IDEAS home Printed from https://ideas.repec.org/a/gam/jeners/v13y2020i11p2847-d366831.html
   My bibliography  Save this article

Optimal Design of Welded Plate Heat Exchanger for Ammonia Synthesis Column: An Experimental Study with Mathematical Optimisation

Author

Listed:
  • Leonid Tovazhnyanskyy

    (Department of Integrated Technologies, Processes and Apparatuses, National Technical University “Kharkiv Polytechnic Institute”, Dep. ITPA, 2 Kyrpychova St., 61002 Kharkiv, Ukraine)

  • Jiří Jaromir Klemeš

    (Sustainable Process Integration Laboratory—SPIL, NETME Centre, Faculty of Mechanical Engineering, Brno University of Technology—VUT Brno, Technická 2896/2, 616 69 Brno, Czech Republic)

  • Petro Kapustenko

    (Department of Integrated Technologies, Processes and Apparatuses, National Technical University “Kharkiv Polytechnic Institute”, Dep. ITPA, 2 Kyrpychova St., 61002 Kharkiv, Ukraine
    AO Spivdruzhnist-T LLC, 2 Kaplunovskiy per., 19, 61002 Kharkiv, Ukraine)

  • Olga Arsenyeva

    (Department of Automatic Control and Computer Integrated Engineering, OM Beketov National University of Urban Economy in Kharkiv, 17 Marshal Bazhanov St., 61002 Kharkiv, Ukraine)

  • Olexandr Perevertaylenko

    (Department of Integrated Technologies, Processes and Apparatuses, National Technical University “Kharkiv Polytechnic Institute”, Dep. ITPA, 2 Kyrpychova St., 61002 Kharkiv, Ukraine)

  • Pavlo Arsenyev

    (AO Spivdruzhnist-T LLC, 2 Kaplunovskiy per., 19, 61002 Kharkiv, Ukraine)

Abstract

The production of ammonia, consuming up to 5% of natural gas global production, accounts for about 2% of world energy. Worldwide, the Haber–Bosch process is the mainly used method of ammonia catalytic synthesis, involving temperatures up to 600 °C and pressures up to 32 MPa. In this paper, the results of the development and study of the special welded construction of plate heat exchanger (WPHE) for a column of ammonia synthesis are presented. The heat transfer and hydraulic performance of developed WPHE are investigated on a one-pass model in laboratory conditions. An equation for the relation between heat transfer effectiveness and the number of heat transfer units is proposed. A mathematical model of multi-pass WPHE is developed using these results. The validity of this model is confirmed by results of industrial tests performed with the prototype WPHE installed in operating column of ammonia synthesis at temperatures about 500 °C and pressure about 32 MPa. The tests confirmed the reliability of WPHE and its efficiency compared to a tubular heat exchanger. A method of optimal design of WPHE that allows finding the optimal height of corrugations and the number of passes in WPHE for specified conditions of operation is developed.

Suggested Citation

  • Leonid Tovazhnyanskyy & Jiří Jaromir Klemeš & Petro Kapustenko & Olga Arsenyeva & Olexandr Perevertaylenko & Pavlo Arsenyev, 2020. "Optimal Design of Welded Plate Heat Exchanger for Ammonia Synthesis Column: An Experimental Study with Mathematical Optimisation," Energies, MDPI, vol. 13(11), pages 1-18, June.
    • Handle: RePEc:gam:jeners:v:13:y:2020:i:11:p:2847-:d:366831
    as

    Download full text from publisher

    File URL: https://www.mdpi.com/1996-1073/13/11/2847/pdf
    Download Restriction: no
    File URL: https://www.mdpi.com/1996-1073/13/11/2847/
    Download Restriction: no
    ---><---

