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    OPTM NTWORKS FOR AT XCANG

    b

    wa Chals ohann J

    A Disstation Psnt to t

    FACLTY OF T GRADAT SCOOL

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    NS F SN FN

    TH E SHOOL

    NIVERSITY PAR

    LOS ANELES ALIFORIA 000

    hs dssertaton, wrtten by

    g

    9._;* M!.-

    under the drecton of h.i... Dssertaton om-mttee and approved by all ts members haseen presented to and accepted by he Graduate School n paral fulllment of requre-ments of the degree of

    DOCTOR OF PHILOSOPHY

    Date .Yn_:7J

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    ACOWLDGMNTS

    I wish to xss my gatit to all th ol

    who hav hl in th oltion of this isstation

    I a sially int to D F J Lokhat who hasgivn so fly of his tim ing th os of th

    sah Th oth omitt ms D J Rtan D L L any hav also n vy hlfl

    Aitionally I wol lik to aknowlg thfinanial hl fo Gilltt-Pa Mat oany ing th

    io Coting svis ovi y th

    Systs Silation Laoatoy at th nivsity of

    Sothn Califonia a also gatly aknowlg

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    TABLE OF CONTENTS

    Page

    ACOWLEDGMETS

    LIST OF TABLES

    LIST OF FIGURES

    . . .

    . . . . . . . . . .

    . . . . . . .

    ii

    v

    vii

    NOME NCLATURE

    ABSTRACT

    CHAPTER

    I.

    xiii

    INTRODUCTION

    II ELEMENTS OF AT EXCHANGE NETWORKS

    1

    7

    8A. Heat Exchangers

    B. Uilities for Heating

    c Uilities for Cooling

    . .

    . . .

    . .

    .

    18

    21

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    Pe

    V CASE SES EWORK ESGN 7A pe Ss te o f or Proces s Str es 7

    B pe C Sste of Sx Process Stres 7 2

    . pe Ss te o f S x Pro ce ss Str es 84

    V HEA EXCHAGE EWORKS N OPERAOA SteStte Response to epertre

    Chne s . . .

    B Ste-Stte Response to Cpct RteChnes . .

    . e rn Responses . .

    V COCSOS . . .

    REERECES . . . . .

    APPECES

    A Gossr . . .

    93

    93

    100

    02105

    10

    108

    109

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    Tbe

    I

    II

    III

    IV

    VI

    VII

    VIII

    LIST OF ABLES

    DATA FOR SIMPLIFIED THEE STRE EMPLE

    FEASIBILITY TABLE FOR TEE STREAM EPLECASE WITH mi 0 F

    o

    FEASIBILITY TABLE FOR THREE STREA EXMPLECASE 4 WITH min 20 F

    FEASIBILITY TABL FOR HREE SRE EPLECASE 4 WITH Omin = 10

    MINIM EA TABLE FOR

    CASE 1 MINIM AREA TABLE FORCASE

    MINI AREA TBLE FORCASE

    Fo

    THREE STREAM EPLE

    THREE STREM EXPLE

    THREE STRAM EXPLE

    DATA FOR SREA CONTETION EXPLE

    Pge

    33

    4

    37

    4

    4

    4

    45

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    Tbe Pge

    III RATE SENSITIVITY F NETWRK SHWN INFIGURE 19 101

    XIX EMPLE CALCUTIN USING RATE SENSITIVITY 103

    D-I ECUTIE CPUTER PRGRA 132

    D-II SUBRUTINE PSDATA 133

    D-III SUBRUTINE DELTA 136

    D-I SUBRTINE BALNCE 137

    D-V SUBRUTINE RANGE 138

    D-VI SUBRUTINE MIUTY 139

    D-VII SUBRUTINE IN 13

    D-VIII SUBRUTI CIG 147

    D-IX SUBRUTINE PATH 152

    D-X SUBRUTINE EXCHNG 155

    D-XI SUBRUTINE DIVIDE 158

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    Fige

    !A

    B

    C

    D

    2

    3

    LIS OF FIGRES

    Netwoks o Singe ocess Ste ype ASte Syste

    Netwoks o One Soce n One Sink ocess

    Ste ype B Ste System

    A ossibe Netwok o One Soce n SeveSink ocess Stems o One Sink n SeveSoce ocess Stes ype C Ste Syste

    A ossibe Netwok o Seve Soce nSeve Sink ocess Stes Type D Syste

    epete Rnges o hee Ste ExmpeCse 2

    Lck o Tepete Contentin in heeSte Expe Cse 1

    Rnge o Tepete Contetion in hee

    Ste Expe se 3

    ge

    28

    28

    2 9

    29

    3

    0

    40

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    Fiue

    14

    1 5

    1

    1 7

    18

    19

    2 0

    2 1

    Feasibe Netwok Space fo pe D SsteExape

    Effect of Miniu epeate of Appoac onCosts fo pe D Sste Exape

    Entap Dia fo pe D Sste Exape

    Netwok Sntesis sin Entap Diaa ofpe D Sste Exape

    Netwok Afte Lee et a

    Netwok Snte s ized si n te EntapDiaa

    Entap Diaa fo pe C Sste Exape

    Netwok Afte Westbook

    2 2 Feasibe Netwok Space fo pe C Sste

    2 3

    Exape

    Netwok Sntesis wit Cude Stea Diided

    into Fou Bances

    Pae

    7 0

    7 1

    73

    74

    7 5

    75

    7 8

    79

    8 0

    8 2

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    Figue

    A-3

    C-2

    3

    C-4

    C-5

    C-6

    o eat Loa Loops Counte-Cuent eat ane

    Thee Stea Counte-Cuent eat Tanse

    ee Steam Syste with empeatueContention

    Miniu Aea Netwok

    A Stea Syste ich Reuies eatxchanges in Seies

    A Steam Syste ih Reuies eatxcanges in Paallel

    age

    11423

    2 3

    24

    125

    26

    26

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    NOENCE

    y f h rm d phr d h dr

    hv b gv pc mg wh ppd

    chg wrk h b cry c hr pry pcfc vcbry drb m f h

    ccp dvpd Sm f h rm hv b dg

    d by ymb d ppr h Nmcr; hwvr

    fr p f h rm ppr

    Gry ppd I

    bc

    h chgr c prmr

    rfr r f chgr k

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    M

    N

    - miniu nub o xangs qui to

    onstut a at xang ntwok o agivn stam syst.

    - nub o xangs qui o a ntwokwit t iniu total at tans aaA*.

    oiints in t tpatu viationquation o sou stams

    - oiints in t tatu viationquation o sink stams .

    nub o sou stas in a givn sta

    syst inluing utility stams .- nub o sink stams in a givn sta

    syst inluing utility stams .

    - nub o tans units in a givn xang .

    - at tans in xang k

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    Toutput

    the deviation from the design value for the

    temperature at point i,f tactual tdesign

    input tperature of a given stream to aheat echange netork

    outlet temperature of a given stream from a

    heat echange netork

    deviation of a stream's temperature from the

    design value, = Tdesign - Tactual

    overall heat transfer coefficient forstreams i and

    eight rate of stream i

    temperature dierenc at n point in anexchanger, tsource - tsink

    smallest minim temperature of approach for

    an exchanger in gven netork

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    ABSTACT

    Ecoomic operaion o mern chemical processes re

    quires ha he pars o he process wih excess hea be

    couple o hose ha requre hea is hermal couplin

    is accomplishe hrouh he use o hea exchaners Te

    hea exchaners, heaers a coolers in moern plans orm

    hihl inerae an complex neworks

    Te cos o such hea exchane neworks epens no

    onl on he pairin a sequencin o sreams exchanin

    hea, bu also on he amous o upplemenal heain an

    cooli use perai coss are primaril a uncion o

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    with het exchge etwrk t evep prctic

    etwrk eig eth he reerch h hw tht there

    exit " j uxtptiu r egi " i which if fere t eigs

    ct be itiguihe cst bi becuse f t

    ucertities itgibe Bus this regi c

    be c cute " ecic ptiu etwrk es ig i

    e whi ch ie withi thi j uxtptimu regi

    Utiizig e f the theryic spect f the

    prbe it i pibe t ccute bu fr etwrk e

    ig Fir t eth h bee evepe fr eteri i g

    the iiu ut temperture eve f utiity

    tres require Se cy it i pibe t c c ute

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    eork desgs ca be deermed by comparso o dea

    ms addo o comparso o eac oer

    o cocude e researc, severa meods o e

    ork syess ere epored ad e bes pars o eac

    amped Meods ere aso deveoped o mprove gve

    eork desgs ad o predc e eec o sream

    cages o eork operao Numerca eampes are used

    o usrae e desg ad operao o ecoomc opm

    eorks

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    TE I

    INTIN

    I a oder peroe refer or ceca pa, a

    arge fraco f o e a capa vee ad

    e cog operag co ca e ared o e

    pp ad reova of ea . To redce co

    proce deger ae e of ea excage ewe e

    o ad cod proce rea addo o eag ad

    coog b e . Te reg grp of ea ex

    cager, cooer, eaer, reoer, codeer ad/or

    frace are p caed e excage ewor

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    be rewarding to develop the best esigns Such is the

    case, since cnsiderabe cost ifferences can result in

    network designs depending on the pairing and sequencing

    of the streams exchanging heat

    2

    e technica literature contains informative

    articles on design and optimization of individua heat ex

    changers but there is ittle practica information on de

    sign or optimization of networks for heat exchange e

    iterature that is availabe has been groupe in an anno

    tated bibliography (Appendix

    i dissertation divides the probe of heat ex

    change network design int a number of parts for analysis:

