Comparison a simulation model of heat exchanger with real equipment
Jan Kukurugya, Jan Terpák
Institute of Control and Informatization of Production
Processes,
BERG Faculty, Technical University of Košice
Košice, Slovakia
e-mail: jan.kukurugya@tuke.sk , jan.terpak@tuke.sk
Abstract — Proposed article deals with simulation model of
heat exchanger and its comparison with real equipment. Heat
exchanger is an equipment which is used for heating-up one
medium by the other. Indirect heat transfer is considered i.e.
medium are not in direct contact and heat transfer occurs
through the wall. Mentioned heat exchanger is typical for area
of raw materials processing and it is used mainly for
preheating of combustion air, fuel. Exchanger is also used for
cooling of equipment, warmed products etc. In the case of
exchanger, above all, processes of heat transfer by convection,
heat transfer by conduction and accumulation of heat are
modelled and described in article. Mathematical model built
by means of balancing equations represents base of simulation
model created in Matlab Simulink by using s-function. Real
data is gained from laboratory experimental equipment and
are compared with simulation results. In the end part of article
reasons of variation of data from simulation model and from
real equipment are analyzed. Possibilities of improving and
extension of model to create model more exactly are
mentioned.
Keywords-heat exchanger; heat transfer; simulation model ;
I. INTRODUCTION
Heat exchanger is one of the basic equipment from area
recovering and processing of raw materials and mainly is
used for heating different media as combustion air or fuel
etc. Regenerator and recuperator are the two basis types of
heat exchanger. The regenerator, which is presented in
figure 1, is used for heating of some medium by another
medium by indirect heat transfer through the wall of certain
matter and thickness. In recuperator the medium is heated
by indirect heat transfer when hot medium heats the walls of
recuperator by flowing through it. Subsequently, cooler
medium is flowing via recuperator and is heated by walls
which were heated in previous process. In article is
described two stream regenerator. Equipment has cylindrical
shape and is used for heating one medium by second
through the wall.
By heat exchanger can be understood also multi stream
exchanger [1], louvered exchanger [2], transient exchanger
response [3] and so on.
Simulation model creation is the important element for
increasing of effectivity of production in mentioned area.
978-1-61284-361-2/11/$26.00 2011
c IEEE
Andreas Voigt
Process Systems Engineering
Otto-von-Guericke University
Magdeburg, Germany
e-mail: voigt@mpi-magdeburg.mpg.de
Main function of model is to predict outputs of exchanger
by proposed inputs with as high probability as possible.
Model of heat exchanger describe mainly change of
medium temperature during the passing through the
exchanger by heat transport from one medium to another.
Theoretical data gained from a model will never be
completely adequate to data from real process, but they can
come close to them. During the creation of mathematical
model of exchanger it is necessary to ensure the highest
accuracy as possible by considering also influence of
environment, which real exchanger, up to a certain point, is
affected. The most effective way how to verify transparency
of model is to compare theoretical model data with data
from real process. Using data from real equipment for
verifying of model is sometimes not possible and not so
effective. In the most of the cases experimental data are
used for comparison with model (theoretical) data instead of
data from real process. Experimental data are gained from
experimental equipment. Character of processes in
experimental and real equipment is the same. Process data
is more simple and cheaper to gain from experimental
equipment than from real one. Experiment is sufficient
when are taking into account the same conditions which can
occurs in real equipment. Differences between equipments
real and experimental need to be regard. Experimental
equipments are in the most of the cases dimensionally
different, walls are made from different material etc.
Simulation model has to have option to take account these
differences when input parameters of model and simulation
are set. Character and type of processes running in
experimental equipment have to be adequate to processes in
real equipment from qualitative view.
Verification of model can emphasise mistakes of model
same as can confirm transparency and usability of model for
real process.
II. HEAT EXCHANGER
It is considered only change of energy because the value
of inflow equal the value of outflow of thermal jacket has
the same value and volume in tank is without change.
Energy transfer from one part of wall to adjacent part by
direct contact without flowing, what is heat transfer by
conduction, is running in wall. Energy transfer is occured
234
between wall and fluid caused by flowing and moving fluid. dTo1 c p1.ρ1.( IVI 1.TI 1 − IVo1.To1 ) − α1.S P1.(T01 − Tw1 ) − I QE (4)
Direction of heat transfer can be the same as is showed in =
dτ S1.h1.c p1.ρ1
figure 1, from jacket to tank (IQ12) and from jacket to
environment (IQE). In case of free cooling is direction of
energy transfer inside of exchanger opposite (- IQ12). During dTo 2 IVI 2 .cP 2 .ρ2 .TI 2 − IVo 2 .cP 2 .ρ 2 .To 2 + α 2 .S P1.(TW 2 − To 2 ) (5)
=
free cooling is direction follows, from tank to jacket (- IQ12) dτ S2 .h2 .c p 2 .ρ2
and from jacket to environment (IQE).[4]
Wall between thermal jacket and thermal tank was
imaginary divided into two half to easier describe process
of heat transfer by equations. Energy balance for each half
of wall is represented by equation for calculation of
temperature change of first half of wall (TW1) and second
one nearer to thermal tank (TW2) .

