Bulletin of the Chemists and Technolo~ts

of Macedonia,

Vol. 15, No. 1, pp. 39 - 44 (1996) ISSN 350 - 0136 UDC 66. 011 : 66.045.1 Original scielltific paper

GHTMDD - 270 Received: February 20, 1995

OPTIMUM DESIGN OF SHELL-AND-TUBE HEAT EXCHANGER

Liljana Markovska, Vera Mesko~Radmila Kiprijanova, Aleksandar Grizo
Faculty of Technology and Metallurgy, The "Sv. Kiril & M etodij" University, 91000 Skopje, Republic of Macedonia

Optimization of shell-and-tube-heat exchanger is accomplished by use of the OPTIMIZER software package. The objective function is defined together with the implicit constraint. Thesimultaneous equation solving method is used to solve the equations that describe the process. The advantages of the simultaneous equations solving approach are that: (1) it is a natural way to specify a problem since the design problem is by nature an optimization problem and the engineer does not have any other criterion for specifying many arbitrary variables, (2) it is easy to specify variables and constraints, and (3) it can handle highly integrated systems since all equations are solved simultaneously. The Extended Complex algorithm is chosen for such optimization study. The optimal value of the objective function and appropriate design variables are obtained. Key words: optimum design; shell-and-tube heat exchanger; optimization; Complex method

INTRODUCTION An optimum design is based on the best or most favorable conditions. In almost every case, these optimum conditions. can ultimately be reduced to a consideration of costs or profits. Thus an optimum economic design could be based on conditions giving the least cost per unit of time or the maximum profit per unit of production. When one design variable is changed, it is often found that some costs increase and others decrease. Under these conditions, the total cost may go through a minimum at one value of the particular design variable, and this value would be considered as an optimum. '!Wotypes of quantitative problems are commonly encountered by the design engineer when he is dealing with heat-transfer calculations. In the first type, all of the design variables are set, and the calculations involve only the determination of the indicated non variant quantities. By choosing various conditions, the engineer could ultimately arrive at a final design that would give the least total cost for fixed charges and operation. Thus, the second type of quantitative problem involves conditions in which at least one variable is not fixed, and the goal is to obtain an optimum economic design. In general, increased fluid velocities result in larger heat-transfer coefficients and, consequently, less heat-transfer area and exchanger cl;)stfor a given rate of heat transfer. On the other hand, the increased fluid velocities cause an increase in pressure drop and greater pumping costs. The optimum economic design occurs at the conditions where the total cost is a minimum. The basic problem, therefore, is to minimize the sum of the variable annual costs for the exchanger and its operation. The objective function is the total annual cost for heat exchanger. In this paper the optimum design of a heat exchanger is developed by use of a new technique.

SOFTWARE REQUIREMENTS The optimization of the heat exchanger network is accomplished using the ChemEng Software OPTIMIZER [1]. This package consists a set of ,optimization routines specially selected for solving the chemical engineering problems. Real engineering optimization problems are characterized by being highly constrained, both with explicit and implicit constraints, and by having many discontinuities [2,3]. OPTIMIZER consists of four algorithms with different characteristics which are suitable for different types or different stages in the optimization of engineering systems - particularly the optimization of

processes [4,5].

The most suitable method for optimizing a heat exchanger is the Extended Complex Method. The method is used for nonlinear optimization problems with constraints [6]. But application of this method to unconstrained problems is also possible. This method

40

L. Markovska, V. Mesko, R Kiprijanova, A. Grizo

has the advantage of easy implementation on a digital computer, of easy handling capability for implicit inequality constraints, and of not requiring computation of any derivatives. The simultaneous equation-solving method is used to solve the equations that describe the process. The basic idea of this method is simply to collect all the equations describing the flowsheet and solve them as a large system of non-linear algebraic equations. Mathematically the problem can be stated as solvef(x,u) = 0 with g(X,u) :s 0 where x is vector of dependent (state) variables u is vector of independent (decision) variables

f(x, u) is the set of process model equations g(x, u) is the set of inequality or equality constraints. Alternatively, the problem may be formulated mathematically as an optimization problem, minimize h(x, u) with f(x, u) = 0 g(x, u) :s 0 where h(X, u) is the objective function andf(x, u) and g(x, u) have the same meaning as before. The equality constraints are the same set of equations described above, but rather than specify the decision variables arbitrarily, they are selected to minimize the objective function.