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    network, i.e. to find h changes i iput

    variables affect outts for a iven fixed

    etwork

    3

    T stucturing or synthesis of a network (Part (a)

    of the process dsign problm) is very difficut in all

    but the most simple cases is is a irect result of the

    astonishing nuber of technically possible networks if

    ore than three or four process streas are consided

    Recently several authos have trid to foruate the nt

    work synthesis probl so that it could b sov by opera

    tions esearch technies Hever, these forlations

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    4

    opimiaio chiqu a w Herei ie ecod

    difficuy for e proce gieer The ouio ech

    iqu are im coumig v oug doe o hig pd

    digia compur

    e ecod par of h proce deig probem {b)

    ca oy be aemped afr h work a b ruc

    urd Ti probem i more coveioa ad chiqu

    uch a dyamic prograig hav be ued o opii

    giv ework Hever h copuig co for he

    echique i ao uuay i hig

    Par (c) of h proce eig probem provide h

    i i d i Wih

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    5

    efe o an poin wihin his jua-opi egion as

    he opiu e auho has developed seveal copue

    aided echniques fo finding his ua-opiu egion fo

    hea echange newos ese echniques ae fleile and

    a e used a each sep of he design pocess o oain

    he juaopi o he accuac pemied b daa and

    ie liiaions

    Realisicall, he acual design of a cheical

    plan o a peoleu efine uni poceeds in seveal

    seps and so s he design of an associaed hea echange

    newo In he iniial o concepual sep he enginee

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    emphaszes the ntal desgn of heat exchange networks

    e last part of the network desgn proble con

    sdered s not often nclded n optmzaton stdes

    That s how does the nt respond to transents and/or

    steady-state process changes? e "operablty of a

    process can be of great mportance n ts start-p and

    economc operaton Operablty shold be consdered

    drng ntal desgn stages and not left as a problem to

    be soled later e athor has ade a stdy of the ef

    fect of process changes on heat exchange networks and has

    deeloped me general crtera whch shold ad the

    6

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    CHAPER II

    ELEMENS OF HEA EXCHANGE NEORKS

    o fcilitt study ht xchng ntworks r

    considred to b cposed of individul building blocks

    or lmnts which opert on th ntwork procss strms

    s lments hv bn grouped into four bsic typs nd

    ch type is discussd in section of this chptr

    individul lnt typs hve ben studid xtnsively

    in the litrture but r reviewd re to surize thir

    most importnt chrctristics In network t lemnts

    do not oprte indpndently but th prformnc of ch

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    8

    detiled techniques cn be used to finlize the best design

    for ech element Hoever it should be noted tht the

    desgn ltitude is not ver gret in the finl project

    engineer ing stges

    Het xhnger s

    Generl D scription

    Het exchngers re unique group of netork ee

    ments since the m be described s the nodes of the net

    ork nd the onl plce ithin netor here het trns

    fer is considered to tke plce A het exchnger m be

    brodl defined s n pprtus in hich one fluid trns

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    In ractice te first fuid fls troug a bunde of

    tubes e te second fuid fls on te outside of te

    ube bunde and is contaned by an outer se Actuay,

    many variations of te basc se-and-tube design are

    utiized as described by Perry (15) and oter sources

    ese varations are made in an effort to otimize te de

    sign of an individual excanger for te articuar service

    anticiated Te tree most mortant factors affecting

    tis otimization are usualy: eat transfer area, res

    sure dro across te excanger, and maintenance costs

    Maintenance costs are rimarily a functon of material of

    i d f d bl d l i f

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    value can hen be use o characerize he excanger for

    iniial rocess cos evaluaions Exchanger ressure ro

    is also usually esablishe so ha exchanger esign an

    uing requireens can be deermined

    ssuing a simlifie dble-ie moel for he

    hea exchanger one can wrie for each ifferenial seg-

    en of he excanger a seaysae hea conucion

    equaion:

    (II

    I is also ossible o wrie a ea balance for boh fluis

    in e ifferenial secion of he exchanger

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    Solving Equation II for dq and substituting gives

    d9U9d

    9outlet - inlet>

    qexcanger{II4)

    fter rearrangement te wole excanger may be modeled as

    outlet

    d 9outlet inletue qexcanger

    xchanger

    d

    (II5)

    fter integration wit constant and rearrangemet

    inlet - 9outletq U

    l

    n

    i

    n

    l

    t

    o

    u

    t

    l

    t

    UQ (II6)

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    an compensate for ing an other effects

    For esign cacuations invoving other than the

    oube-pipe f geometry a correction factor F is

    custoariy incue in Equation II6 to correct the og

    mean terature ifference to the true integrate

    temperature ifference for the new exchanger geometry

    us Equation II6 becomes:

    q = A9 II8)

    eoreticay F may vary from to se ow vaue but

    in practice few exchaners are buit with an F vaue ess

    than 85 is is a resut of the reative costs esign

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    3

    ount of het trnsferre uh rtin or simution

    utions ou be one usin ution however

    n i nvove tr i n err or soution wou be r eui re

    ortunte n e ff i ient ir ect soution r t in

    metho hs been eveope b Ks n onon (7). he

    het tns fer r te euti on ) n n energ eution

    2 ) re the two esript ive eutions for het ex

    hne r hese eutions m be roupe s bove or re

    written usin sever imensioness roups t hve phsi

    s in if ine xh nger het tr ns fer e f fetivenes s

    e ) i s efine s the r t io of tu het trnsfer r te to

    th th i i it i h t t f t

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    14

    smller strem cpcit rte (Cin> in the echnger under

    considertion e number of het trnsfer units Ntu is

    n epression of the het trnsfer size of the prticulr

    echnger nd is defined by

    lO UdA in

    U

    in(II10)

    Cpcit rte rtio is the rtio of the smller to the

    lrger of the strem ccit rtes Like echnger ef

    fectiveness, cpcit rte rtio is never greter thn

    unit nd equls zero if one of the two strems is vpor

    izing or condensing

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    15

    1 0 exp u

    l R

    = R _ exp u l.OR) o 0 o R = 0 0 II2

    o u s e h boe expes s on s n n exhn ng

    lulon one hou po ollos:

    l u o enon gen n

    Eon II0

    2 lule R o Eon II1

    (3 Dene e o he pul oe u

    n R lu es o s pl ouneu en

    oub le ppe exh ne us e Equon I I2

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    6

    fr the sae fuids r frm a previus desin alulatin

    three fat rs miht hane it ir st , i f vei t of the

    f ui ds thruh the exhaner is hne , U w i l ar . A

    r uh r ue is that U vr ies as the rat io f the st ream

    rtes t the 0 8 pwer , with an inr ea se in rate eadin

    t an increased The seond fatr is ar iat in in f u i

    prper ti es due t a hne in fu id temper ature s . If fui

    vis c si ty der eases , e o it thruh the exhaner w i l

    either remain nstant r inrease for a fixed pressure

    drp . hanes in issity an be pronouned with heav

    petr eum i s . Lsty the ndit in of the heat ex

    hner ( ean r fue d) hs a s in i f iant e ffe t n the

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    As mentioned earlier these three facors are manipulaed

    in he design o individual exchangers to ry ad arrive

    at a minim cost for a given service Hever, they

    may not always be reely varied and if, for examle,

    stainless steel tubes are required because of corrosive

    streams, exchanger cost wil be doubled In addition

    shipping and installation can add significanty to the

    initial cos of heat exchangers

    I materials o construction are ixed, exchanger

    17

    cost can, as a first aproximaion, e related o area as:

    D aA

    b

    c {II-13 E

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    18

    e ul o ppox e u he o el e o

    nu o exhnge un well o he ne e

    To o e le op e eono nl o h e ex

    hnge newo nenne o o he exhnge

    houl e n lue

    B le o Heng

    eleen o he exhnge ne wo u l e e

    onee o poe n nee wh exenl oue

    n n o he I h ou gh he u le o he

    ng h he l ene g o he p o he n e

    wo h e e h ghe epe u e ene g h n l

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    1

    ac le y ooe ( 1 saze s soe o he e s a

    oea coseao s . Feely , las have hee

    levels o sea hea avalale : hh es se (00 s ,

    lo esse (100 s a eas hese levels o

    seam esse ove a ealy eal hea e h

    he eeae ae o ao 00 o 00F Seam

    sally sasses all he hea e hs emea

    e ae ecas e o s avalaly , saly , c os ,

    h eaaso caacy , a s aey

    ees a mehas ve cos es o ocess

    les a s ees o oe ha se o

    he hhe esse l evel hee s a e lave ly sal l cos

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    0

    syses ae eely se. Dhe A s a ola l

    o hs ose e he age 00 o 0F . he cos

    o ho ol syses s c os eal hghe ha ha o

    sea ae o he la so sys e Fo he

    ho ol syse s ec ess ay o have a seaae heae ,

    ho lg a ae e sevos a s . Heve , o he

    avaages o hghe eeae asece o ae (

    soe a lcaos ho ol s se .A h ye o ly hch s oe se o

    heag ocess seas o hgh eeaes s he ec

    e heae. I eole eg he heae s calle

    a e o es ll heae os heaes ae l h

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    he ocess sea le es emeae s cease

    o a xe le emeae o oose eecs ae

    lace a salle heae ll e ee ecase less

    hea s e ee , he le as es leave a a hhe

    eeae h oe hea los he as . s , hee

    1

    s a ecooc ae o he eece sac as a

    oces s sea eeae he ae l l vay o cos e ,

    ee o hea a el coss A ossle movee

    h e o ees heaes s o ha oe l coole col l hoh he covecve seco hle aohe

    l hoe loe he aa seco.

