Recent Advancement in Synthesis and Pinch Analysis of Heat Exchanger Networks

Crude oil distillation units in many global crude oil refineries contribute to the ultimate exergy disruption and massive thermal energy consumption compared to other components in such plants. Implementing pinch analysis, retrofitting , careful design, rearrangement, and optimization of heat exchanger networks (HENs) is considered influential and valuable for reducing the total annual cost and total energy consumption. Over the past few decades, numerous studies have employed conventional linear programming methods that are time-consuming, inefficient, and unable to accommodate nonlinearities, intricate system dynamics, various thermodynamic properties, and uncertainties that arise under actual operating conditions. Recent publications emphasize the shift from strictly mathematical approaches to hybrid simulation-optimization frameworks. Comprehensive research on HENs generally falls into two distinct categories: Heat Exchanger Network Synthesis (HENS) and integrating commercial process simulators (like Aspen Plus) with metaheuristic algorithms. The simulation and optimization of Heat Exchanger Networks (HENs) using Aspen HYSYS emphasize three primary methodologies: Pinch Analysis (via Aspen Energy Analyzer), rigorous steady-state and dynamic simulations, and stochastic algorithms integrated with HYSYS to minimize total annualized costs and energy use. The present review is conducted on the recent advancements, influential impacts, and advantageous benefits of active pinch analysis, synthesis, and retrofit procedures performed to manage crude oil refinery operations and refine existing low-efficiency heat exchanger networks.