HEAT EXCHANGER The design of a heat exchanger involves initial conditions in which the following variables are known: - process-fluid rate of flow - change in temperature of process fluid

PROBLEM

inlet temperature

of utility fluid (for cooling or

heating). With this information, the engineer must prepare a design for the optimum exchanger that will meet the required process conditions. Ordinarily, the following results must be determined: - heat-transfer area; - exit temperature and flow rate of utility fluid; - number, length, diameter, and arrangement of tubes; - tube-side and shell-side pressure drops. The variable annual costs of importance are the fixed charges on the equipment, the cost for the utility fluid, and the power cost for pumping the fluids through the exchanger. The total annual cost for optimization, therefore, can be represented by the following equation [7]:
Tv

utility fluid is condensing steam), solution of Eq. (1) for optimum conditions can often be simplified. For the case of no change in phase, the solution can become complex, because the velocities and resulting power costs and heat-transfer coefficients can be varied independently over a wide range of values. In the following analysis, the general case of steady-state heat transfer in shell-and-tube exchangers with no change in fluid phase is considered, and a specified tube diameter, wall thickness, number of passes, and arrangement of baffles and tubes are assumed. Simplifications are indicated for the common conditions of turbulent flow. Choice of independent variables The heat-transfer area An can be related to the flow rates and the temperature changes by an overall heat balance and tt!e rate equation.
Q

= QScpit2 -

tl)

Qrcpr(tl'

- t2') = KnAn

!:!..tsr

(2)

From Eq. (2)

Qs

Q cps

= AnTpCAn

+ QfI,CS

+ Arf/i,Ce

+ ArfJIFn

[ (!:!..tl !:!..t2) (tl' - t2 +

(3)

(1) The terminology used in solving the problem and the values of the variables are defined at the end of the paper. Under ordinary circumstances,the effect of tube diameter on total cost at the optimum operating conditions is not great, and a reasonable choice of tube diameter, wall thickness, and the tube spacing can be specified at the start of the design. Similarly, the number of tubes is usually specified. If a change in phase of one of the fluids occurs (for example, if the

where!:!..tI = t2' - tI and!:!..t2 = tI' - t2' Since Q, cps' !:!..tI' and'tz' are constant, Qs is a function only of tI', the independent variable !:!..tz. area An is known if The Kn and !:!..tsr fixed. The overall coefficient is known are if the inside and outside film coefficients, av and an' are fixed, and for a given number of tube passes, !:!..tsr varies only with changes in !:!..tz. herefore, An is a T function of av ' a,l' !:!..tsr' shown by the following as equations:

!:!..tsr =~=~ Q KnAn

(~+-L+RI
An lDvav an

(4)

BulI.Chem.TechnoI.Macedonia,

15, 1, p.39-44(I996)

Optimum

design of shell-and-tube

heat exchanger

41
E v = "It a4.75 't'n n (9)

FT(!!.tZ

- !!.t1)= ~
KnAn

=~

(~

-.l.

+R
]

An ~Dvav

an

where
(5)

With no change in phase av depends on mass flow rate Gv inside the tubes, as it can be seen from the following equation for turbulent flow (Re> 10000):

1jJv- Bv

12000D\~.5 ,u~.83(;.lzl,uv ),63

ge

ZA2.33 1.17 nPv v cp.'

(10)

B N N

~~a,(D~G'r (;f
n

(:XI4
0.33

(6)

rp
n

2a D DO.75 p.75 Il1.4Z

n r 0 n c n s fn (11) 11 Ne ;TT; a4.75 g p2 A3.17 c1.58 p n c n fn Pro ] [

The relevant equation for an depending on shellside mass velocity is:

( ~=;:D~Gn

( if )

(7)

The Eq. (6) is valid for 10000 < Re < 120000, 0.7 < Pr < 120 and LID = 60. In this ranges av = 0.023, n = 0.8 and m = 0.3. The Eq. (7) is valid for 20000 < Re < 40000, an = 0.33 if the tubes are staggered, an = 0.26 if the tubes are in line and

= 0.6.