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    scsses he ee cool syses a soe o he

    eas os o choos eee he .

    heoyacally hea ss ae he o ae o

    hea soces . he vale ee s o he ay o

    eey he s ca ac ce he l oes eeae a hch

    eey ca e accee a he chae s eeae

    as ac ces eey . oeve shol e oe ha

    h vay s a soce sea eeaes he o

    le o ae o acco o he cos o eey as

    ee a a ve hea exchae a eo s vey

    cl.

    I ece yeas a cool has cease avo

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    23

    ass o ecc lae hoh coo l es . Booe scsses soe o he ecoocs volve he s

    o a cospo o ly ae lae pocess

    plas . He caes ha ly ae ca cosly a

    ha ae cosevao s poa oh he es

    a opeao o plas .

    Ocehoh cool ae s o se as ch as

    oce as ecase o le soces . e a avaae

    o ocehoh cool ae s s l epeae he

    copae o close cycle cool ae hch ca eve e

    coo le ha he e l a epeae . Paccally

    ecclae cool ae s avalale eee 80 a

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    wa o a cool a h cos cass aply as h

    s pau s low Bcaus o hs ga

    cool s us oly wh cssay a h a a pa

    u ll us l ha ha u o h pocss

    sa Ds a opao o h sys o po

    ga cool usually cs uch ao

    caus o h coss ol

    D cocos

    cocos s h oa m us o goup

    h ls ha coy h pocs s sas houh a ha

    xchag wo c lu hs oup a pp

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    5

    a o aly copa Gally , ppg a o

    coss wll g o wos olg o a

    cags us a s appoao mg o la

    coco coss o um o a cags

    ly , s s a oug sao u s oa

    o cos sos sgca c coss

    as soca a cag os .

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    HAPTER III

    ANAYSIS OF STREAM SYSTEMS

    The purpse f ths chpter s t pvde n dey

    fmewrk tht cn be used t vew nd pce n pespectve

    the vbe s s s ted wth ne twks f het exchne

    In ths context vbe i s bod def ned to en nt

    n ths e quntt es tht v contnuus but s

    thse which chne fom ne dscete stte to nothe

    Identfctin nd chcteztion of vbe intec

    t ins desc be the ste sste es ibe so ution spce

    Once bounds hve been est bi sed n the s utn spce

    netk desns cn be effcient ppsed nd ccutey

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    7

    spciid according to tpratur ll an possilyaxiu aounts aai lal or th syst rtr ic tions

    ar coplt .

    Onc a coplt st o syst rstrictions has n

    g in a str a sys t can di nd . Th str a syst

    is th coination o th gin procss stras plus th

    chosn aounts o th aail al uti l it is . Thrmoynam

    ic a ly th syst rs tr i ctions din a low syst y

    spciying liitations iposd at th systsurroundings

    oundary. aditional undrstoo spciication is that

    thr is no hat low twn syst an surrounings x

    cpt that coupld with sra low . That i s hat is onl y

    xchangd at spci i hat xchangr s . Actually any

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    SouceStream

    S n Stream

    ef ge ran t oo ng Wa te r

    Process

    Hot 0 St eam

    F g ue A Ne twos fo a S n ge P roce ssSteam ype A Steam System

    Pocess Process

    P

    2 8

    A

    F e dFunace

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    D E

    A

    U t t y

    F gu e A Po b e Netwo fo One Souce and

    Sevea S i n Poce Steam One S n and SeveaSouce Poce Steam ype Steam Sytem

    D E

    2 9

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    3

    sour or sink procss stram A utility is usd to cool

    or hat th str am i a pro css uti li xchagr . Thr

    is no choic as to h xchangr ha load ut slction

    o th typ o utility can ad As discussd i

    Chapr ach typ o utility usually xcls or a

    crtai tmpratur rang Howr this rang dpds

    sowhat o currnt uility and xchangr costs ad will

    ary ro plat to plan as wll as wih tim Prhas

    th most ailiar xamp o Typ A stra syst optimiza

    t ion is th choic tw air or ar coolr s

    Stra s Tp B cosits o two rocss stras

    o sourc stram a on sik stram plus chosn utili

    t i s ) Th hat xchag works or syst Typ B

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    3 1

    hper IV.

    Sr e s s t e pe n be ons der bl ore o

    pied hn pes or B pe onssts o onesour e , se ve r s nk sr e s , nd t l i es or one s nk ,

    se ver l sor e s r e s , nd u i e s . eworks o pe

    sstes re r s he he exhne trn n rude

    ds ti ll ton unts or s lqueon pl nts . Re t ve l

    i e l i er ur e i s v bl e on the s nhes s nd opt

    z on o pe nework s . Pe (14 ) for expe , pr e

    sents so e q t i ve r ue s o be us ed i n the des n o

    oolers whe Wesbrook (17 ) llus tr es the use o

    dni pro r n o op ze i ven n etwork . he best

    ppr o h ppe rs t o b e ht o Wh is tler (1) He uses

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    3

    three trem ytem The next two ection o thi

    chpter be their dicuion o networ bounds on the

    thre e str em exmple preented in Tble ote tht the

    het lod of the two our ce s tre m A nd B) i eual i n

    mgnitude to the het lod of the in tem (C) or the

    exmpl e The term inl tepertur e given in Tble

    de ine our exmple ce The igni i cnce o these

    our ces nd the terminl tempertures given i di

    cued l ter in thi chpter

    B Syte Feii lit

    The irst uetion tht should be nswered or

    i t t i h th t it i ibl t

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    3 3

    TBE

    DT O M ED THEE TEM EXME

    Capac i t ate Heat oadteam C BTUH)

    Q

    MM BTUH)

    70 , 000 7 . 00B 48,000 - 9 . 60

    5 5 3 3 3 1 6 6 0

    UC 0 0 BTUHt2 UBC

    1 0 0 UHrt2

    Termina Temperatre )

    Cae 1 Cae 2 Cae 3 Cae 4tream n O t n O t n O t n O t

    650 550 600 500 500 400 500 400 B 550 350 550 350 550 350 550 350

    4 1 4 4 5

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    TBLE

    E B L TY TBLE OR TREE TREM EXMLE CE 2 W T

    9 = 20

    mn

    Rane#

    1

    2

    3

    4

    5

    oce team in teamTemp ame

    ( OF )

    600550

    5 50 - 500B

    500450 B

    450350 B

    350 1 50

    Q Temp ame Q QMM BTU) (0F ) MM BTH) Rane

    3 5 0 5 30-5 80

    3 5 0480-530 5 90 2 4 0

    2 4 0 430480 2 4 0

    4 8 0 330430 5 5 3 073

    1 30330 1 1 0 7 1 1 0 7

    Q Tota 0 0

    Raneea i b i i t

    0

    0

    0

    0

    0

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    3 5

    ne f the tre in the rnge i l given A bln

    indicte there re n trem in the given range Given

    next t ech tre ne i the enthlpy chnge ( ) fr

    the tre r the given teperture rnge.

    Feibility tble re cntructed by tarting with

    the highet teperture tre in the yte nd prgre

    ing dwnwrd in teper tur e leve l A new r nge i tart ed

    e ch tie tre (ur ce r ink) i encuntered . A

    new r nge i l tr ted whenever the ter in l teper

    ture f tre i reched. Figure give a pictrial

    view f the f ive teper tur e r ange r Ce

    The ttl het ld fr ech teperture rnge i

    diplyed under the heding Q Rnge in the feibility

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    36

    feaibi l ity colun i all e ro a in Table II then i t

    i feaible to contruct a networ in which echanger

    have at leat a F in iu tper ature of approach

    On the other hand the range feaibilit column i

    not alway all ero Table III contructed for Cae 4

    of the Three Strea Eaple ha a te range feaibilit

    column which annot be ade all ero Thi occur in

    pite of the fact that the eaple i in overall heat

    balance at the tabl e how i that in the fir t teper

    ature r ange ther e i ore in capacit than can be ued

    Liewie in the econd teperature range there i more

    ource capacity than an be ued b an of the lower te

    per atur e r ange Thu i t i impoibl e to contruct a

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    3 7

    AB L E

    FEAS B L Y ABLE FOR HREE SREAM EXAMPLE CASE 4 W H a . Fm n

    Soue Steams S i n St eamsRange ems Name Q emps Name Q Q Range# ( F (MM BU/H ( F } MM BU/H} Range Fe as i b i i ty

    B 4 480 - 530 2 . 77 . 7 . 7

    4A 7 . 848 . 6 7 -0 . 37B 4 .8

    400- 350 B .4 330- 380 . 77 . 7

    4 . 5 . 53 Q o t a l .