2.λ
2.(α1.S P1.(T01 − Tw1 ) − .S P1 (TW 1 − TW 2 ) )
dTW 1 l (6)
=
dτ Vw1.c pW .ρW

2.λ
2.( .S P1 (TW 1 − TW 2 ) − α 2 .S P1.(TW 2 − To 2 ) )
dTW 2 l
= (7)
dτ Vw1.c pW .ρW

S P1 = π .d 1 .h1
(8)
V w1 = S P1 .l
(9)

Figure 1. Considered type of heat exchanger Same approach is used for expressing heat transfer
through the wall between environment and thermal jacket.
Mathematical model comes from scheme in figure 1. In Heat losses to environment are described by heat flow of
mathematical model of heat exchanger is also considered heat loses (IQE).
material balance. The volume in tank is considered stable
than is not necessary in this case calculate material balance. I QE = α 1 .S P 2 .(TO1 − TEW 1 ) (10)
Energy balance of heat exchanger involve processes such as
heat accumulation, heat transfer by conduction through the 2.λ
walls of exchanger and heat transfer by convection from 2.( α1.S P 2 .(T01 − Tw1 ) − S P 2 (TWE1 − TWE 2 ) )
dTEW 1 l (11)
wall to medium and contrariwise. [5] =
Starting point of mathematical model is equation (1) and dτ Vw 2 .c pW .ρW
(2) from energy conservation law:
2.λ
2.( .S P 2 (TWE1 − TWE 2 ) − α E .S P 2 .(TWE 2 − TE ) )
dQ1 dTEW 2 l
= I QI 1 − I QO 2 − I Q12 (1) = (12)
dτ dτ Vw2 .c pW .ρW
S P 2 = π .d 2 .h2
dQ2 (13)
= I Q 2 − I Q + I Q12 (2)
V w 2 = S P 2 .l
dτ (14)

dTO 2 All used variables variables are described in table 2 placed

ρ1 .c P 2 .S 2 .h2 . = I Q 2 − I Q + I Q12 (3) in the end of article. Mathematical model of heat exchanger
dτ
was implemented in programming environment Matlab.
Final equation for calculation of temperature in thermal III. EXPERIMENTAL EQUIPMENT
jacket (4) in time and temperature in tank (5) in time.
Experimental equipment consist from thermal jacket and
thermal tank which are divided by glass wall. Water is
warmed by circulation from jacket to equipment for heating

2011 12th International Carpathian Control Conference (ICCC) 235

of fluid called „JULABO CF31“. Warmed water get inside
to jacket through the opening in the lower part of jacket and
colder is taken out by opening in upper part of jacket, while
temperature reach the desired value. Complete scheme of
measuring chain is showed in figure 2.
Figure 2. Scheme of measure chain
Julabo CF31 is equipment which insure circulation water
when cold water leak out and hot water leak into jacket .
Inflows and outflows openings are on vertical wall of
thermal jacket. In the cover of exchanger are placed
openings for sensors for temperature measuring.
Figure 3. Heat exchanger
TABLE I. PARAMETERS OF EXCHNAGER
Variables Value Unit
500 ml
Volume
Diameter of bottom of exchanger 130 mm
Sensor is placed in thermal tank near the wall. Data are
transported with certain period through the display unit to
computer where are saved to text file.
IV. EXPERIMENTS
Basis of experiment is consist of two parts. In first part is
watched temperature of water in thermal tank from
beginning (initial condition) till steady state. In the second
part is recorded temperature of water in thermal tank during
the free cooling. On follows comparison theoretical and real
data is shown if simulation model of heat exchanger
respond to reality.
Kelvin is used as a unit of temperature in simulation
model. Measure chain works with Celsius degrees. Change
of all units which contain unit of temperature from Kelvin to
From reason of unification of units was Kelvin convert to
degrees Celsius.
Fluid used in experiment is water. Temperature of
environment was considered laboratory temperature (24°C)
what was also initial temperatures of water in jacket and
tank.
In first part it considered thermal jacket inflow change on
the beginning. Input values and conditions was the same for
both, model and experiment. Walls of exchanger are made
from glass and the same thickness (1,2 cm). Temperature in
thermal jacket was growing form 24°C to value 85°C for
time 860 seconds and with sample time 20 seconds.
When temperatures in jacket reach the desired
temperature (85°C) it becomes constant, but watched
variable, temperature in thank, is still growing. Temperature
in thermal tank reach steady state 1490 seconds later.
Comparison of progresses of temperature in thermal tank
from simulation model and from real equipment with
progress of temperature in thermal jacket is shown in figure
4.
Free cooling starts from moment when temperature in
thermal tank reach desired value (85°C). Equipment for
warming water is shut down. Inflow and outflow to the and
from the thermal tank and thermal jacket is equal to 0.
Watched variable is temperature in thermal tank during the
cooling. In this case is occurs heat losses to environment
trough the wall from thermal tank to thermal jacket and also
from thermal jacket through the wall to environment.
Temperature of environment is known. Graphical result of
free cooling is presented in figure 5.
All parameters needed for simulation was set by
experimental equipment (Table I.) or calculated by
equations 1-14.