All the terms in the brackets are set by the design conditions. The values of Bv and Bn l11p are not completely independent of the film coeffIcients, but they do not vary enough to be critical. As a first approximation, Bv is usually close to 1, and Bll is taken to be equal to the number of baffle passes~. Thevalue of the safety factor Fs is taken as 1.6 for design estimates. The ratio NrN/Nc depends on the tube layout and baffle arrangement. For rectangular tube bundles and segmental baffles, the ratio is equal to one. For other tube layouts and segmental baffles, the ratio is usually in the range of 0.6 to 1.2. The relevant equations study are: Objective function:
T =A
v

The variables in Eq. (1) areAn, Q, El" En' and their values are set if av ' an and !!.t2are known. The optimizing procedure is simplified by retaining the following variables: av' an !!.t2andAn' Defining relevant equations for optimization study The first step is to express Eq. (1) in terms of the fundamental variables. The following relationships for power loss inside tubes and power loss outside tubes are suitable for conditions of turbulent flow and shell-side fluid flowing in a direction normal to the tubes [7,8]:
E v =.It a3.5 't'v v (8)

for the optimization

An

QH.C
C

ps

(!!.t 1 -!!.t

+ t 1 I - t 2 I)
HjCn

+
(12)

+AnHjCe1jJva~.5

+Anrpna~.75

Implicit constraint:
FT(!!.t2

!!.t1)

--

1 An (

Dn -+-+R Dvav

1 an
J

=0

Q In (!!.tZI!!.t1)

(13)

OPTIMIZATION

The optimization of the objective function Eq. (12) with implicit constraint Eq. (13) is possible using classical methods of searching the optimum. The Lagrange multiplier method is used for development of the optimum design for a shell-and-tube heat exchanger [7,8]. The optimum values of the variables are obtained by partial differentiation of the objective function incorporating the Lagrange multiplier, equating the derivatives to zero and solving these equations. In the present paper the optimization of shelland-tube-heat exchanger is accomplished by use of OPTIMIZER software package. The advantage of using this software is the saved time and efforts for such analysis.

Ewmple A gas under pressure with properties equivalent to air must be cooled from 65C to 38 Qc. Cooling water is available at a temperature of 21C. On the basis of the following data and specifications, it is necessarily to be determined the tube length and the number oftubes for the optimum exchanger which will handle 10000 kg/h and will operate 8760 h per year. Exchanger specification: - steel shell-and-tube exchanger with cross-flow baffling, - cooling water passes through shell side of unit, - one tube pass and counter current flow, - outside diameter of the tubes 25 mm,

rnac.xeM.TeXHon.MaKe,[{oHHja,

15, 1, c.39-44(1996)

42

L. Markovska, V. Mesko, R Kiprijanova, A. Grizo

- inside diameter of the tubes 20 mm, - 24 mm triangular pitch. Tubes are staggered. Costs: - purchased cost per surface unit is 8500 den/m2, - installation cost equals 15% of purchased cost, - annual fixed charges including maintenance equal 20 % of installed cost, - cost for cooling water (not including pumping cost) is 1.5 den/m3, - cost for energy supplied to force the cooling water and the gas through exchanger (including effect of pump and motor efficiency and cost) is 5 den/kWh Operating conditions: - aver~e absolute pressure of gas in exchanger is 98.1 10 N/m , - correction factors Bv and Bn are: Bv Bn

average bulk water temperature 32.5 DC, average bulk gas temperature 51.5 DC, average water film temperature 33.4 DC, inside wall temperature 35.4 DC, - physical properties for water and air are selected due to the correspond temperatures. The dimension of the investigated problem is four and it is assumed: !1tz -+Xl,
av -+ Xl, an -+ X3, An-+X4