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    38

    tepe tue of ppoch The nbe o nges in e s i -

    bi li t tble i s of no pt icul s igni ine , eet to

    indicte the nbe of difeent te teinl tee

    tues The eltionship ong iniu tepetues o

    ppoch util it eui eents nd netwo costs is

    discus sed in Sect ion D of thi chpte

    The bove pocedue o deteining the esibilit

    of constucting netwo fo given ste sste is

    ppl ic le to sste with n ube of tes The

    ethod cn be esily coded fo use on digitl coute

    nd eecute uicl. ppendi D contins ORRN IV

    pog n eple of fesibilit nd iniu utilit

    te clcultion

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    nd hve the me overll het trner coeicient with

    repect to iven in trem their potentil het lux

    will be the me In uch ce the tre re id to

    be in " temper tur e contention ht i ei ther one o

    the could eliver het to the in t the me cot in

    ter o het exchne re I i t exit thi teper

    ture contention will hold over ome rne Fiure how

    tht there i no temperture contention or Ce o the

    hre e S tr em Exmpl e However or Ce the contention

    exit over bro d r ne hon in Fiure Ce

    lo h r ne o teperture contention ( to F

    networ will hve the minium totl het trner

    re i ech dierentil element o het or ll tre

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    7

    4 8

    nthapy (MM UHr

    F i g u r e ac o emperature ontention n h ree S t rea m E xamp e a e

    0

    '

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    4

    he pr ere s sr e h sr e s eq eper

    re e e s r s fer he w h he sme he x m

    per pr gr s hes ze s h ewr s b r f r

    s ge pped x D . Expe r e b es r

    pex s r e s s es r e s g e .

    Fr s sses he re ewrk be

    be e s e Tbe V ges he

    r e ewr f r sr e s se wh h es he

    eper re e . Tbes VI d VI I g e he

    re ewr k f r w s s ems wh er e

    s f epe r r e e .

    Lke he fes b be e r e be

    s mpse f eper re r ges e s r e

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    ABLE V 2

    MIN IMM AREA ABLE FOR HREE STREAM EXAMPLE CASE 1

    Source S rea S k S rea Exchager Ca cu a oRage ep Nae Q ep Nae Q 1 Area#

    2

    Rage#

    2

    ( F ) ( F )

    650550 A - 7 0 304430

    550350 B -9 . 6 3 0 3 0 4

    7 . 0

    9 6

    A B L E V

    { F ) ( F ) ( F ) ( F 2 )

    00 220 247 233 300

    0 0 2 4 7 2 2 0 2 3 3 4 1 2

    E = 2 , = 22 0 A = 7 1 2

    M N IMM AREA ABLE FOR HREE SREAM EXAMPLE CASE 2

    Source S rea S k Srea Exchager Ca cu a o

    ep Nae Q ep Nae Q 2 A Area F ) ( F ) ( F ) F ) { F ) (F2 )600550 A - 3 . 5 367430 3 . 5 1 0 0 7 0 1 83 1 7 7 1 9 8

    550500 A - 3 . 5 260367 5 . 9 1 0 0 83 2 40 2 0 2 8 B 2 4

    7 2 3 1 3 .

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    4

    terinted so tht the het lost b the source stres

    ust euls tht gi ned b the s in str es us the

    rnge is in het blnce nd the vle of cn be deter

    ine d ddit ionl r nges re fored unti l ll the stres

    in the sste hve been included The finl rnge should

    end with the lowest source stre outlet teperture nd

    the lowest sin stre input teperture If overll het

    trn sfer coeff ic ient vlues ( ' s re nown for e ch

    str e cob intion n r e vlue cn be deterined fore ch r nge The su of these re vlues is then the

    inium totl het exchnge re for the given stre

    sste

    Notice tht the miniu teperture of pproch for

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    4 4

    ytem i n whi ch var iou tre am cobination have d i eren t

    ove al l hea t trane coe i c ient For uch a c ase the

    var iou trea may be in trea contention . t e

    contention exit when the product U euals ue AC Table VIII give an example o a thee team system

    in which two in tr eams are in tempe atu e contention

    Figure 5 show that the contention exit ove the whole

    tempeature range o both tre However the over all

    heat tanser coeicient are dieent or the two

    te am Thu tre am contention alo exi st There or e

    to calculate a tr ue minimu are a netwo anges in the

    minium area table mut be determined on the bai o

    potential heat lux T able I X hows the con

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    Srea

    A

    B

    400

    ABLE V I I I

    DAA FOR SREAM CONENION EXAMPLECapac y RaeC ( B/HrF )

    20 000

    1 55 0

    4 4 5 0

    eperaure ( )I Ou

    400 .

    259

    259

    320

    320.

    320

    He aQ (M B/H)

    5 86 . 0

    7 0 4 6

    8 8 4

    4

    AB E X

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    Rage

    l

    2

    3

    M IN IMM AREA ABE CON DR NG RAM CONEN ON

    ource rea k rea E ch ager Ca lcu la o ep Nae Q ep Nae Q [ue ] 1 [ U a ] 2 2 Area

    400-382 A - 3 5 6 289-320 B 3 5 6 79 30 . 9240 1 0 0 7 9 3 9 2 4 8 5 6 4 1 6

    382- 3 39 - 8 4 3 259-289 B 349 9240 8030 1 0 0 9 2 4 8 0 3 86 . 3 4 0 4286-320 . 494 1 50 6 1 5 5 3 . 6 5 7 . 5 5 7 . 3

    339-320 A - 3 8 7 259-286 3 8 7 8030 9 1 50 . 1 5 0 5 3 6 6 1 0 5 7 3 4 5 0 E = 4 , = 5 3 6 , A = 1 84 3

    32 0 F

    A400 O F

    :

    .

    320 O F

    259 F

    I

    A

    2 89 F 2 5 9 FB

    F i gu re 6 M i u Area Nework Co i der g Srea Coe o

    E #

    1

    23

    4

    4

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    4

    TAE X

    M N MUM AREA TALE ONS DER N ONY TEMPERATURE ONTENT ON

    Source StreamsRange Temps Name Q# O F

    S in StreamsTemp s Name Q{OF

    A

    7

    8 8

    E x c a n g e a l c l a t o n s 91 9? Area

    F

    F

    ) { F ) ( F t

    8

    6 ]

    8

    E+

    = ,+

    6 8e = A = 1 m n

    4 8

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    4 8

    strea cotetio is oe which ust be ore thoroughly

    ives tigate be fore it ca be cos iere to be neglig ible .

    D . Mi ium eper at ur e of pproach

    he theral r ivi g for ce or teper ature i ffer ence 9 ) wi ll vary fr o oe e of a exchager to the other ,

    uless the source a sik streas have ietical capacity

    rates. he iiu teper atur e o f appro ach 9i > for

    a exchager is the smalest value of 9 for that exchager his value will usually occur at one of the es of the

    exchager However , for soe ser vices the r ivig for ce

    may be sa le st at a poi t i ter al to the exchager

    9

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    the pertinent ot i required. The cot o dditionl

    9

    exhnger re ut be blnced gint the vlue o the

    increed heting nd ooling tht would te plce. Thi

    type o nlyi h been conduted by itler 8 ) nd

    other. The nlyi depend on the reltive cot o

    heting ool ing n d exhnger re but the eonomic

    inimu teperture o pproch i lot lw le thn

    2 F nd ore probbly 1 F onidering the high cot o

    utilitie in tody plnt.

    ctul ly te eonoi minimu temperture o p

    proch i not ontnt but depend on the teperture

    level t whih het being trnered. For re r iger

    tion yte the eonomic inimu teperture o pproh

    50

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    50

    Ths calclatin f several feasibility tables

    with varing min va es make it ps s ib le to e terine the

    effec t f min imm temper atre f apprac n t i l i ty r e

    qir ements fr any s tre am s ste . he r ange of intere s t

    fr 9 vales i s fr 0 t perhaps 5 0 p. I f the str eammn

    sstem is nt feasible at very lw in vale s then ti i

    ties wi certain be neee in a netwrk. On he oter

    han if the str eam s stem is fe as ible for a la rge in im

    teperatre f apprach (greater than 5 0 ) aitiona

    tiities are nt necessary.

    btain a mre qantitative view of these inter

    actins min im netwrk area an be cal cla te fr a

    r ange f til ity strea r ates . plt f minim newrk

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    steam system is deined as:

    E M + N - -2)

    whee M is the nme o soce steams and N te nme

    o si nks netwok s ing ony the as i-minimm ne

    o echanges can e constcted o any steam system

    that is easie see Section B ) Sch a netwok may e

    ie si tting st eams ; howeve at each ecange in

    the netwok one o the sys tem ste ams mst eac its ot

    et teme ate discssion o te easiiity o net

    woks containing ony ecanges is given in endi mati oat can e sed to visaize netwoks

    with di e ent ne s o eat echanges The ee senta

    5 2

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    5 2T A B L E X I

    HE NMBER OF HEA EXCHANERS I NV A R I O U S NTWORKS FOR A SEVEN STREAM SSEM

    SourcesA B D S i n Q

    y : 3 . 3 3 oopt

    S i n s F102 . 6 3 1 0 0

    G 7 60 6 7 Source Q 30 40 70 . 60 200

    A . Seven Exchangers W i l Resu t i n a Heat Load Loop

    SourcesA B D S i n Q

    .

    30 3 3 3 S n s F 3 7 6 3 0 0

    5 3

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    5 3

    detemined and i t is not poss ible to ay an o the ex

    hange heat loads without upsetting the system heat

    balane . Howee othe s ix exhange netwoks an be

    onstuted o the gien steam system o most steam

    sys tems the bes t o these pos s ible netwoks annot be

    ound by diet seah sine thee ae too many possibi

    li ties to enume ate .

    I oe than the quas i minimum numbe o exhange s

    ae used Pa t o Tabl e XI a heat load loop will

    eis t in the netwoks . The sign iiane o the loop is

    that the exhange heat loads in the loop ay be alteed

    without di stub ing the oea ll netwok he at balane . o

    netwok s wi th head load loops opt iiz at ion o exhange

    5

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    5

    costa its The temeate eves o the ste ams i

    vove mst be checke beoe oe ca say i it is ossibe

    to costct etwok C .

