Automated retrofit targeting of heat exchanger networks

Abstract

The aim of this paper is to develop a novel heat exchanger network (HEN) retrofit method based on a new automated retrofit targeting (ART) algorithm. ART uses the heat surplus-deficit table (HSDT) in combination with the Bridge Retrofit concepts to generate retrofit bridges option, from which a retrofit design may be formulated. The HSDT is a tabular tool that shows potential for improved re-integration of heat source and sink streams within a HEN. Using the HSDT, retrofit bridges—a set of modifications that links a cooler to a heater to save energy—may be identified, quantified, and compared. The novel retrofit method including the ART algorithm has been successfully implemented in Microsoft Excel^TM to enable analysis of large-scale HENs. A refinery case study with 27 streams and 46 existing heat exchangers demonstrated the retrofit method’s potential. For the case study, the ART algorithm found 68903 feasible unique retrofit opportunities with a minimum 400 kW·unit⁻¹ threshold for heat recovery divided by the number of new units. The most promising retrofit project required 3 new heat exchanger units to achieve a heat savings of 4.24 MW with a favorable annualised profit and a reasonable payback period.

Graphical abstract

Keywords

process retrofit / pinch analysis / heat exchanger network / heat recovery

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