2024 AIChE Annual Meeting

Redesigning Heat Exchanger for Enhanced Air Compression in a Global Industry Leader's Separation Process

Water scarcity is one of the most critical global issues facing our world today, significantly affecting various sectors, including industrial processes. This urgent challenge has widespread implications for economies, societies, and the environment. To effectively mitigate the economic impact of this situation and safeguard the company's reputation in an increasingly competitive market, it is crucial to implement meaningful and strategic modifications to existing equipment. In this context, a comprehensive redesign of the heat exchanger was sought for a leading company in the production and supply of industrial gases, with the aim of optimizing the air separation process, particularly in the critical area of air compression. Notably, this redesign was conducted under the assumption of using only oxygen, effectively treating nitrogen and argon as if they were not present in the mixture.

The analysis of the current heat exchanger was conducted using detailed operational statistical data and flow information provided by the training partner. This thorough examination included calculating key factors such as global coefficients, the allowed fouling factor, and local heat transfer coefficients. The design modifications focused primarily on improving these critical coefficients by optimizing overall thermal resistance, Reynolds number, fluid velocity, and pressure drop in both the tubes and the shell.

The implemented changes successfully achieved a remarkable 26% increase in oxygen mass flow, significantly enhancing overall heat transfer efficiency. This substantial increase will allow the company to store and transport more oxygen, resulting in greater profits and improved operational capabilities. During the redesign process, essential regulatory standards were carefully considered to ensure that the results remained within the ranges established by heuristic rules. Additionally, relevant norms from associations such as TEMA were thoroughly researched to identify the specific parameters that the new design needed to meet.

Furthermore, the design changes resulted in a 7.4% reduction in water mass flow, thereby fulfilling two of the three objectives set by the company. These advancements not only improve operational efficiency but also strategically position the company to tackle the pressing challenges of water supply in the industrial sector. Ultimately, this approach contributes to sustainable practices, economic growth, and a positive corporate image in a world that increasingly values environmental responsibility. By focusing solely on oxygen in the redesign, the company can further streamline its processes and enhance productivity in the air separation industry.