    I o iea eeec ie s exis t betwee te soce

    a s ik steam sbsets it is io ss ib e to costct

    a etwok with ewe ta the asi-miimm e o

    heat exchage s S ice sch sbset eaity i s iey

    o most ea s team systes E ay be geeay vieedas the acta miim me o exchages

    * .

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    5

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    for network desin is presened.

    . nthes i z in etwork Ds ins

    he on de sr iption of the enthap di agr m or mor e

    expiit the temperatureenthap diaram in the lira

    ture appears at the end of an artie b ister 8 ) .

    He indiates hat it is used b a nuber of eniners but

    is not unier sa l epoed . Essential the dira in

    ols pottin the streams to be inuded in a ntwor on

    a epr atur e s enthap sa l . Th i s was don for the

    exmpl es in Chapter I I I .

    With the streams portrad in suh a fashion it is

    re at ie ea s to snthes iz e ood networks . ine the

    5 7

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    stat with the highest temeae soce and sin steam

    te eciing how these shod e echange one ne

    cons ide s the owes t teme at e ste ams hen ac o

    the hi ghe temea e s again eventa y woing a d

    the mide temeate ste ams ctay sevea ne

    wos may aea to e good and it is then necessay to

    comae etaied cacations o each

    he steams isaye on the enhay diagam need

    not have constant heat caacity ved ines can e

    dawn and man iate j st as we a s st a ight ones .

    Sitting a steam into a nme o anches is somewhat

    awwa d on the enthay i agam owe caac ity ate

    steams have a steee soe an so otaying anches

    8700 r-

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    700

    500

    300

    1000

    Exchanger # 1

    8

    Enha l py (MM

    F i g u r e 8 E n h a l p y D i a g ra m S t h es i s A l t e r na te A .

    5 9

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    A

    A Ser e F l ow

    A

    A

    Ser e F l ow (A l erae)

    60

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    hapter or the more omplex sstems , some sk i l l i sinole in s ing the enthalp iagr an a s might be

    expete pr ati e impr oes one s fai l it with the tool

    B Optimizing etwork Designs

    One a network onf igur at ion has been sele te , the

    inter nal temper atur es an r ates ma be a j us te to optimize

    the requir e heat trans fer ar ea More aurate l , the

    temperatures an rates shoul be ajuste to optimize net

    work ost s i s uss e in hapter I I , ost shou l not

    onl inlue the effet of network area but some ontribu

    t ion epenent on the number o f heat exhanger s .

    he f ir st in i ation as t o whether the interna l

    TAB L E 6 1

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    Srea

    A

    D

    TAB L E DAA FOR HEAT LOAD LOOP EAMPE

    Capac y Re Teperare F ( BTU/HrF ) O

    1 4 , 45 0 1 40 3 2 0

    1 0 8 2 0 1 0 0 1 8 0

    1 6 7 2 2 3 2 0 200

    20 , 000 3 5 3 300

    A 1 u eq a 1 5 0 BTU/HrF2 F

    Heat oQ MM BTU/ r )

    2 60

    0 86

    -2 00

    1 46

    6 2

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    A network has been proposed for ths sst ue 11)

    and an optization of the nternal net tate

    s es ire d . Str ic tly speakn g e minu tt to

    area occurs when the temperature t 1 s at 23 r

    iure 2 shows soe ore detail concerning total tk

    are a . The slution sur face is rea lly qu ite flat fo a

    teperature of t1

    between 222 and the lmitn ta

    ture of 25 2 Oer this range, the total area s th

    2 of the mniu. Thus r athe tha chose th tepe a-

    tures such that total network area s a im t s

    bette to select t equal to 2 2. At th s alue ex

    changer s 1 , 2 an carr the entir e network heat load

    and exchanger 4 is not necessar.

    63

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    i to the es i o exche etwos 6 ) pe sets

    the ie o cobini ou esibe netwos into sie

    supe etwok . Thi s supe etwok is the optimi z

    iictes tht the upoitbe exches shou be

    e ii te o the i optii e supe etwo . Ho

    eve s ice Hw e tes etwok cost oy to e hi s

    "optiu esin ivoves o the thitee exches

    p e set in the o ii supe netwok The qus i iimu

    ube o exches o this ste syste is oy ive

    n so i t wou ppe tht soe o the exche s c ou

    be esiy eiite. Uotutey s ic iet t e

    ot pe set i the t ic e to check this hypothe s i s

    Aothe expe om the itetue tht iictes

    4

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    ranches which have the smaer teperature differences 6 Since the ranch rates are not in equal propotion to the

    heat oad this procedure is caed disproportionate

    stream spittin In Fiur e C the st ream s r anches

    have een optiiz e This is shown y the fact tht the

    outet tempertures of the two ranches are not equal

    c Overa Stratey

    he oa of a desin stratey s to present a pln

    of attac that wi produce an econoic dsin ithn the

    appicae time and re source constr aints To ad ths

    desin proces s increas in ider u se has een made o

    diita computers Coputers are not as yet ae to

    6 5

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    - lc ra y

    Dr Q a M Nbr of Ha Exchagr

    C a l c l a O p U l y Ra ad M prar of pproach

    ad o Crr Co

    yhz Nwork U gE h a l p D a g r a

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    f a fw agr The strateg s nteracve n the

    sense that the engneer ust ake the esgn ecsns

    athugh the cuter can avse h f the cnseuences

    f the ecsns.

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    CHAPTER V

    CAS STUDES IN HEAT EXCHANG NETWRK D

    Stues on tree fferent stream systems are

    pre sente n ti s capter Tese sys ems er e selec ted

    from to art cles n te i ter ature 1 17 and ar e n

    cude to lu strate a ide var ety of esn probles an

    so uti ons Most o f te ca lcul at ons for tese eampes

    ere done it te computer prorams iven n Appen D

    Representative roram output is iven for eac of te

    eample s n te appen di ltou te pror ams ar e soe

    at come tey eecute qu ickl y and not mor e tan

    fifteen mnutes computaton tie as equre to cacuate

    68

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    ProcessStrems

    2

    3

    4

    i i tyStrems

    Stem

    TAB L E X DATA FOR TYPE D SYSTEM O FOUR PROCESS STRS

    Ref 1 0)

    Cpc i ty Rte Tempertures F ) et o BTU/r ) Q {MM BTU/ r )

    1 4 , 4 50 1 40 3 20 2 60

    1 6 6 6 7 320 200 2 00

    1 1 ' 5 3 0 240 500 3 0 0

    20 , 000 480 2 8 0 -4 00

    Descr i t i on

    Sturted t 540 F tent het 6 5 6 6 BU/Lb

    69

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    Fiue 14 umie the ccutios o iiu utiit

    equi emet mi iu tot etwok e Tese c cu -

    tio outie the eibe soutio pce o the sstem.

    A ue o poit o the bou e iicte. ee-

    i to Fiu e 14 po it bove the cuve i i the

    eibe etwok spce whie it i ipoibe to costuct

    e ibe etwok whi ch wou ie beow the cuve

    ee et ive oe cot iue o het ex-

    che e o the utii tie . U i the i imu e

    cuve {Fiue 4 pu thei ccutio etho o te

    e pout 8 h ow time ecooic evu

    tio c be me o the optiu uti it tes . The opti

    mu ste te i bout 26 TU with suiciet

    Coo i g Ut i l i ty MM B U/ r 0 8 0 1 0 1 1 1 2

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    tworkAr

    F t2

    00

    Boo

    700

    600

    t

    I

    E = 1 3 9 =

    5 F m

    9 = 1 0 F m A E = 5 9 = 20 F m

    I

    , J

    _

    l

    X i h

    uu .

    . 2

    n

    Rate % a bove n mum U t t es )5 0 100

    7 1

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    7

    6

    Cost

    $/Yr)

    3

    Tota Cost

    5 0 100

    n mu m e two r Area and E 5

    7 2

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    data en n fea s be netwo space aps .

    n enta daa s pesented n Fue 1 fo

    te exape sot stud of te da w sues t a

    pos s b e neto no n f e excanes Fue 1 7

    sows ow te netwo was constucted on te aa

    Lee ' s constant of 2 0 F tepeatue of appoac was an

    taned so te snteszed netwo coud be copae to te

    one pes ented n s at ce e to ne two s ae pe

    sented n F ues 18 and 9 Lee s netwo eques a

    tota of 59 ft2 of eat excane aea we te one

    snteszed b te entap daa eques on 706 ft2

    s s an 8% poeent a n about 6 % aboe te n u

    ae a ese two netwos ae sown o n F ue 4 a s po n ts

    Steam emperatre Leve

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    500

    400

    emperature

    { O F )

    300

    200

    1000 2

    Range of Coo i ng-Wate r

    emperatre

    3 4 5

    Enthapy (MM BTU/Hr)

    F i gu re 1 6 En tha py D i agram for ype D Sysem Examp l e .

    7

    .

    w

    Steam

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    500

    400

    Temperature

    (OF )

    300

    200

    1000 1 2 3 5

    Enth al py (MM BTU/Hr)

    F i gu re 1 7 Network Synthes i s Us i ng Entha l py D i agram f Type D System Example.

