Thermal-economic optimization of an air-cooled heat exchanger unit

Thermodynamic modeling and optimal design of an air-cooled heat exchanger (ACHE) unit are developed in this study. For this purpose, ε–NTU method and mathematical relations are applied to estimate the fluids outlet temperatures and pressure drops in tube and air sides. The main goal of this study is minimizing of two conflicting objective functions namely the temperature approach and the minimum total annual cost, simultaneously. For this purpose, fast and elitist non-dominated sorting genetic-algorithm (NSGA-II) is applied to minimize the objective functions by considering ten design parameters. In addition, a set of typical constraints, governing on the ACHE unit design, is subjected to obtain more practical optimum design points. Furthermore, sensitivity analysis of change in the objective functions, when the optimum design parameters vary, is conducted and the degree of each parameter on conflicting objective functions has been investigated. Finally, a selection procedure of the best optimum point is introduced and final optimum design point is determined. ► Multi-objective optimization of air-cooled heat exchanger. ► Considering ten new design parameters in this type of heat exchanger. ► A detailed cost function is used to estimate the heat exchanger investment cost. ► Presenting a mathematical relation for optimum total cost vs. temperature approach. ► The sensitivity analysis of parameters in the optimum situation.