Thking into account all specifications and assumptions the objective function Eq. (12) takes the form: OBJFN

= 1955*X4+886950/(

44- Xl)+

+ 56781.8*X23.5*X4+0.33hX34.75*X4(14)
with implicit constraint:
Xl

= np ,

= 1.2

17

1.25

- safetyfactor Fs for the outside filmcoefficient is 1.3, - fouling coefficient for cooling water is 8400 W/mzK,

78.571n(Xl/17)

- X4 ( X2 + X3 + 0.29) = 0
(15)

fouling coefficient

for gas is 11200 W/mZ K,

- at the optimum conditions flow on tube side and shell side is turbulent,

- the factor N,NoINc = 1.

Assumptions:

!1t,

exit temperature

of exit water 44C,

-average M over cooling water film 10 % of total

- average!1t

over air film 85 % of total M,

- temperatures: tl' = 65C, tz' = 38C, tl = 21C, tz = 44C, !1tl = tz' - tl = 17C,

The objective function Eq. (14) and the implicit constraint Eq. (15) have to be incorporated in the program segment OPTMOD*.FOR in FORTRAN notation. The way of introducing the implicit constraint in the subroutine OPTMOD* .FOR is important. The software is designed for constraints of unequality type. In this paper the constraint (Eq. 15) has to be written in the form X4=G(Xl, X2, X3), where X4 denotes the heat transfer area. The bounds of the constraint in the optimization procedure are taken 0 and 0.01 which is satisfactorily error of estimation the heat transfer area. The FORTRAN subroutine source code must be compiled with the same compiler as the other object segments and then the program can be linked.

RESULTS OF OPTIMIZATION The response surface methodology is used for optimization the objective function and the most suitable a~gorithm is the Extended Complex method. This algorithm consists of iteration steps, the maximal number of which is chosen as a stopping criterion. In this investigation the number of iterations is 20. The input data of the design variables (lower bounds, upper bounds and starting points) used during the optimization are selected due to the physical understanding of the process. The optimization is accomplished by use of ten different starting points. The obtained optimum points depends on the values of the variables at the starting points as it is shown in the Thble 1. In this table the results from only five different points are given. The applied algorithm is repeated 2-5 times to reach reproducible results. So the number of iterations to reach the optimum points is at least 100. Studding the obtained results in Thble 1, the result at the starting point 5 is acceptable. The minimal value of the objective function is 96027.2 and the variables are Xl =20.2391, X2=0.306, X3=3.4653 and X4=19.721. Introducing
optimum

the appropriated assignments the

are: An

design variables

19.721 mZ, av =

0.306 kW/mz K, an =3.4653 kW/mz K, !1tz = 20.2391 Dc. For shell-and-tube heat exchanger the number of tubes and their length might be calculated. For this exchanger the total annual variable cost and its operation is 96027.2 deniyear.

BulI.Chem.TechnoI.Macedonia,

15, 1, p.39-44(1996)

Optimum

design of shell-and-tube

heat exchanger

43

Ta b Ie I Results of optimization of shell-and-tube heat exchanger

LOWER BOUND Xl X2 X3 X4 OBJFN STARTING POINT (2) Xl X2 X3 X4 OBJFN STARTING POINT (3) Xl X2 X3 X4 OBJFN STARTING POINT (4) Xl X2 X3 X4 OBJFN STARTING POINT (5) Xl X2 X3 X4 OBJFN 18 0.1 2 16 25 0.5 5 25 21.5 0.3 3.5 20.5 18 0.1 2 16 25 0.5 5 25 21 0.25 3.4 22 18 0.1 2 16 25 0.5 5 25 21 0.3 4 18 18 0.1 2 19 25 0.5 5 25 20 0.3 2.8 19 18 0.1 2 16 UPPER BOUND 25 0.5 5 25 STARTING POINT (1) 19.5 0.3 2.8 19,5 OPTIMUM POINT 18.5603 0.3418 2.9308 18.9504 98089.1 OPTIMUM POINT 20.1853 0.3440 2.7672 18.1430 98064.2 OPTIMUM POINT 21.4853 0.3062 3.8977 18.9770 97632.3 OPTIMUM POINT 19.5623 0.3250 2.7797 19.3453 96431.1 OPTIMUM POINT 20.2391 0.3060 3.4653 19.7210 96027.2

