Abstract
This paper presents a methodology to compute the location of heat exchangers in the chemical process plant based on a fixed-topology heat exchanger network. The location of the heat exchangers is computed by minimising the pipe length required to transport the heat-integrated streams from the supply process equipment to the target process equipment. The pipe length is estimated as the sum of the rectangular distances between the coordinates of the process equipment connected along the pipe, using a mixed-integer linear model, and provides a lower bound for the pipe length required by the exchanger network. Layout constraints can be added to the model, such as minimum distances between equipment and zones of the plant where heat exchangers are restricted to being placed. It is also possible to restrict heat exchangers to being near specific equipment, such as heat-integrated reboilers located beside their distillation columns. The proposed methodology is applied to a number of heat integrated processes, with varying degrees in number of streams and heat exchangers.
This is a preview of subscription content, log in via an institution to check access.
Similar content being viewed by others
References
Akbarnia M, Amidpour M, Shadaram A (2009) A new approach in pinch technology considering pi** costs in total cost targeting for heat exchanger network. Chem Eng Res Des 87(3):357–365. https://doi.org/10.1021/ie010343l
Aldridge GA, Verykios XE, Mutharasan R (1984) Recovery of ethanol from fermentation broths by catalytic conversion to gasoline. 2. Energy analysis. Ind Eng Chem Process Des Dev 23:733–737. https://doi.org/10.1021/i200027a018
Backhurst JR, Harker JH (1973) Process plant design. Butterworth-Heinemann, Oxford
Barker GB (2017) The engineer’s guide to plant layout and pi** design for the oil and gas industries. Gulf Professional Publishing, Oxford
Bausbacher E, Hunt R (1993) Process plant layout and pi** design. Prentice Hall PTR, Hoboken
Biegler LT, Grossmann IE, Westerberg AW (1997) Systematic methods for chemical process design. Prentice Hall PTR, Hoboken
Caputo AC, Pelagagge PM, Palumbo M, Salini P (2015) Safety-based process plant layout using genetic algorithm. J Loss Prev Process Ind 34:139–150. https://doi.org/10.1016/j.jlp.2015.01.021
Chew KH, Klemeš JJ, Alwi SRW, Manan ZA (2013) Industrial implementation issues of total site heat integration. Appl Therm Eng 61(1):17–25. https://doi.org/10.1016/j.applthermaleng.2013.03.014
Chew KH, Klemeš JJ, Alwi SRW, Manan ZA, Reverberi AP (2015) Total site heat integration considering pressure drops. Energies 8(2):1114–1137. https://doi.org/10.3390/en8021114
Craw S (2010) Manhattan distance. In: Sammut C, Webb GI (eds) Encyclopedia of machine learning. Springer, Berlin, pp 639–639
Dantzig GB (1997) Linear programming. Springer, Berlin
Ejeh JO, Liu S, Papageorgiou LG (2018) Optimal multi-floor process plant layout with production sections. Chem Eng Res Des 137:488–501. https://doi.org/10.1016/j.cherd.2018.07.018
Kemp IC, Lim JS (2020) Pinch analysis for energy and carbon footprint reduction: user guide to process integration for the efficient use of energy. Butterworth-Heinemann, Oxford
Lai YQ, Alwi SRW, Manan ZA (2019) Heat exchanger network retrofit considering physical distance, pressure drop and available equipment space. Chem Eng Trans 76:367–372. https://doi.org/10.3303/CET1976062
Meissner RE III (1996) Plant layout. Kirk–Othmer encyclopedia of chemical technology, vol 19, 4th edn. Wiley, Hoboken, pp 144–175
Moran S (2016) Process plant layout, 2nd edn. Butterworth-Heinemann, Oxford
Mukherjee S (2021) Process engineering and plant design: the complete industrial picture. CRC Press, Boca Raton
Nair SK, Guo Y, Mukherjee U, Karimi IA, Elkamel A (2016) Shared and practical approach to conserve utilities in eco-industrial parks. Comput Chem Eng 93:221–233. https://doi.org/10.1016/j.compchemeng.2016.05.003
Nair SK, Soon M, Karimi I (2018) Locating exchangers in an EIP-wide heat integration network. Comput Chem Eng 108:57–73. https://doi.org/10.1016/j.compchemeng.2017.08.004
Pavão LV, Costa CB, Ravagnani MA (2018) A new stage-wise superstructure for heat exchanger network synthesis considering substages, sub-splits and cross flows. Appl Therm Eng 143:719–735. https://doi.org/10.1016/j.applthermaleng.2018.07.075
Polley G, Shahi MP (1991) Interfacing heat exchanger network synthesis and detailed heat exchanger design. Trans IchemE 69:445–457
Pouransari N, Maréchal F (2014) Heat exchanger network design of largescale industrial site with layout inspired constraints. Comput Chem Eng 71:426–445. https://doi.org/10.1016/j.compchemeng.2014.09.012
Rathjens M, Fieg G (2018) Design of cost-optimal heat exchanger networks considering individual, match-dependent cost functions. Chem Eng Trans 70:601–606. https://doi.org/10.3303/CET187010
Rodera H, Bagajewicz MJ (2001) Multipurpose heat-exchanger networks for heat integration across plants. Ind Eng Chem Res 40(23):5585–5603. https://doi.org/10.1021/ie010343l
Roetzel W, Luo X, Chen D (2019) Design and operation of heat exchangers and their networks. Academic Press, New York
Serth R, Lestina T (2014) Process heat transfer: principles, applications and rules of thumb, 2nd edn. Academic Press, New York
Smith R (2005) Chemical process design and integration. Wiley, New York
Smith PR, Thomas JV (1987) Pi** and pipe support systems. McGraw Hill Book Co, Boston
Souza RD, Khanam S, Mohanty B (2016) Synthesis of heat exchanger network considering pressure drop and layout of equipment exchanging heat. Energy 101:484–495. https://doi.org/10.1016/j.energy.2016.02.040
Wang R, Zhao H, Wu Y, Wang Y, Feng X, Liu M (2018) An industrial facility layout design method considering energy saving based on surplus rectangle fill algorithm. Energy 158:1038–1051. https://doi.org/10.1016/j.energy.2018.06.105
Whitcraft DR, Verykios XE, Mutharasan R (1983) Recovery of ethanol from fermentation broths by catalytic conversion to gasoline. Ind Eng Chem Process Des Dev 22:452–457. https://doi.org/10.1021/i200022a019
Xu S, Wang Y, Feng X (2020) Plant layout optimization for chemical industry considering inner frame structure design. Sustainability. https://doi.org/10.3390/su12062476
Acknowledgements
Valter Bravim Jr. would like to thank the National Council for Scientific and Technological Development (CNPq) for the PhD scholarship (Process 140904/2019-0).
Author information
Authors and Affiliations
Contributions
VB: conceptualization, investigation, methodology, software, validation, writing—original draft, writing—review and editing. RZ: conceptualization, investigation, methodology, software, validation, supervision, writing—review and editing.
Corresponding author
Ethics declarations
Conflict of interest
On behalf of all authors, the corresponding author states that there is no Conflict of interest.
Additional information
Publisher's Note
Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.
Rights and permissions
Springer Nature or its licensor (e.g. a society or other partner) holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.
About this article
Cite this article
Bravim, V., Zemp, R.J. Design of heat exchanger network physical layout in process plants using a mixed-integer model. Braz. J. Chem. Eng. (2024). https://doi.org/10.1007/s43153-024-00462-y
Received:
Revised:
Accepted:
Published:
DOI: https://doi.org/10.1007/s43153-024-00462-y