Performance monitoring of heat exchanger networks using excess thermal and hydraulic loads
Fouling in heat exchanger networks (HENs) affects thermal and hydraulic efficiencies resulting in economic penalties to the process industries. Conventionally, overall heat transfer rates of the heat exchangers in HENs are monitored to identify fouling. However, apart from fouling, these rates also...
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| Published in | Chemical engineering research & design Vol. 200; pp. 225 - 243 |
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| Main Authors | , , |
| Format | Journal Article |
| Language | English |
| Published |
Elsevier Ltd
01.12.2023
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| Subjects | |
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| Abstract | Fouling in heat exchanger networks (HENs) affects thermal and hydraulic efficiencies resulting in economic penalties to the process industries. Conventionally, overall heat transfer rates of the heat exchangers in HENs are monitored to identify fouling. However, apart from fouling, these rates also vary with inlet conditions. Hence, estimating the degree of fouling accurately based only on heat transfer rates can fail. Previously, we had proposed the use of excess thermal and hydraulic loads as the basis for monitoring fouling in standalone exchangers (Patil et al., 2022). These are quantified as thermal and hydraulic performance indicators that can be easily tracked through suitably constructed charts. In this paper, we extend the approach to HENs wherein deviations in temperature drop across a heat exchanger vis-à-vis the clean condition also depends upon upstream heat exchanger(s). The network performance monitoring charts rely on normalized performance indicators and temperatures across heat exchangers and also have explicitly denoted normal, alert, and alarm regions. The proposed charts are applicable to HENs with or without temperature controllers. Two case studies comprising multiple scenarios of flow rate and setpoint changes are studied. The results show that the method can effectively identify the degree of fouling.
•Fouling is a widespread problem in heat exchanger networks and results in various inefficiencies.•We previously proposed a strategy to estimate fouling in standalone exchangers without lab tests or sophisticated models.•Here, we extend it to networks and account for interactions between exchangers.•Changes in pressure drop and mass flowrate vis-à-vis the clean state are calculated while accounting for input changes.•It is suitable for industrial settings and can accommodate even control loops. |
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| AbstractList | Fouling in heat exchanger networks (HENs) affects thermal and hydraulic efficiencies resulting in economic penalties to the process industries. Conventionally, overall heat transfer rates of the heat exchangers in HENs are monitored to identify fouling. However, apart from fouling, these rates also vary with inlet conditions. Hence, estimating the degree of fouling accurately based only on heat transfer rates can fail. Previously, we had proposed the use of excess thermal and hydraulic loads as the basis for monitoring fouling in standalone exchangers (Patil et al., 2022). These are quantified as thermal and hydraulic performance indicators that can be easily tracked through suitably constructed charts. In this paper, we extend the approach to HENs wherein deviations in temperature drop across a heat exchanger vis-à-vis the clean condition also depends upon upstream heat exchanger(s). The network performance monitoring charts rely on normalized performance indicators and temperatures across heat exchangers and also have explicitly denoted normal, alert, and alarm regions. The proposed charts are applicable to HENs with or without temperature controllers. Two case studies comprising multiple scenarios of flow rate and setpoint changes are studied. The results show that the method can effectively identify the degree of fouling.
•Fouling is a widespread problem in heat exchanger networks and results in various inefficiencies.•We previously proposed a strategy to estimate fouling in standalone exchangers without lab tests or sophisticated models.•Here, we extend it to networks and account for interactions between exchangers.•Changes in pressure drop and mass flowrate vis-à-vis the clean state are calculated while accounting for input changes.•It is suitable for industrial settings and can accommodate even control loops. |
| Author | Patil, Parag Srinivasan, Rajagopalan Srinivasan, Babji |
| Author_xml | – sequence: 1 givenname: Parag orcidid: 0000-0002-1328-831X surname: Patil fullname: Patil, Parag organization: Department of Chemical Engineering, Indian Institute of Technology Gandhinagar, Gandhinagar 382355, India – sequence: 2 givenname: Babji surname: Srinivasan fullname: Srinivasan, Babji organization: Department of Applied Mechanics, Indian Institute of Technology Madras, Chennai 600036, India – sequence: 3 givenname: Rajagopalan orcidid: 0000-0002-8790-4349 surname: Srinivasan fullname: Srinivasan, Rajagopalan email: raj@iitm.ac.in organization: Department of Chemical Engineering, Indian Institute of Technology Madras, Chennai 600036, India |
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| Keywords | Excess hydraulic load Fouling Heat exchanger network Excess thermal load Monitoring |
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