    '

    L

    Stre S t rem 4 S tem7 5

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    Strem 3

    Strem 1

    C l n g Wter

    4 0 F

    1 80 F

    5 4 0 F

    F g re 8 Netwrk After Lee et l

    7 6

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    rcessStreams

    Ga s 1 i e

    Kers i e

    Gas 0 i 1

    Gas O i 1

    A s p h a l t

    C rde

    U t i l i t yStreams

    2

    T A B X V

    DAA OR YE C SYSM O S IX PROCSS STRAMSRef 1 )

    Capac i ty Rates emperatres oF Heat adC BTU/Hr ) I O t

    Q

    MM BTUHr )

    3 2 3 0 0 2. 1 0 0 . -5 6

    39 ,400 . 400. 1 0 0 . 1 1 . 8

    0 4 0 0 00. 1 2 0 . 2 .

    220 , 000 . 550 . 350 . 4 4 . 0

    2 2 0 0 1 0 . 1 1 . 8

    244 400 . 0 1 4 0 .

    7 7

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    akes t uh easer to suaze and reeber strea

    data

    Westbrook s art e deas wth the use o dyna

    progr ang to opt ze heat ehange network he network

    he hose to opt ze s gen n Fgure 2 Thee are

    seera ontradtons and errors n the tepeature d

    gen n the arte but the teperatures n Fgure 21

    appear to be those Westbrook ntended

    The arge nuber o derent heat od oops n

    the network akes or a op e opt z a on . esbr ook

    dd not nude any unt oss o ehngers and so a

    o the ehangers orgnay present are retaned n the

    network ater h s " optz aton " Atua y the network

    800

    Ut i l t y H eat Leve l

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    700

    Goo

    sooI

    Temperature( 0_ 400

    300

    200

    100 l

    00

    Ut i l t y H eat Leve l

    1 As ph a 1 t

    Crude

    Gaso I neI

    Gas O 1 I

    I

    Co o ng-Wat erTemperatur Range

    50 1 00 1 50 200 2 50 30 0

    ntha l py (MM BTU/Hr)

    F i gu re 20 Entha l py D iag ram for Type C Sysem Ex amp .-

    (

    G as l e Kerse Ga s 1 Gas 1 As p al t

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    C rude

    75 F

    C l gWater

    7 5 f

    G as l e

    2 7 5

    Kerse

    4

    Ga s 1

    5

    Gas 1

    55

    g r e 2 1 Nerk Afer Westbrk

    As p al t

    6 7 5

    r e drace

    6 5

    C oo g U y MM BTU / r )

    28

    a

    0 1 1

    i

    2

    q

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    eworkArea

    M 2 )

    2 4

    2

    1 6

    A E

    I

    f

    6 , = 25 m

    = 25 m

    M mu U 1 y: for ea Baace

    E r e Lo cu s

    E+= 3 + = 25' m

    C E = ,

    =

    m

    1 2 -0 8 52 56 60

    ea g U i y MM B TU r )

    i gu re 22 Feas b e ework Space of Type C Syse Exmp e

    i h i h

    8

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    cooi ps excher costs eterine the ont o

    ti it ies tht sho be se . Thi s wi l vry soewht

    ro pt to p t with t ie . However te oti

    tiities c be qicky ccte ro Fir once

    costs re estbishe.

    Westbrook s etwork ieti ie by on the igre

    ses re ot o ti it ies . This is ot necessry

    the ethpy ir c be se to constrct net

    work withot y coo i wter . Figre sows sc

    sythes i s . The cr e stre hs een s it ito or

    brces . Fire 2 pi ctr es te network syntes i zed . The

    retive sizes o the vrios cre stre brches were

    chose to ive exchers o roy eq tepertres o

    700

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    00

    500Tempe ra tu re

    F ) 400

    300

    200

    100

    00 2 5

    CrudeBrancB

    E 3

    Gas0 i 1I

    As

    c

    5 0 75 1 00

    En ha l py MM BTUHr)

    Furnace

    Tal rudeSrea r

    Suer

    Branc 0

    1 25 1 50

    F i g u re 23 erk S yn es i s W i C r u de S rea D v ded n ur B rances .

    G a so l i n e Gas 0 i 1 2

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    Branch A-

    75 F \ 1 1 2 6 F\.

    5 2 6 F

    5 5 0 F f r '

    Branch B

    75 F 35 6 f

    u

    7 5 1 2

    0

    u F

    r

    os

    i n

    ranch C

    75 f

    1 5

    o

    f

    s

    F

    4 4 8 f

    Gas O i 1

    Branch D

    75 F

    F igure 2 4 Network Synthes i zed Us i ng Entha l py D iagram .

    4 8 4

    6 5 0 F

    Ow

    Tpe D Sstem o S ix Pocess Stems

    84

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    Tpe D Sstem o S ix Pocess Stems

    The in exmpe in this chpte is anothe Tpe D

    sstem om the tic e b ee et T e X gies the

    stem inomtion This exmpe is consiea moe

    compex thn the ist one pesente temeate

    enap i g m Fige 2 5 shows the age mont o

    tempete contention pesent

    n n cs e the e sibe netwo sace cn e

    etemine n this gives n ieiate iea o the inte-

    e tionshis between eqie netwo e n ti itie s

    Fige 26 shows that stem is eqie on i it is e-

    s i e to s e moe thn the min imm mont o coo ing-wte

    Point D on the ige shows the minimm e netwo con-

    TABLE XV

    8 5

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    PrcessStreams

    3

    4

    5

    6

    t i l i t yStreams

    TABLE XV

    DATA FOR TYP D S Y S T M O F S I X PROCSS STRAMSRef ( 1 0 )

    Capac i ty Rate Temper at ures 0 F) Heat adC ( B T /H r F ) n O u t

    Q

    (MM TU/H r)

    1 6 , 0 0 0 0 0 . 4 3 0 . 5 . 8

    8 0 0 0 . 440. 5 0 - 8

    3 , 7 6 0 1 8 0 350 . 5 5 7

    3 8 0 0 . 5 0 300. -5 . 24

    6 3 5 0 00. 40 0 . 5 7

    3 3 6 0 0 . 390 5 0 . 8 0 6

    esc r i p t i o n

    500

    Steam emperature eve

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    400

    emperature( F )

    300

    200

    100

    0

    C i n g{WaterRange

    2 4 68 0 2

    n t h a p y MM B/Hr)

    F ig u r e 25 n t h a p y D ia g r a m f r S x P r c ess S t r ea m y e D S yst em x a m p e

    1 4

    2 . 5

    C oo l i n g U t i l i t y ( MM BTU / H r )

    6 . 0

    A E 6 a . = 4 0 F ' m n

    B

    E = 5 9 = 40 F" m n

    6 . 5 7 . 0 7 . 5

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    NetworkArea

    Ft2)

    2 . 3

    2 1

    1 . 9

    I C : E 7 a 20F1

    m n

    I

    5 3 MM BTU /Hr Coo l i n g .I M i n i mum U t i l i ty fo r He a t B a l an ce .

    _

    a+

    = 50 F-

    m nT .I

    II

    I

    I

    En

    t

    i

    r

    e Locus

    + + E = 29, 9 . 50 Fm n

    II

    1 7 .

    1 . 60 0 4 0 8 1 . 2

    He a t i ng U t i l i ty (M M BTU/Hr)

    2 . 0 2 4

    F i gu r e 26 Feas i b le e t w or k S pac e f or S i x P r oce s s S t r eam Type D System Example.0-

    88

    for crtain procss sras, and thn as utility rat is

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    for crtain procss sras, and thn as utility rat is

    incrased other procss sras ay aso b xand ih

    the utilitis.

    L ' s " optial ntork for th s tr ea syst on

    tains sevn xchanrs and is desinatd as point in th

    ntok space iure 2 7 pictures e ' s ntork. His

    ntork uses on ore than th quasiiniu nuer of x

    chanrs (E 3 + 4 - 1 6 It is possibl o construct a ntork usin only

    th quasiiniu nuber of exchanrs ith th aid of th

    tepraturnthalpy diara. Suh a ntork is prsntd

    in igur 28 and reprsntd as point on th fasibl

    nork spac . Hoevr , note that xchanr #3 is very

    89

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    Stream 1

    S t r e a m 2 Stream 4 S t r eam 6

    9

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    Stram

    Stram 6 Stram Stram 4

    and ea ansfe aea equeen ae caned on

    9

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    q

    s fo e newo n F ue 8

    Reducon of e ea excane equeen o fve

    usaes e need fo nvenvenes s on e pa o f e

    pocess desne S c spea n e n u nube

    of excanes s e quas n u nube fo s exae.

    No souce o s n sea subse s ae denc a equa

    Howeve n pac ce e n u nube of ecanes can

    be educe o fve and a newo consuced As o

    wee o no newo B s e econoc coce depends on

    coss assocaed w e nube of excanes n a

    ne wo

    9

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    S t e a m 3

    S t e am 5

    Steam

    8 0 F

    2 0 0 F

    0 0 F

    S t eam 2 S t eam 4

    2 2 4 F

    73 F

    4 40 F 5 2 0 F

    400F

    2 5 2 F

    4 3 0 o )

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    CHAPTE I

    HEAT EXCHANGE NEOS IN OPTIO

    Coiutio sythesis siig o the iiiu

    eemets is oy pt o the iomtio poces eig-

    e ees o compete het exche etwok esi He

    shou so he kowee o the opeti chcte-

    i st ic s o the etwok Thi s chpte ttept s to we

    soe o the y questios tht the esige ight he:

    1 ) s i t poss ibe o sm pocess chge to cuse

    sti c ches i etwok pe omce? ) Whi ch

    eemets o the etwok e most seitie to chge?

