Cost-effective reconstruction of existing two-stream heat exchanger systems

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Abstract

This paper proposes a method for optimizing a two-stream heat exchange system, taking into account the technical limitations imposed by the heat exchange equipment and cost-effectiveness of the reconstruction project. Optimization of the heat exchanger network is performed taking into account the need for industrial safety expertise in case the design temperatures for the heat exchangers are exceeded by the process flows. This method was applied to optimize energy consumption at a real hydrocracking unit. Two types of heat exchangers were considered – shell-and-tube and plate heat exchangers for possible increase of heat exchange surface area in the existing heat recovery system. For shell-and-tube heat exchangers, the minimum present value of the reconstruction project is observed when the heat exchange surface is increased by 500 m2, which corresponds to the installation of a two-section heat exchanger. It allows to reduce specific consumption of hot utilities by 51%, and cold utilities – by 31%. However, the simple payback period of such a project is ~ 1.5 years. At the same time for plate heat exchangers the minimum annual costs are observed when the heat exchange surface is increased by 400 m2. The cost of such a modernization project is 18% less than for shell-and-tube heat exchangers, and the reduction of specific consumption of hot and cold utilities is 66% and 40%, respectively.

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About the authors

L. M. Ulyev

National Research Tomsk State University

Email: tag7@tpu.ru
Russian Federation, Tomsk

T. A. Gil

National Research Tomsk State University

Author for correspondence.
Email: tag7@tpu.ru
Russian Federation, Tomsk

V. V. Norin

National Research Tomsk State University

Email: tag7@tpu.ru
Russian Federation, Tomsk

Е. V. Kuvardina

LLC Gazpromneft – Industrial Innovations

Email: tag7@tpu.ru
Russian Federation, St. Petersburg

D. O. Kondrashev

LLC Gazpromneft – Industrial Innovations

Email: tag7@tpu.ru
Russian Federation, St. Petersburg

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2. Fig. 1. Grid diagram of a two-stream heat exchange system with N heat exchangers: 1 – hot stream; 2 – cold stream; – temperature of the hot coolant at the outlet of the i-th heat exchanger; – temperature of the cold coolant at the outlet of the N + 1 i-th heat exchanger; Qi – heat load on the i-th heat exchanger; CPh, CPc – flow heat capacity of the hot and cold coolant, respectively; QCmin, QHmin – useful power of cold and hot utilities, respectively, C – cold utility; H – hot utility.

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3. Fig. 2. Flow chart of the light hydrocracking process: AC – air cooling; C – separator; E – tank; F – furnace; K – column; P – reactor; T – heat exchanger; X – refrigerator; ОВ – cooling water.

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4. Fig. 3. Two-flow heat exchange system of the hydrocracking unit: a) classic view of the heat exchange network; b) grid diagram of the heat exchange network.

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5. Fig. 4. Dependence of the heat load (Q) on the heat exchange surface area (S): a) for recovery: 1 - on the first heat exchanger; 2 - on the second heat exchanger; 3 - on the third; 4 - on the fourth; 5 - total capacity of heat energy recovery in the new heat exchange system. b) for the useful power of utilities consumed by the process: 1 - hot utilities; 2 - cold. Solid line - when installing a shell-and-tube heat exchanger, and dashed line - when installing a PTO.

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6. Fig. 5. Change in the temperature of coolants (∆t) in heat exchangers depending on the area of the fourth heat exchanger (S): a) when installing a shell-and-tube heat exchanger; b) when installing a plate heat exchanger. 1 – hot flow in the first heat exchanger; 2 – hot flow in the second heat exchanger; 3 – hot coolant in the third apparatus; 4 – hot flow in the fourth heat exchanger; 5 – cold flow in the first heat exchanger; 6 – cold flow in the second heat exchanger; 7 – cold flow in the third apparatus; 8 – cold flow in the fourth heat exchanger.

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7. Fig. 6. Dependence of the temperature of the coolants on the heat exchange surface area of the new heat exchanger. a) for the cold coolant: 1 – temperature at the inlet of the fourth heat exchanger; 2 – temperature at the inlet of the third heat exchanger; 3 – temperature at the inlet of the second heat exchanger; 4 – temperature at the inlet of the first heat exchanger; b) for the hot coolant: 1 – temperature at the outlet of the first heat exchanger; 2 – temperature at the outlet of the second heat exchanger; 3 – temperature at the outlet of the third heat exchanger; 4 – temperature at the outlet of the fourth heat exchanger. Solid lines – when installing a shell-and-tube heat exchanger, dashed lines – when installing a PTH.

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8. Fig. 7. Discounted cost: 1 – annual cost of energy; 2 – reduced capital costs; 3 – total reduced cost of the modernization project. Solid lines – when installing a shell-and-tube heat exchanger, dashed line – when installing a PTH.

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9. Fig. 8. Dependence of the simple payback period of the heat exchange modernization project (Pb) on the size of the surface area of additional heat exchange (S): 1 – for a shell-and-tube heat exchanger; 2 – for a PTH.

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