Synthesis of Combined Heat and Mass Exchange Networks Via a Trust Region Filter Optimisation Algorithm Including Detailed Unit Designs

Abstract Mass and heat integration are important to achieving economically and environmentally sustainable processes through increased efficiency. Typically, heat and mass exchange networks are solved separately using process integration techniques such as pinch technology or formulating nonconvex mixed-integer nonlinear programming (MINLP) problems, which are challenging to solve. To simplify the MINLP, shortcut models are employed, which can result in under/overestimation of the real network, leading to suboptimal or infeasible designs. We introduce a new optimisation algorithm for combined heat and mass exchanger network synthesis (CHAMENS), including detailed design models. The method uses shortcut models in an MINLP to find network topology, followed by a nonlinear programming (NLP) suboptimisation. The NLP allows non-isothermal and non-isocompositional mixing, uses detailed unit models of packed columns based on orthogonal collocation on finite elements (OCFE), and detailed shell and tube heat exchanger designs. We incorporate a differential-algebraic equation (DAE) based shell and tube heat exchanger design model via surrogates in a trust region filter (TRF) framework, guaranteeing optimal solutions for the detailed exchanger models are found by the surrogate models. We demonstrate the proposed approach on a case study, showcasing its performance and the need to incorporate detailed unit models in topology optimisation to find practical optimal designs.