    ) D etwok s chcte ist ics hep o hie pt

    9

    V- )

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    V )

    Fr the def init in f ef fi cienc in Eaton -a ne

    a a wr ite :

    -)

    f the ave equatin are cined the eltng ex-

    pein fr uce and ink ide f th exchange ae

    t t - t > n u n u ce C e {tn rce in

    Cin/R ) { tut - tin> ink

    - t k )n n

    ine

    V-3)

    VI- )

    t e ) t + et V-7

    9 5

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    tut suce

    = e ) t n suce

    + et n snk V-7

    / tut snk eRtn suce

    + l eR ) t n snk V-8

    hee tepeatues tten as " epesent ffeencesfrom the design values , i . e . t = tactual - tdes ign

    nce nue ca l the capac t ate at R ) an

    ef f cenc e th ust aas e eteen an an

    changes ae n the net tepeatues f an exchange

    l appea nshe n tes f changes that ccu nte utlet tepe atue s

    Equatns V-7 an 8 can e e tten n the f:

    < t t Fkt

    + Gkt k V-9

    9 6

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    urce A

    n

    n D

    rce B

    4

    9 7

    s pstv and ust b lss than and so tpatu

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    changs n th nput to a ntwok cn on ppa as

    dnshd changs f th sa algbac sg on ntwok

    outt tp atus It shuld also b notd tt chang

    n ntwok outlt d v d b nlt chang s cos tnt

    Ths constant s cald th tpatu ss

    facto

    Tabl XVI lsts tpatu sst factos fo

    th ntwok shwn n Fgu 9 pag 7 5 ) . hs factos

    w coputd b subutn SENSIT n n Appnd D.

    To us th tabl on s pl f nds h colun of th s t a

    whos nt tpatu s vd and th ow of th ut

    lt ntd at tp atu ds d. T fact at

    AB XVI

    8

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    #

    # 2

    O u t l e t #3

    eperatueFactrs #4

    c w

    Stea

    MPRAUR SS I I V I FACF O R W O R K S H O W I F U 9

    Stea Whse I n l e t e p e a t u e I s#

    . 1 39

    0

    #2 #3 #4

    08

    409" 0 00

    2 3 8

    0 8 3 9 7 042

    8

    2 4 2

    c w .

    3 4

    0

    0

    V a iedSte

    0

    0

    "

    0

    32 7 0 0 . 473 0

    0 0 0 0 0 l

    9

    TABE XV I

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    EXAMP CALCULAT ON US I NG MPERAT R S E N S I T IV ITY FACTORS

    A

    S i m u l t i o nT C a l cu l a t ed F ro S en s i t i v i ty FactosStrea Due to 1 0 F0 Due to + 1 0 F0 Tot l C l . ",

    Tout

    C h n ge i n # 1 C h an ge i n #2 Chnge Both Chnges

    1 3 9 + 1 . 08 0 3 1 0 3

    2 -2 50 + 4 09 +1 . 59 + 1 5 9

    3 0 0 0 0

    4 3 . 0 6 + 2 3 8 - 0 6 8 - 0 6 8

    c w . - 2 0 0 +3 2 7 2 7 + 2 7

    .

    tl - 3. 79 + 6 2 1 +2 42 +2 42

    t2

    - 5 63 + 4 3 8 + 1 25 + 1 . 2 5

    100

    points in a network can be qickly ientiie by ooking

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    for the larges t factors in the table . It al o qickly

    seen where a change wil prouce no efect on a iven

    strea teperatre (zero sensitivity actor ) .

    B Steay-State Response to Capacity Rate Chane

    For a oble-pipe heat exchanger o fixe ein

    ef fic iency can be expre e in ters o stre a r ates

    Combining Equations II-10 an II-12a ives:

    e 1 . 0 - exp UA/Cmin - UA/Cax

    Ci n/Cax - exp UA/Cmin - UA/Cmax(VI-11)

    Ths ef iciency i a rather coplex nction o inivi ual

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    1

    (page 7 5 ) . erentage strea ate hange is l iste d at the

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    top o eah oln ah ro in the tl oesponds to

    an inte rnal or oe t str ea teperatr e hange . Note

    that ost of the teperatre hanges ae ol linear

    over the -1 % to +1 % r ate r ange . s ith tre

    sen si tiv ity the ost sens i tive par ts of a neto e

    deterined qiky by ooking for the largest ns in

    the tab e . Notie that the teperate sensitivit nd

    the r ate sens it iv ity of a netork ar e not th sa .

    Gener al ly , the netork otlet tepetr of a str ea i s

    ore sensitive to a hange in its o te ad less sensi

    tive to a hange in its inpt teperare than are the

    other streas in the netok

    103

    T A B L E X I X

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    EXAMPE CALCULAT ON US NG RAE SENS V I TY ABLE

    T C a l c u l a t e d F rom R a te S en s i t i v i t i e s S i m u l a t i o nStream Due to -5% Due to +5 otal C a l c . f C h a n g e i n # C h an g e i n #2 Change Both Change

    out

    3 . 5 3 0 7 3 6 8 3 . 6 8

    2 0 . 5 3 3 . 92 4 .45 4 4 5

    3 0 0 0 0

    4 3 4 0 . 3 8 3 9 3 8

    c w . 0 . 4 3 2 0 2 4 4 2 4 2

    1 0 8 2 69 3 . 5 0 3 . 4 7

    2 3 60 69 3 8 5 3 86

    04

    London dvot a captr to t sary of 8 transint

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    rspons probls that av appard in th litratr

    Th soltion to t probls ar prsntd in trs of

    dins ionl ss qanti ti s c lik tos sd in t x

    cangr r at ing ca lcl ation procdr . Coon to th so l

    ti on o f a ll o f ths probl ms i s t act tat th dynamic

    rspons o individal xcangrs to stp changs is

    ovrdpd i no osci llations occr .

    Addi tional ly t govrn ing dif fr ntial qations

    ar s aid to b l inar within t sa l idal izations

    Th s th tpr atr r spons to any pr trb atio ns otr

    tan a stp nction can b obtaind by linar dynic

    tcniqs Bcas ac indiv idal xcangr tnds to

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    REEREES

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    1 . Boas , A. H. , " Optza ton a Lnea and DnaPoan, " eal

    Engn n,

    7 0 , o . 4 8 5 - 8( 19 6 } .

    . Booe , M. , "ate , " hemalEngn n , 1 ' o 1,

    1 5 - 1 8 ( 19 7 0 .

    . an , L . T . , and S . an , The Ds ete aumP ncpl ,

    Jon Wle & Sons;n , ew Yo , 1964 .

    4 . G az z , L . , a nd R . P as e o P o e ss oo l n S s tes , "Hdocabon Poc ssng,

    49 , o 1 0 , 8-90 (197 .

    5 . Happel , J . , heal Poess Eonoms , John le &Sons , n , ew Yo , 195

    6. Hwa, s , " ppl aton of Math odels n . E Resea, Desn, and Poduton, A . . h . E . ns .h e . En s . , 4 Pape 4 1 , ondon eetn, 8 -8(June 1965

    0

    2 Mono L. S a Chal Engneen 7 7 No

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    2 334 (7 3 Nlson L . ol Refney Engneeng 4h

    on MGawH ll Boo Co Nw Yo

    4 ag M os l Cool ng Ts a NwAoah o as s Ds gn al

    Engneeng

    7 4 No 7 3 ( 67

    John alEngnees

    Hanboo 4h on MawHl l Boo o Nw Yo 63

    6 s M an K D Thas lanDes

    Eonos ChalEngnees

    MGawHll Booo Nw Yo 6 8

    7 sboo G T s T s Mho o S EahSag fo Bs a on Hyoaon oessn anol fn No 2 26 (6

    s l A M Ha Exhangs as Mon s

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    A P P E N D C E S

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    PPENDIX

    GOSSRY

    Single Ste Tems

    Steam Inteaction ems

    System and etwok erms

    0

    This lossary ontains the seial ters and

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    hr ases used in thi s di ssert ation . t as neessa ry to

    define these seialize ters sine there is at resent

    no seifi voabulary in the literature that an be used

    to desr ibe soe of the onets develoed The lo ss ar y

    is divided into three setions ith the ters in eah

    setion lsted alhabetially

    INGL TR TRM

    NTRNAL TRAM TMPRATUR - s tr ea teer at ure that

    our s it hin the heat exhane netork . This ould

    usually be at soe teerature beteen the terinal

    SPLIING A SRE - dv dn a ea n w o e

    1 1 1

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    banch tea a uated bew.

    B Note: t ouA

    1 n

    deter ned by anentha py ba lancearound te summer

    Fue A-1 . A Typca Tw-way Sea Sp .

    SPLITING THE H LO OF A SRE - exchann h ea

    b th th h

    112

    STREAM INTERIN TES

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    HEAT ECNGER ES IGN CALCULATIN - deten ng the a ea

    equed o a heat exhange so that the soue and

    snk steam tempeatues hange ove a speed

    ange The tempeatues ae onsstent wth an

    enthapy baane that gves the amount of heat to be

    tansfeed

    HEAT ECHNGER RATING CALCULATIN - detenng the st ea

    outet tempeatues and the aount o heat tansfeed

    n a heat exhange o a gven desgn a ea xed)

    w th known st eam ne t tempe atue s A onvenent

    det auaton atng method s the tansfe unt

    ff th d K d L d

    3

    str e rou gout the r e o f te conten ti on the

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    two source stres wl be ble to supl etg

    to the sink t the se cost ters of e.