100 mm V. CONCLUSION
Diameter of thermal tank
Comparisons real temperature with model data indicates
Height of exchanger 200 mm differences between theoretical and model generated data by
simulation model of heat exchanger. Anomalies can be
caused by heat losses during the transport of water from
heating object Julabo CF31 to heat exchanger or not taking

236 2011 12th International Carpathian Control Conference (ICCC)

into account hole surface of heat exchange during the
calculation heat flow of losses to environment. In graph on
figure 4 is shown that differences between temperatures in [1]
different time is not the same what can be caused by using
heat capacity, heat transfer coefficient etc. as a constants. In
real process are heat transfer coefficients, and heat capacity
[2]
function of temperature. Theoretical temperature can reach
steady state of real temperature after allowance of
mentioned correction of model .
[3]
ACKNOWLEDGMENT [4]
This work was partially supported by grant VEGA
[5]
1/0567/10, 1/0746/11 and 1/0479/06
REFERENCES
Xing Luo, Meiling Li , and W. Roetyel, “A general solution for one-
dimensional multistream heat exchangers and their
networks,”International Journal of Heat and Mass Transfer , vol. 45,
pp. 2695–2705, 2002.
M. Khaled, F. Harambat , and H. Peerhossaini, “Analytic and
empirical determination of thermal performance of louvered heat
exchanger – Effects of air flow statistics ,”International Journal of
Heat and Mass Transfer , vol. 54, pp. 356–365, 2010.
Juan Jin, M.K. Jensen , “Analytic model for transient heat exchanger
response ,”International Journal of Heat and Mass Transfer , vol. 46,
pp. 3255–3264, 2003.
O. Lievenspiel, “Engineering flow and heat exchange ,”USA:
Plenum Press,New York, pp. 320, 1998, ISBN 0-306-45682-6.
J.Terpak, ď. Dorþák, “Procesy premeny ,”Slovakia: Technická
univerzita, Košice, pp. 212, 2001, ISBN 80-7099-733-8.

Figure 4. Comparison of progress of real temperature in tank (blue curve) and model temperature (green curve)
during the heating

Figure 5. Comparison of progress of temperature in tank during free cooling

from real equipment(blue curve) and from model (green curve).

2011 12th International Carpathian Control Conference (ICCC) 237

 TABLE II. MEANING, SYMBOL AND UNIT OF VARIABLES USED IN MATHEMATICAL MODEL OF HEAT EXCHANGER

Inflow of heating fluid to the Heat in volume of fluid in thermal jacket Q1 J

IvI1 m3.s-1
jacket
Heat in volume of fluid in thermal tank Q2 J
Input temperature of heating
TI1 K Heat inflow of thermal jacket IQI1 J.s-1
fluid (jacket)
Inflow of heated fluid to the tank IvI2 m .s3 -1
Heat outflow of thermal jacket IQO1 J.s-1

Input temperature of heated fluid

TI2 K Heat inflow of thermal tank IQI2 J.s-1
(tank)
Outflow of heating fluid from the
IvO1 m3.s-1 Heat outflow of thermal tank IQO2 J.s-1
jacket
Outflow of heated fluid from the
IvO2 m3.s-1 Heat flow from jacket to tank IQ12 J.s-1
tank
Surface of bottom of thermal jacket,
Diameter of the bottom of d1, d2 m S1, S2 m2
thermal tank
exchanger , diameter of tank Surface of heat transfer area jacket-tank,
SP1,SP2 m2
Height of exchanger H m jacket-environment

Heat capacity of Temperature of environment TE K

cP1, cP2 J.kg-1.K-1
heating fluid , heated fluid
Temperature of first half of wall
TWE1 K
-3 between thermal jacket - environment
Density of ȡ1, ȡ2 kg. m
heating fluid , heated fluid
Temperature of second half of wall TWE2 K
between jacket – environment
Coefficient of heat transfer of Į1, Į2 W.m-2 .K-1
heating fluid , heated fluid
Temperature of first half of wall TW1 K
Conductivity of wall Ȝ W.m-2 .K-1 between jacket -tank

Heat capacity of wall cPW J.kg-1.K-1 Temperature of wall of second half of TW2 K
wall between jacket and tank
Density of wall ȡW kg. m-3 Volume of wall between environment VW1 m3
thickness of walls between tank and thermal jacket
and jacket, jacket and l m
environment Volume of wall between thermal jacket VW2 m3
and thermal tank
Heights of level of fluid in jacket h01, h02 m Heat flow of loses to environment IQE J.s-1
and tank
K
Initial temperature of fluid in T01
jacket in IJ=0
K
Initial temperature of fluid in T02
tank in IJ=0

238 2011 12th International Carpathian Control Conference (ICCC)