Enhanced Optimization of Heat Exchanger Systems Using the Branch and Cut Method: A Case Study in Industrial Thermodynamics

Abstract

Heat exchangers are vital components in various industrial processes, where their performance significantly impacts overall energy efficiency and operational costs. This study explores the application of the Branch and Cut optimization method to enhance the performance of a shell-and-tube heat exchanger system used in an industrial chemical processing plant. The optimization problem is formulated as a mixed-integer programming (MIP) model, incorporating both continuous and discrete variables to account for the non-linear and combinatorial nature of heat transfer processes. The Branch and Cut algorithm is applied to systematically ex- plore the solution space, using branching rules to handle discrete design decisions and cutting planes to refine the feasible region. Key challenges addressed include the linearization of non-linear relationships, such as heat transfer coefficients, and strategies to improve computational efficiency, such as pre-processing steps and advanced branching strategies. The results demonstrate that the optimized config- urations achieved a 15.1% increase in heat transfer efficiency and a 10% reduction in pressure drops compared to baseline scenarios utilizing traditional optimization methods. Additionally, the optimized system yielded an 11% annual cost saving, highlighting significant operational and economic benefits. The study confirms the robustness and effectiveness of the Branch and Cut method in managing complex, real-world optimization problems in thermodynamic systems, suggesting its broader applicability to similar industrial challenges. The findings emphasize the potential of advanced optimization techniques in enhancing energy efficiency and reducing costs in industrial applications.