as hard constraints:
CA: Corrosion tolerance (inches) E: Weld join efficiency.
S: Allowable stress in the shell (psi) [Pmáx] Maximal allowable pressure (psi)
1. [33] Criteria, which establishes that the reduced frequency by the
vortex shedding must be greater than twice the Strouhal number.
6. The circumferential stress in the tubes according to ASME code
fn ·do section VIII must be smaller than the allowable stress of the tube’s
> 2Su
V (14) material [29]:

where: P (R + 0, 6)
Scirc = < Sperm
E (t + 1) (20)

fn – Natural Frequency in 1/s Su – Strouhal number where:

V – Reference cross flow velocity, ft/sec. do – Outside diameter of tube, inches.

t – Nominal tube thickness (inches) P – Maximal internal design pressure (psi)

2. Maximum response, ymax of the tube span between two baffles. The R – Tube internal radio (inches). E – Weld join efficiency according to ASME.
maximum response, (ymax) of the tube span between two baffles S – Allowable stress of the tube material at the design temperature [29], (psi).
due to the vortex shedding and the turbulent buffeting, must be less
than 0.02 d o [32,35]”. 7. The longitudinal stress in the tubes according to code ASME section
CL·ρo ·do·V 2 VIII must be smaller than the allowable stress of the tubes material
ymaxvv = [29,35]:
2·π 2·δT ·fn2 ·wo (15)
P (R − 0, 4·t )
CF ·ρo ·do·V 2 Slong = < Sperm
2·E ·t (21)
ymaxit =
8·π δT fn3 ·wo (16)
8. The equivalent stress in the tube (σeq ) considering it as thin walled
where: cylinder must be smaller than the allowable stress of the tube’s
material (σperm ) [11]:
ymaxvv – Maximum Value of the vortex shedding amplitude in the
middle of the span length for the first mode of vibration (for single 3 p∗D
σeq = ∗ < σperm
phase fluids) in inches. 4 h (22)
ymaxit – Maximum Value of the turbulent buffeting amplitude in the where:
middle of the span length for the first mode of vibration (for single
phase fluids) in inches.
p – Tube internal pressure D – Mean diameter of the tube
h – Thickness of the tube wall
ρo – Density of fluid outside the tube at the local shell side δT – Logarithmic decre-
fluid bulk temperature, lb/ft3. ment (damping). 9. The equivalent stress in the tube considering it as thick walled cy-
fn – Fundamental natural frequency of the tube span, c- CL – Lift coefficient for
linder must be smaller than the allowable stress of the tubes material
ycles/sec vortex shedding
wo – Effective tube weight per unit length of tube, Ib/ft. CF – Force coefficient. 2

σeq =
3
∗p∗
( D
h
+1 ) < σperm
D
3. Checking for the elastic instability of the fluid. According to 4
h (23)
Pettigrew and Taylor, the velocity of the fluid inside of the tube
must be smaller than the critical velocity [32]: 10. The equivalent stress in the tube considering it as a thick-walled
V < Vcrit cylinder and considering the temperature must be smaller than the
allowable stress of the tube’s material [27]:
where
(ε + 1)2
m ·δT ⎞
0,5 σeq = ∗ 3 ∗ p2 + 3 ∗ p ∗ m1 ∗ Δt + (m1 ∗ Δt )2 < σperm
Vcrit = 3fn ·do ⎛⎜ 4∗ε (24)
2⎟
⎝ ρs ·do ⎠ (17)
where:
E ∗ α ∗ α1 2∗ε
m1 = α1 = − 1yε = D / h
4. The operating equivalent stress in the shell (σact ) must be smaller
1−μ (ε + 1)2 ∗ ln ( )
ε+1
ε−1
than the allowable stress the shell material (TEMA 2007):
P×r
σact < σ1adm = E – Modulus of Elasticity of tube m- α – Coefficient of thermal expansion of tube
tcirc (18) aterial material
µ – Coefficient of Poisson of tube
where: material

P – Internal pressure in the shell r – Shell inside radius. 3.7. Case study
tcir – Thickness of the Shell wall according to circumferential stress.

In order to evaluate proposed procedure, a case study [9] is ana-

5. The allowable maximum pressure in the shell, according to “ASME lyzed and discussed.
standards (2007)”, must be higher than the operating pressure: This example consists of designing an exchanger to sub-cool con-
S·E ·(t − CA) densate from a methanol condenser from 95 °C to 40 °C. The Flow-rate
Pact < [Pmax́ ] = Do
− 0, 4·(t − CA) of methanol is equal to 100,000 kg/h. Brackish water will be used as the
2 (19)
coolant with a temperature between 25 °C and 40 °C. The coolant is
where: corrosive and it is placed in the tube side. The data of the problem are

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M.B. Reyes Rodríguez, et al. Applied Thermal Engineering 156 (2019) 91–98

Table 1
Values of variables and results for the case study without optimization.
Tube length in m. Tube diameter in mm Number of tubes Spacing between baffles in mm Cost in $ Ecological Function in kW

