Economic Optimization of Rotary Heat Exchangers Using CO2 Pricing Scenarios Based on Validated Fluid Dynamic and Thermodynamic-Based Simulation

Rotary heat exchangers have been widely used in paint shops, combustion power plants, and in heating, ventilation, and air conditioning systems in buildings. For these processes, many types of heat exchangers are available in the market: Tube-shell heat exchangers, plate heat exchangers, and rotary heat exchangers, among others. For the rotary heat exchangers, the problem is that there is no net present value method and lifecycle assessment method-based optimization found in the literature. In this work, we address this issue: An optimization is carried out with help of an empirically validated simulation model, a life-cycle assessment model, an economical assessment, and an optimization algorithm. The objective function of the optimization simultaneously considers economic and environmental aspects by using different CO2 pricing. Different CO2 pricing scenarios lead to different optimization results. The ambient air empty tube velocity va, 2.1 optimum was found at 1.2 m/s, which corresponds to a specific mass flow msp of 5.4 kg/(m2·h). For the wave angle β, the optimum was found in the range between 58° and 60°. For the wave height h* the optimum values were found to be between 2.64 mm and 2.77 mm. Finally, for the rotary heat exchanger length l, the optimum was found to be between 220 mm and 236 mm. The optimization results show that there is still potential for technical improvements in the design and operation of rotary heat exchangers. In general terms, we recommend that the optimized rotary heat exchanger should cause less pressure drop while resulting in similar heat recovery efficiency. This is because the life cycle assessment shows that the use phase for rotary heat exchangers has the biggest impact on greenhouse gases, specifically by saving on Scope 2 emissions.