Modeling and Temperature Control of

Heat Exchanger Process

Under the guidance of Shubham Saini (14283)

Dr. Veena Sharma Surjeet Singh (14222)
Akashdeep Verma (14260)
Bhagwan Sahay (14229)
 Contents
 Introduction
 Objective
 Heat exchanger system
 Principle of heat exchanger
 System description
 Mathematical model
 Control Algorithm
 Controllers
 Simulation Results
 Conclusions
 References
 Introduction
 Heat exchangers are commonly used equipment in industrial
chemical processes used to transfer heat between two process
streams
 They are indispensable part of process streams
 They are mainly used to maintain specific temperature conditions by
controlling the exit temperature of the process fluid
 This project analyses the performance of different controllers such
as feedback, feedback plus feed-forward and internal model
controller
 Objectives

 To study the mathematical model of shell and tube type heat

exchanger
 To study the model and design of different types of controllers such
as feedback, feedback plus feed-forward and internal model
controller
 To analyze the performance of these different controllers to regulate
the temperature of outlet fluid
 Heat Exchanger System
 Heat exchanger transfer heat between two fluids without mixing
them up
 The dynamics of heat exchanger depends on many factors like
- temperature difference
- heat transfer area
- flow rate of fluids
 There are various type of heat exchanger which are categorized with
respect to construction, transfer process, flow and phase
 Shell and tube heat exchanger is the most common type of heat
exchanger applicable for a wide range of operating temperature and
pressure
Principle of Heat Exchanger
System Description
 Mathematical Model
 To design a controller, a proper mathematical model of the process has to be
determined
 Most of the industrial system are non-linear and can be approximated as first order
plus time delay (FOPTD) or second order plus time delay (SOPTD) models
 So the transfer function of the shell tube heat exchanger is given by
𝑘𝑝
𝐹 𝑠 = 𝑒 −𝑠𝜏𝑑
𝜏𝑝 𝑠 + 1
where 𝑘𝑝 is the process gain, 𝜏𝑑 is the time delay and 𝜏𝑝 is the time constant
 Considering the experimental data, the transfer function model of heat exchanger
50
is 𝐺𝑝 𝑠 = 𝑒 −1𝑠
30𝑠+1
 Transfer function model of valve is
0.13
𝐺𝑣 𝑠 =
3𝑠+1

 Transfer function model of sensor is

0.16
H 𝑠 =
10𝑠+1

 Transfer function model of disturbance is

1
𝐺𝑑 𝑠 =
10𝑠+1

 The process transfer function is represented as

5
G 𝑠 = 2 𝑒 −1𝑠
90𝑠 +33𝑠+1

which is in the form of SOPTD

 Control Algorithms

 To control the outlet temperature of heat exchanger system closed

loop control is required which can be achieved by a controller
 The control algorithms considered to achieve the desired control
objective are
- Proportional-Integral-Derivative (PID) control
- feed-forward control
- internal model control
 PID control
 The block diagram of a closed loop feedback control setup of heat exchanger is
shown below

 In this block diagram classical PID controller is used as the controller.

 An ideal interacting PID controller can be represented as
1
𝐺𝑐 𝑠 = 𝐾𝑐 1 + + 𝜏𝑑 𝑠
𝜏𝑖 𝑠
 Feed- forward Controller
 Feed-forward control limits the deviation caused by the disturbance
but it works in one condition that the disturbance should be
measured or estimated
 The transfer function of feed-forward controller can be represented
as
𝐺𝑑 𝑠
𝐺𝑐𝑓 𝑠 = −
𝐺𝑝 𝑠

where 𝐺𝑐𝑓 𝑠 is the transfer function of feedback-feed-forward

controller,
𝐺𝑝 𝑠 is the process transfer function and
𝐺𝑑 𝑠 is the disturbance transfer function
 The block diagram of feedback plus feed-forward controller is illustrated in figure
below

 The control signal of feedback controller and feed-forward controller is summed

up and provided to the process
Simulation Results
 Conclusion
 This project evaluates different methods to control the fluid
temperature of shell and tube heat exchanger
 Till now, the performance of feedback and feed-forward controllers
are evaluated
 The feedback controller implemented using classical PID controller
shows a higher degree of overshoot and settling time
 The use of feed-forward controller with feedback controller reduces
the overshoot and settling time
 Future work

 To analyze the performance of internal model control and to

simulate its characteristics
 To calculate and compare the error indices of different control
methods
 References
 Subhranshu Padee, Controller design for temperature control of heat exchanger system,
WSEAS Trans.on systems and control, volume 9, 2014
 Sarabeevi G.M., Temperature control of shell and tube heat exchanger system using
internal model controllers, International conference on next generation intelligent systems
(ICNGIS), 2016
 S. Skogestad, “Tuning for smooth PID control with acceptable disturbance rejection”,
Industrial and engineering chemistry research, vol. 45, no. 4, pp.7817-7822, 2006
 https://www.mathworks.in/help/control/.../temperature-control-in-a-heat-exchanger.html
 B. W. Bequette, Process control: modeling, design, and simulation. Prentice Hall
Professional, 2003
Thankyou