    Contention cn lso est for two snk stres d

    sgle source o fo severl stres of ec tpe.

    TEMPERATURE COTENTON - the s pl fed cs e of st e

    conteton whee te effect of the overll et

    trsfer coeffcient U i s ot cos idered . To o

    oe souce streas re i teperture conteton

    wt ec oter if ty e vlble for het echge ove coo tepe tur e nt er vl Sink

    stres c lso be in tepeture coteton

    TEMPERATURE SENS TVIT ACTOR - fo het ecnge et

    114

    steas in the stea syste

    AT LOA LP t t i l th th t

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    AT LOA LP - a te se to es ie l oe pth that

    st exist in a heat exhange network i or a ixe

    strea syste the network are an e hange y

    alteing only intenal teperates an/or anh

    steam rates The loop st stat at one exhanger

    an retrn to that sae exhange y ollowing strea

    paths The loop my hange o oll owin g the path

    o one steam to that o anothe only at heat ex

    hangers In oth o the networks il ls tate elow

    a loop an e ae thogh exhange s 1 3 4 2 an

    ak to exhange 1 .

    115

    TA-OPTI REGION - that reion o the ea sible solu

    ti h i h b t t i ti

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    tion space , wh ich becau se o ata uncert ain ties

    an intanibles is as oo as the optium or esin

    purpose s . Any attempt to reine a esin beyon this

    near optial reion is not economically justiie

    because the mathematical oel use in the optiiza

    tion simply oes not escribe the real solution

    space (or system) any ore accurately .

    MINM AREA ETWORK - or a spec i ie s tre a sys te a

    network in which the total heat transer area (A*

    }

    is a inimum

    MINIM UTILITY STREAM SYSTEM - a s tr eam syste compose

    o a ien set o process streas plus the inimu

    6

    QUS MNIMUM BR OF HT XCHGRS st ic t def ined

    M + N Si ifi f E i th t it i th

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    as M + N 1 Sinificance of E is that it is theini nbe of heat echanes eqied to con

    stct a feasibe netwok fo soce and sink stea

    sets that ae inea indeendent That i s no

    soce stea sbset is identical eqa in anitde to an sink stea sbset Fo sch a sste

    thee st be a ini of M + N heat echanes

    STRM S TM the cob inat ion of the iven oces s

    steas and the chosen aonts of availabe tilitiesas iven b the sste estictions Stea sstes

    can be classified into fo basic tpes deendin on

    the nbe of soce and sink ocess steas

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    PPENDIX B

    N NNOTTED BIBIORPHY ONHET EXNE NERS

    Netok SnthesiNetok tiization

    118

    An extensve search o the engneerng lteratre

    ( nclu ng ASA publc aton s ) was concte Th s sea rch

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    ( nclu ng ASA publc aton s ) was concte . Th s sea rch

    showe that a relatvely sall nuer o artcles s-

    css e heat exchange networks . These artcles are lste

    be low n two grops

    ETWORK STHESIS

    1 Ke s le r M . G . an P o Parker "Optal etwors o Heat Exchange . Che Enq . Pr or Sypos iu Seres 5 o . 92 , 111-120 (199)

    General scusson o network synthessus ng a o e as s gnent al gor th Thetechnqe breaks each network strea ntounts o 1 M BU an operates on thesents One exaple s gven .

    2 L K F A H M F R "B h

    A r ia an er ror approa for r uur inga i ru ai ng waer em Ef fe of ooin g ower o i a o in ue ne expe

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    in g ower o i a o in ue . ne expeiurae e eniue

    5 Ru D F Te Snei of Syem De ign I Eeenary Deopoiion Teor A. I E .Journa No 2 { 68 ) .

    A aeaia approa o yneiing anework for a ipe re a em Te ing eeape given i rgy in erm ofgeneraize mo

    6 i ter A M "Hea Exanger a MoneMaker " Peroeu Refiner 2 No 8386 8 )

    Ti arie iue e eonomi forone proe -pr oe exanger However een of e arie rief menion eeperaure-enapy iagra an iuraei ue wi a Tpe C rea e

    120

    3 Hwa, c s , "Applcaton of Mth Mols n ChERsarch, Dsgn an Proucton A. I . Ch E .

    I n s Ch. Engrs 4 Ppr . 12 Lonon Mtng83 88 ( 196 )

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    I n s Ch. Engrs 4 Ppr . 12 Lonon Mtng ,83 -88 (Jun 196 )

    Gnral scusson of sparl lnarprogr mng Tchnqu s ppl to onlar ge (many xchangr ntwork Howr , n suffcnt ata prohts dtal nlyssof th rsults

    4 . J ns s n, s K , "Hat Exchngr Optmzton , "Chcal Engineering Proress, 6 No 9 6 6 ( 1 9 69 )

    Ths artcl scusss th optzatonof prs sur rop n a ha t xchangr Ex

    changr cost appars to e rltly nsnstv to pressur drop

    Rud, D F an c C Watson St r ateg ofProcss

    Engineering

    John Wley Sons , Inc Nw York , 19 68

    Wesbrk T , "Use Thi s th S iz eEach Sae fr Bes Opa tion ,

    Hydrcarbon

    Ptre Ri ner , 0 No. 92 0 1 2 0 6 1 9 6 1 )

    2 1

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    Prc ssing & Ptre Ri ner , 0 No. 9 2 0 1 -2 0 6 1 9 6 1 ) .Genera

    prrminsme eta i .he ext anddiffic

    discssin f he se dynamic exampes are presen inSeera incnsistencis beween

    ires akes he exampesinterpre

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    AEDIX

    SUORTIG REASOIG OR EASIB SOUTIOSACE BOUDIG AGORITS

    Mu Aea etosQuasu ube oHeat Exchaes

    1 2 3

    MINIMUM OK

    F t t t th t il h t

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    For a two strea sste the est possile heat

    excane "network" is a conter-crrent aranent as

    so in Fie C-1 .

    emp.

    E n h a y

    Fi e C-1 Conter -C ent Heat rans fe

    he avantae of sch a stea arraneent is that eac

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    25

    A

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    i n k n i n k O u t

    B

    Figr e C-4 i i Are a Newrk

    This arrageen is he ni area newrk fr he

    hree s reas

    m n

    26

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    Tm

    ntha y

    m nc

    Fire C-5 A Sream Syse hich eqiresea xchaers i Ser ies

    Fire 6 as shws a feasibe srea sysem

    weer i hi s cas e he w sr ce sr e ams chae erhe same emper are ee Aai he sr ce sr eam

    eria emperares are js 9mi abe he sik srea

    The y feasibe ewrk fr sch a sysem ies he

    1 2 7

    Anasis of the reqireent for feasiiit shows

    that a feaie tream te fa eteen these two

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    worst case . ence i t i s a wa poie to constr ct

    a feaie networ with the qasi-in ner of heat

    exchaner s .

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    ANDIX D

    AUTOTION OF HAT XHNGENTWORK AUATIONS

    9

    Thi s aeni is opose o a ser ies o taes .

    The TAN IV oter prors se or network cac

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    at os are ie . so se s o the ott or the

    three eames presete in Chater V are ice.

    The MAIN coter proram (Tae DI ) is an

    eecte r or am that contr o s the network ca c at ions .The cacatios ca be iie to three basc types

    ) Determ i etwork bos 2 esnin or sizn

    echaer s for networks an 3 Sati the effect of

    temeratre a/

    or r ate chanes o etworks . s te

    beow ar e the fctios o f each sbrot ie .

    SDATA - eas roe an str ea ata a per fors

    soe nit a ca c atos sch as

    3 0

    MIY - Ti s sbrtin clcats fasi bi iy

    ab fr a n stra sst an

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    mpr ar f appra c It n rmins

    ility rqirnt an if rqs

    AMIN

    i incls ncssary iliis in

    sra sysmTis sbrin caclas ini nwrk

    ara sin cnc f rar

    cnnin

    CONFIG as an sins sr sc if i nwrksf a xcanrs I cntrs

    r a in f nx fr sbr i ns

    ATH T calcain rr fr CONFIG s in

    SENS IT - Netwrk rte n temper tre senst t

    c ctns re sper ise by th sb t Lik COIG t th

    3

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    sbrtne Like COIG t r eq re s the

    se f TH S n DIVIDE

    NTC - Het echaner r tn r s m tn

    cactns are ne b ths sbrtne

    when t s ce b SENSIT

    Tb es D- I I thr h D-XIV e the sr ce prr ams fr

    ech f the be sbr tne s

    Tpc prram tpt fr three eampes s pre

    sente n Tabes D-X D-XVI a n D-XI I I The tpt s

    r e s e f-ep antr n shws the etent t wh ch

    netwrk ccatns he been tmte fr ths re

    lV

    h P; VRS !N 3, V E L D IE T H U Y 13t

    E MAI N PAM FUR C L T I O S IM EYRK fRUT fXCiNE THE OiM S N l T RQ CAUL OD ) ! A SPI F t IN Ht RAY "Lr' T PRuRA . $l( h H O P N H E : P u A HE!t. CU NC lMu"T T fLLW ABL W L IA DeJ M u : b T S

    PAGE 0

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    001

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    00 0

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    0 0

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    0 0 1 00

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    O O b0 0

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    0 0 w P N AM , J I O O ; f UR T H 1 0 , l L U Y A N D E A I T Y T A E FUR lA4/

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