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Process Design and Optimization: University of Punjab Lahore

This document describes optimizing the recovery of waste heat from industrial processes. It presents a mathematical model for determining the optimal temperature difference between a heat source and working fluid in a power generation system. The objective function to minimize is the total annual cost, which is the sum of the operating cost and capital cost of the heat exchangers. Taking the derivative of the objective function and setting it equal to zero provides an equation that can be solved for the optimal working fluid temperature. The model shows that the optimal temperature difference increases with increasing heat source temperature, though this seems counterintuitive from a thermodynamic perspective.

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Abubakr Khan
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63 views

Process Design and Optimization: University of Punjab Lahore

This document describes optimizing the recovery of waste heat from industrial processes. It presents a mathematical model for determining the optimal temperature difference between a heat source and working fluid in a power generation system. The objective function to minimize is the total annual cost, which is the sum of the operating cost and capital cost of the heat exchangers. Taking the derivative of the objective function and setting it equal to zero provides an equation that can be solved for the optimal working fluid temperature. The model shows that the optimal temperature difference increases with increasing heat source temperature, though this seems counterintuitive from a thermodynamic perspective.

Uploaded by

Abubakr Khan
Copyright
© © All Rights Reserved
Available Formats
Download as DOCX, PDF, TXT or read online on Scribd
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Process design and

optimization
Assignment

Submitted by:
Abu-Bakr fareed

Roll No:
15-CHE_101

Submitted To:
Pro.Dr mahmood saleem

University of Punjab Lahore


OPTIMIZING RECOVERY OF WASTE HEAT

Process Description and Analysis

A variety of sources of heat at elevated temperatures exist in a typical chemical plant


that may be economically recoverable for production of power using steam or other
working fluids, such as Freon or light hydrocarbons. Figure is a schematic of such a
system. The system power output can be increased by using larger heat exchanger
surface areas for both the boiler and the condenser. However, there is a trade-off
between power recovery and capital cost of the exchangers. Jegede and Polley
(1992), Reppich and Zagermann (1995), Sama (1983), Swearingen and Ferguson
(1984), and Steinrneyer (1984) have proposed some simple rules based on analytical
optimization of the boiler AT In a power system, the availability expended by any
exchanger is equal to the net work that could have been accomplished by having each
stream exchange heat with the surroundings through a reversible heat engine or heat
pump. In the boiler in Figure heat is transferred at a rate Q (the boiler load) from the
average hot fluid
Developing Models for the Constraints

Mathematical models in Standard Format and Suitable


Optimization Strategy
Schematic of power system

Temperature T, to the working fluid at Tw The working fluid then exchanges heat with
the condenser at temperature T2 If we ignore mechanical friction and heat leaks, the
reversible work available from Q at temperature T, with the condensing (cold-side)
temperature at T2 is

T ❑s −T 2
W 1= Q (
Ts ) (a)
The reversible work available from the condenser using the working fluid temperature
TH (average value) and the heat sink temperature T2 is

T h−T 2
W 2 =Q ( Ts ) (b)

Hence the ideal power available from the boiler can be found by subtracting W2 from
W,

T2 T 2
W 1-W 2 =∆ W =Q
( −
TS Th ) (c)

In this expression T, and T2 are normally specified, and TH is the variable to be


adjusted. If Q is expressed in Btulh, and the operating cost is Cop, then the value of
the available power is

T2 T2
C op=C h ηyQ ( −
Th Ts ) (d)

Where η = overall system efficiency (0.7 is typical)

y = number of hours per year of operation

CH amalgamates the value of the power in $/kWh and the necessary conversion
factors to have a consistent set of units

You can see, using Equation (d) only, that C op is minimized by setting T h=T s = O?
(Infinitesimal boiler ∆T). However, this outcome increases the required boiler heat
transfer area to an infinite area, as can be noted from the calculation for the area
Q
A= (e)
U (T s−T H )

(In Equation (e) an average value for the heat transfer coefficient U is assumed,
ignoring the effect of pressure drop. U depends on the working fluid and the operating
temperature.) Let the cost per unit area of the exchanger be C A and the annualization
factor for capital investment be denoted byr. Then the annualized capital cost for the
boiler is

C A Qr
C C= (f)
U (T S−T H )

Objective Function
Finally, the objective function to be minimized with respect to T H the working fluid
temperature, is the sum of the operating cost and surface area costs:

T 2 T2 C A Qr
f =C H Qηy ( −
TS Th ) + U (T
S−T H )
(g)

To get an expression for the minimum off, we differentiate Equation (g) with respect to
T H and equate the derivative to zero to obtain

−T 2 C A Qr
C H Qηy
( )
T 2H
+ U (T
S−T H )
(h)
To solve the quadratic equation forT H , let

α 1=C H ηy T 2 U

α 2=C A r

Q cancels in both terms. On rearrangement, the resulting quadratic equation is

( α 1−α 2 ) T 2H −2 α 1 T H T S + α 1 T 2s =0 (I)

The solution to (I) for T H <T , is

α 1− √ α 1 α 2
T H =T S ( α 1−α 2 ) (j)

Solving Problem by Using Appropriate Computational tool

For a system with C, = $25/ft2, a power cost of $0.06/kWh (CH = 1.76 X 10 5)

U = 95 Btu/ (h) (° R) (ft2), y = 8760 hlyear, r = 0.365, η = 0.7, T2, = 600°R, and T S =
790°R, the optimal value T H is 760.7°R, giving a ∆T of 29.3°R. Swearingen and
Ferguson showed that Equation (h) can be expressed implicitly as

1
α1
∆ T =T S −T H =T H ( )
α2
2
(k)
Result and Discussion

In this form, it appears that the allowable ∆ T increases as the working fluid
temperature increases. This suggests that the optimum ∆ T for a heat source at 900°R
is lower than that for a heat source at 1 100° R. In fact, Equation (j) indicates that the
optimum ∆ T is directly proportional to T S Sama argues that this is somewhat
counterintuitive because the Carnot "value" of a high-temperature source implies using
a smaller ∆ T to reduce lost work. The working fluid must be selected based on the
heat source temperature, as discussed by Swearingen and Ferguson. See Sama for a
discussion of optimal temperature differences for refrigeration systems; use of
Equation (k) leads to ∆ T ' S ranging from 8 to 10° R

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