    References listed on IDEAS

    as
    1. Zhang, Hanfei & Wang, Ligang & Van herle, Jan & Maréchal, François & Desideri, Umberto, 2020. "Techno-economic comparison of green ammonia production processes," Applied Energy, Elsevier, vol. 259(C).
    2. Klemeš, Jiří Jaromír & Wang, Qiu-Wang & Varbanov, Petar Sabev & Zeng, Min & Chin, Hon Huin & Lal, Nathan Sanjay & Li, Nian-Qi & Wang, Bohong & Wang, Xue-Chao & Walmsley, Timothy Gordon, 2020. "Heat transfer enhancement, intensification and optimisation in heat exchanger network retrofit and operation," Renewable and Sustainable Energy Reviews, Elsevier, vol. 120(C).
    3. Mangrulkar, Chidanand K. & Dhoble, Ashwinkumar S. & Chamoli, Sunil & Gupta, Ashutosh & Gawande, Vipin B., 2019. "Recent advancement in heat transfer and fluid flow characteristics in cross flow heat exchangers," Renewable and Sustainable Energy Reviews, Elsevier, vol. 113(C), pages 1-1.
    4. Flórez-Orrego, Daniel & de Oliveira Junior, Silvio, 2017. "Modeling and optimization of an industrial ammonia synthesis unit: An exergy approach," Energy, Elsevier, vol. 137(C), pages 234-250.
    5. Arsenyeva, O. & Kapustenko, P. & Tovazhnyanskyy, L. & Khavin, G., 2013. "The influence of plate corrugations geometry on plate heat exchanger performance in specified process conditions," Energy, Elsevier, vol. 57(C), pages 201-207.
    6. Penkuhn, Mathias & Tsatsaronis, George, 2017. "Comparison of different ammonia synthesis loop configurations with the aid of advanced exergy analysis," Energy, Elsevier, vol. 137(C), pages 854-864.
    7. Perevertaylenko, Olexander Yu. & Gariev, Andriy O. & Damartzis, Theodoros & Tovazhnyanskyy, Leonid L. & Kapustenko, Petro O. & Arsenyeva, Olga P., 2015. "Searches of cost effective ways for amine absorption unit design in CO2 post-combustion capture process," Energy, Elsevier, vol. 90(P1), pages 105-112.
    Full references (including those not matched with items on IDEAS)

    Citations

    Citations are extracted by the CitEc Project, subscribe to its RSS feed for this item.
    as


    Cited by:

    1. Picón-Núñez, Martín & Rumbo-Arias, Jamel E., 2021. "Improving thermal energy recovery systems using welded plate heat exchangers," Energy, Elsevier, vol. 235(C).
    2. Yee Van Fan & Zorka Novak Pintarič & Jiří Jaromír Klemeš, 2020. "Emerging Tools for Energy System Design Increasing Economic and Environmental Sustainability," Energies, MDPI, vol. 13(16), pages 1-25, August.
    3. Olga Arsenyeva & Leonid Tovazhnyanskyy & Petro Kapustenko & Jiří Jaromír Klemeš & Petar Sabev Varbanov, 2023. "Review of Developments in Plate Heat Exchanger Heat Transfer Enhancement for Single-Phase Applications in Process Industries," Energies, MDPI, vol. 16(13), pages 1-28, June.

