Margin design, online optimization, and control approach of a heat exchanger network with bypasses

During the life cycle operation of a heat exchanger network (HEN), factors such as equipment aging, gradually decrease heat transfer performance and increase energy consumption. Industrial HEN design currently fails to effectively solve these problems. To resolve this problem, we present an online optimization and control approach method for an HEN with bypasses. The approach is based on the principles of sustainable energy conservation during the life cycle. The area margin of the heat exchanger is gradually released via bypass adjustment, thereby resulting in energy conservation. First, bypasses are set on the HEN to enhance HEN control and enable optimal manipulation of the equipment. Then, the total cumulative cost increment of the HEN, including the increment of utility costs and equipment investment costs, is regarded as the objective function. The effects of the heat transfer efficiency of the heat exchanger and the effects of bypass adjustment are also taken into account. We solve the optimal design margin of the HEN, thereby providing an operational space for optimal control. Finally, using the margin optimization design of the HEN with bypasses as basis, we treat the cumulative costs of the HEN in a certain cycle as the objective function to solve the optimal opening dynamically. While, we present an optimal control structure, which is combined with existing conventional control loops. The HEN of a given crude distillation unit in a refinery is chosen as the research object. And, results illustrate the effectiveness and application prospects of the proposed method.

► The margin design is especially important for HENs that have longer operating cycles.
► Bypass adjustment can further improve operational efficiency and reduce HEN costs.
► Sustained energy saving of HENs is grounded in reasonable bypass and margin design.
► The area margin is gradually released via optimal bypasses during the life cycle.
► The regulatory controllers are used for the approach of optimal control.