4.83 20 918 178 58296.58 254.62

the following: Table 2

Values of variables and results of the optimization for the case study.
Tube Tube Number of Spacing Cost in $ Ecological
– Methanol Heat Capacity or specific heat = 2.84 kJ/kg °C – Tho = 40 °C
length in diameter in Tubes between Function in
– Water heat capacity or specific heat = 4.2 kJ/kg °C – Tci = 25 °C
m. mm baffles in kW
–ṁ s = 100,000 Kg/h – Tco = 40 °C
mm
– Thi = 95 °C

1.001 80 758 484.09 8977.01 41.39

1.024 79 762 479.26 8979.49 42.59
1.235 78 761 481.95 8984.35 49.82
4. Result analysis 1.505 80 764 480.12 8988.87 58.39
1.702 79 759 481.19 8993.06 64.12
Table 1 shows the values of cost and ecological functions without 1.861 79 764 480.89 8996.24 68.77
optimization. It is important to highlight that in this example proposed 2.187 79 764 482.47 9002.25 77.30
2.299 79 763 479.08 9006.03 80.26
by [9] it was not calculated the cost and the ecological function, but the
2.635 67 769 453.16 9046.74 91.88
data and results were used during the calculation of these functions. 2.646 79 763 477.56 9013.79 88.42
To develop the optimization procedure, the length of the tubes was 3.444 73 766 461.18 9049.40 106.36
varied between 1 and 5 m. The diameters were established between 20 3.957 70 768 471.79 9061.67 114.52
and 80 mm according to the standard tube diameters. The number of 4.255 70 777 469.16 9068.98 119.34
4.699 69 766 454.63 9096.04 126.03
tubes was varied between 100 and 800 and the spacing between baffles 4.917 53 776 176.28 11790.32 154.08
between 100 and 500 mm. It is important to obtain the highest possible 4.940 47 776 144.01 14562.24 157.40
value of the ecological function. Fig. 2 shows the Pareto front of the 4.996 48 778 163.17 12870.86 156.18
obtained results. 4.970 43 777 139.11 15916.52 158.30
4.998 46 777 142.33 15050.53 158.06
Fig. 2 shows that there is a direct relationship between cost and
4.998 46 778 158.31 13464.53 156.78
ecological function. Values of ecological function over 140 kW incre- 5.000 42 778 135.58 16567.87 158.80
ment cost abruptly. For values of the ecological function of more than
60 kW, the cost exceeds 8500 USD Dollars.
Table 2 shows the data and results obtained from optimization. As
the number of tubes increases the value of the ecological function in-
creases, but also the cost of the heat exchanger becomes higher. When

Fig. 2. Ecological Function versus cost.

96
M.B. Reyes Rodríguez, et al.
all factors are simultaneously considered in the optimization process to
determine the “trade-off” between the cost and the ecological function
it is verified that the tube length is the most influent factor. While in-
creasing the tube length, increases ecological function, but sharply in-
creases the cost.
In the multi-objective optimization, the non-dominated solutions
are the ones that form the set of most interesting solutions. Each so-
lution will exhibit some type of trade-off and represents an option of
choice according to the needs of the problem. When comparing the
optimized results with the non-optimized one some aspects can be ob-
served. The non-optimized cost is 3,5 times higher than the highest
optimized cost, while the ecological function is only 1,6 times than the
highest optimized ecological function. Thus, the point with coordinates
cost = 58296.58 $ and ecological function = 254.62 kW is a point
outside the Pareto front and it is a dominated solution, that is, this point
is not an optimal solution.
5. Conclusions
The entropy generation minimization approach, widely applied to
the modeling and optimization of thermal systems, is associated with
the irreversibility of heat transfer, mass transfer and fluid flow, and
shows inconsistencies when applied to heat exchanger designs. A pro-
cedure involving the multi-objective optimization of shell and tube heat
exchangers is proposed. This procedure is flexible for different types of
fluids and for multiple designs of these devices and in addition con-
siders ten mechanical restrictions built-in the design. In order to per-
form the multi-objective optimization a genetic algorithm of second
generation was used (NSGA II) and continuous and discrete decision
variables are considered. The independent variables can be modified
according to desires of the user, as well as their boundaries. Applying
the concepts Entransy dissipation and the Ecological function of Angulo
Brown, a new and more appropriate ecological function was developed
to evaluate the environmental impact of heat exchangers. In the case of
heat exchangers, it is important to maximize the ecological function,
but, at the same time, to minimize the cost of the exchanger. These two
functions comprise a trade-off and then it is necessary to reach com-
promise solutions through a Pareto front. For the example discussed,
from 140 kW to up, cost grows abruptly. Of all the variables analyzed,
the length of the tube has the higher influence not only in the value of
the ecological function but also in the cost. The optimal value selected
from the Pareto front depends on the available budget because if it is
desirable a minimal ecological impact, the cost increases too much.
Acknowledgments
The research work has been supported by the Ministry of Education
of Brazil under the program for improvement of higher education
personnel scholarship. The authors would like to thank to the CNPq
Productivity of Research Funds Processes 301105/2016-2 and 301478/
2018-0 and to PNPD/CAPES No 88887.314336/2019-00 PEI-UFBA.
Conflicts of interest
The authors declare no conflict of interest.
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