    Most related items

    These are the items that most often cite the same works as this one and are cited by the same works as this one.
    1. Olga Arsenyeva & Leonid Tovazhnyanskyy & Petro Kapustenko & Jiří Jaromír Klemeš & Petar Sabev Varbanov, 2023. "Review of Developments in Plate Heat Exchanger Heat Transfer Enhancement for Single-Phase Applications in Process Industries," Energies, MDPI, vol. 16(13), pages 1-28, June.
    2. Arsenyeva, Olga & Klemeš, Jiří Jaromír & Kapustenko, Petro & Fedorenko, Olena & Kusakov, Sergiy & Kobylnik, Dmytro, 2021. "Plate heat exchanger design for the utilisation of waste heat from exhaust gases of drying process," Energy, Elsevier, vol. 233(C).
    3. Azeez mohammed Hussein, Hind & Zulkifli, Rozli & Faizal Bin Wan Mahmood, Wan Mohd & Ajeel, Raheem K., 2022. "Structure parameters and designs and their impact on performance of different heat exchangers: A review," Renewable and Sustainable Energy Reviews, Elsevier, vol. 154(C).
    4. Wang, Bohong & Arsenyeva, Olga & Zeng, Min & Klemeš, Jiří Jaromír & Varbanov, Petar Sabev, 2022. "An advanced Grid Diagram for heat exchanger network retrofit with detailed plate heat exchanger design," Energy, Elsevier, vol. 248(C).
    5. Hossein Ali Yousefi Rizi & Donghoon Shin, 2022. "Green Hydrogen Production Technologies from Ammonia Cracking," Energies, MDPI, vol. 15(21), pages 1-49, November.
    6. Mucci, Simone & Stumm, Marc-Daniel & Rix, Michael J. & Mitsos, Alexander, 2025. "Model-based evaluation of ammonia energy storage concepts at high technological readiness level," Applied Energy, Elsevier, vol. 377(PB).
    7. Liu, Chenglin & Zhao, Lei & Zhu, Shun & Shen, Yuefeng & Yu, Jianhua & Yang, Qingchun, 2023. "Advanced exergy analysis and optimization of a coal to ethylene glycol (CtEG) process," Energy, Elsevier, vol. 282(C).
    8. Zhong, Like & Yao, Erren & Zou, Hansen & Xi, Guang, 2022. "Thermodynamic and economic analysis of a directly solar-driven power-to-methane system by detailed distributed parameter method," Applied Energy, Elsevier, vol. 312(C).
    9. Halmschlager, Daniel & Beck, Anton & Knöttner, Sophie & Koller, Martin & Hofmann, René, 2022. "Combined optimization for retrofitting of heat recovery and thermal energy supply in industrial systems," Applied Energy, Elsevier, vol. 305(C).
    10. Kimon Keramidas & Silvana Mima & Adrien Bidaud, 2024. "Opportunities and roadblocks in the decarbonisation of the global steel sector: A demand and production modelling approach," Post-Print hal-04383385, HAL.
    11. Xiong, Kang & Hu, Weihao & Cao, Di & Li, Sichen & Zhang, Guozhou & Liu, Wen & Huang, Qi & Chen, Zhe, 2023. "Coordinated energy management strategy for multi-energy hub with thermo-electrochemical effect based power-to-ammonia: A multi-agent deep reinforcement learning enabled approach," Renewable Energy, Elsevier, vol. 214(C), pages 216-232.
    12. Jiang, Jianrong & Feng, Xiao, 2019. "Energy optimization of ammonia synthesis processes based on oxygen purity under different purification technologies," Energy, Elsevier, vol. 185(C), pages 819-828.
    13. Zhang, Hanfei & Wang, Ligang & Van herle, Jan & Maréchal, François & Desideri, Umberto, 2020. "Techno-economic evaluation of biomass-to-fuels with solid-oxide electrolyzer," Applied Energy, Elsevier, vol. 270(C).
    14. Lincoln, Benjamin James & Kong, Lana & Pineda, Alyssa Mae & Walmsley, Timothy Gordon, 2022. "Process integration and electrification for efficient milk evaporation systems," Energy, Elsevier, vol. 258(C).
    15. Realpe, Natalia & Lezcano, Gontzal & Kulkarni, Shekhar R. & Sayas, Salvador & Morlanes, Natalia & Rakib, Mohammad & Aldilaijan, Ragad & Solami, Bandar & Gascon, Jorge & Castaño, Pedro, 2024. "The technological prospects of repurposing methane steam reformers into ammonia crackers for decarbonized H2 production," Applied Energy, Elsevier, vol. 376(PB).
    16. Zhang, Hanfei & Wang, Ligang & Van herle, Jan & Maréchal, François & Desideri, Umberto, 2021. "Techno-economic comparison of 100% renewable urea production processes," Applied Energy, Elsevier, vol. 284(C).
    17. Xin, Yu & Xing, Xueli & Li, Xiang & Hong, Hui, 2024. "A biomass–solar hybrid gasification system by solar pyrolysis and PV– Solid oxide electrolysis cell for sustainable fuel production," Applied Energy, Elsevier, vol. 356(C).
    18. Caglayan, Hasan & Caliskan, Hakan, 2022. "Assessment of a cogeneration system for ceramic industry by using various exergy based economic approaches," Renewable and Sustainable Energy Reviews, Elsevier, vol. 167(C).
    19. Kapustenko, Petro & Klemeš, Jiří Jaromír & Arsenyeva, Olga & Tovazhnyanskyy, Leonid & Zorenko, Viktor, 2021. "Pressure drop in two phase flow of condensing air-steam mixture inside PHE channels formed by plates with corrugations of different geometries," Energy, Elsevier, vol. 228(C).
    20. Chin, Hon Huin & Wang, Bohong & Varbanov, Petar Sabev & Klemeš, Jiří Jaromír & Zeng, Min & Wang, Qiu-Wang, 2020. "Long-term investment and maintenance planning for heat exchanger network retrofit," Applied Energy, Elsevier, vol. 279(C).

    Corrections

    All material on this site has been provided by the respective publishers and authors. You can help correct errors and omissions. When requesting a correction, please mention this item's handle: RePEc:gam:jeners:v:13:y:2020:i:11:p:2847-:d:366831. See general information about how to correct material in RePEc.

    If you have authored this item and are not yet registered with RePEc, we encourage you to do it here. This allows to link your profile to this item. It also allows you to accept potential citations to this item that we are uncertain about.

    If CitEc recognized a bibliographic reference but did not link an item in RePEc to it, you can help with this form .

    If you know of missing items citing this one, you can help us creating those links by adding the relevant references in the same way as above, for each refering item. If you are a registered author of this item, you may also want to check the "citations" tab in your RePEc Author Service profile, as there may be some citations waiting for confirmation.

    For technical questions regarding this item, or to correct its authors, title, abstract, bibliographic or download information, contact: MDPI Indexing Manager (email available below). General contact details of provider: https://www.mdpi.com .

    Please note that corrections may take a couple of weeks to filter through the various RePEc services.

    IDEAS is a RePEc service. RePEc uses bibliographic data supplied by the respective publishers.