Method of diagnosing the influence fouling on the heat recovery in a heat exchanger network

Marian Trafczyński

Abstract

The aim of the dissertation was to elaborate a method of diagnosing deposits influence on the heat recovery in a heat exchanger network. The method is based on mathematical models enabling the interpretation of industrial measurements of operating parameters (temperature, mass flow, chemical composition) of heat exchangers. The crucial assumption is that measurements of the mass flow and inlet and outlet temperature are available for each process stream, this making it possible to evaluate fouling-induced reduction in the recovered energy flow. The proposed approach allows for long-term monitoring of changes in the condition the heat exchanger network and for collecting data that are necessary for scheduling of cleaning interventions on the individual exchangers. The research hypothesis is concerned with the ability to efficiently diagnose the heat exchanger network operational state using the method for determining the losses of heat recovery. The scope of the work comprised: 1) concept of the method of diagnosing the influence of deposits on the heat recovery in the heat exchanger network of an industrial plant, 2) procedure of acquisition, processing and verification of the data base of measurements, 3) analytical model of a tube-and-shell heat exchanger featuring correction of heat transfer coefficients, 4) procedure of determination of the thermal resistance of deposits using the analytical heat-exchanger model, 5) example of diagnosis of deposits influence on the heat recovery in a real heat exchanger network, 6) verification of hypothesis based on the research process and the results obtained. The aim of the dissertation was achieved. Using the proposed method and an industrial data base acquired in a typical Crude Distillation Unit, the mathematical models were validated. This made it possible to work out the diagnosis of deposits influence on the heat recovery in a real heat exchanger network of a petrochemical plant. The developed research method can be used as a tool to assist plant Operator decisions aimed at reducing the losses of heat recovery in the heat exchanger network, and consequently - reducing energy consumption in the plant.
Diploma typeDoctor of Philosophy
Author Marian Trafczyński (FCEMP / IMEn)
Marian Trafczyński,,
- Institute of Mechanical Engineering
Title in EnglishMethod of diagnosing the influence fouling on the heat recovery in a heat exchanger network
Languagepl polski
Certifying UnitFaculty of Civil Engineering, Mechanics and Petrochemistry (FCEMP)
Disciplinemechanical engineering / (technology domain) / (technological sciences)
Defense Date13-12-2010
Supervisor Krzysztof Urbaniec (FCEMP / IMEn)
Krzysztof Urbaniec,,
- Institute of Mechanical Engineering

Internal reviewers Mieczysław Poniewski (FCEMP / IMEn)
Mieczysław Poniewski,,
- Institute of Mechanical Engineering
External reviewers Romuald Mosdorf
Romuald Mosdorf,,
-
Honoredyes
Pages116
Keywords in EnglishEnergy saving, Fouling identification, Heat exchanger fouling, Heat exchanger network, Heat recovery, Shell and tube heat exchanger
Abstract in EnglishThe aim of the dissertation was to elaborate a method of diagnosing deposits influence on the heat recovery in a heat exchanger network. The method is based on mathematical models enabling the interpretation of industrial measurements of operating parameters (temperature, mass flow, chemical composition) of heat exchangers. The crucial assumption is that measurements of the mass flow and inlet and outlet temperature are available for each process stream, this making it possible to evaluate fouling-induced reduction in the recovered energy flow. The proposed approach allows for long-term monitoring of changes in the condition the heat exchanger network and for collecting data that are necessary for scheduling of cleaning interventions on the individual exchangers. The research hypothesis is concerned with the ability to efficiently diagnose the heat exchanger network operational state using the method for determining the losses of heat recovery. The scope of the work comprised: 1) concept of the method of diagnosing the influence of deposits on the heat recovery in the heat exchanger network of an industrial plant, 2) procedure of acquisition, processing and verification of the data base of measurements, 3) analytical model of a tube-and-shell heat exchanger featuring correction of heat transfer coefficients, 4) procedure of determination of the thermal resistance of deposits using the analytical heat-exchanger model, 5) example of diagnosis of deposits influence on the heat recovery in a real heat exchanger network, 6) verification of hypothesis based on the research process and the results obtained. The aim of the dissertation was achieved. Using the proposed method and an industrial data base acquired in a typical Crude Distillation Unit, the mathematical models were validated. This made it possible to work out the diagnosis of deposits influence on the heat recovery in a real heat exchanger network of a petrochemical plant. The developed research method can be used as a tool to assist plant Operator decisions aimed at reducing the losses of heat recovery in the heat exchanger network, and consequently - reducing energy consumption in the plant.
Thesis file
PhD_Trafczyński_M.doc 587 KB

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