Cs cost of utility fluid, den/kg Ce cost for supplying 1 kW energy to pump fluid flowing through inside of tubes, den/m kg Cn cost for supplying 1 kW energy to pump fluid flowing through shell side of unit, den/m kg Qs flow rate of utility fluid, kg/h Hi hours of operation per year, hiyear Ev power loss inside tubes per unit of outside tube area, kW/h m2 En power loss outside tubes per unit of outside tube area, kW/h m2 cps heat capacity of utility fluid, W/kg c cp, heat capacity of process fluid, W/kg c Q, flow rate of process fluid, kg/h
t2'

- tl' temperature-difference

of process fluid, c

t2 - tl temperature-difference of utility fluid, c Kn overall coefficient of heat transfer based on outside tube area, W/m2 c Msr Dn Dv av an R mean temperature-difference outside diameter of tubes, m inside diameter of tubes, m inside film coefficient, W/m2oC outside film coefficient, W/m2oC combined resistance of tube wall and scaling or dirt factors, W/m2oC

FT correction factor on logarithmic-mean temperature difference for counterflow to a,ccount for number of passes; FT = 1 if unit is counterflow and single pass on shell and tube sides, dimensionless Gv mass flow rate inside the tube, kg/h m2 Gfl shell-side mass velocity across the tubes, kg/h m2 cp A f.1 Fs
1/Jv

heat capacity of fluid, KJ/kg c thermal conductivity, W/m2oC viscosity of fluid (subscript z indicates evaluation at wall temperature), Ns/m2 safety factor to account for bypassing effects

factor for evaluation Ev' dimensionless

1/Jfl factor for evaluation En' dimensionless Bv correction factor, dimensionless Bfl correction factor, dimensionless np Nr number of baffles plus 1, dimensionless number of rows of tubes with flow across shell axis, dimensionless

NOTATION Tv total annual variable cost for heat exchanger and its operation, den/year An area of heat transfer outside of tubes, m2 TF annual fixed charges including maintenance, expressed as a fraction of initial cost for completely installed unit CAn installed cost of heat exchanger per unit of outside-tube heat-transfer area, den/m2

Ne total number of tubes in exchanger, dimensionless No number of clearances between tubes for flow of shell-side fluid across shell axis, dimensionless Dc clearance between tubes to gtve smallest free area across shell axis, dimensionless

rmc.xeM.TexHoJl.MaKeJ1oHl1ja,

15, 1, c.39-44(1996)

44

L. Markovska, V.Mdko, R Kiprijanova, A. Grizo REFERENCES

[1] L. M. Rose, OPTIM IZER, Optimization Package for Chemical Engineers; ChemEng Software & Services. Ltd., Version 5.1, Beaminster, England (1992). [2] L. M. Rose: The Application of Mathematical Modeling to Process Development arid Design, Applied Science Publishers, London (1974). [3] D. M. Himmelblau, K. B. Bischoff, Process Analysis and Simulation -Detenninistic Systems, lohn and Wiley & Sons, Inc., New York (1968). [4] D. l. Wilde, C. S. Beightler, Prentice - Hall. Inc. (1967). Foundation of Optimization,

[5] R. lain, The art of Computer Systems Pelfonnance Wiley & Sons, New York (1991). [6] Y. Bard, Non-linear (1974). Parameter Estimation,

Ana~ysis, lohn Academic Press

[7] M. S. Peters, K. D. Timmerhous, Plant Design and Economies for Chemical Engineers, McGraw-Hill Book Company, New York, 1980. [8] A. Grizo, V. Mdko, Proektiranje posrrojki, Nasa kniga, Skopje, 1990. i ekonomika na hemiski

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BuII.Chem.TechnoI.Macedoni3,

15, 1, p.39-44(1996)