CH331:

Temperature Control in Heat

Exchanger

Submitted to: Dr Asad H Sahir

By:
Hardik Rana
Mazhar Laljee
Shivam Pandey
Shubham Sonawane
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 Heat Exchanger Process

❖ The top inlet delivers liquid to

be mixed in the tank as
shown in the figure.

❖ The tank liquid must be

maintained at a constant
temperature by varying the
amount of steam supplied to
the heat exchanger (bottom
pipe) via its control valve.

❖ Variations in the temperature

of the inlet flow are the main
source of disturbances in this
process.
Fig 1: Stirring Reactor with Heat Exchanger
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 Using Measured Data to Model The Heat Exchanger Dynamics

● Inject a step disturbance in valve voltage V and record the effect on the tank
temperature T over time to derive a first-order-plus-deadtime model of the heat
exchanger properties.

Code Code Output

● The times when the response reaches 28.3 % and 63.2% & of its final value are shown
by the values t1 and t2. Tau is the time constant and theta is the dead time for the heat
exchanger.

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Fig 2: Measured response to a step change in steam valve voltage
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Verification of the results obtained:

Here we compare the first-order-plus-deadtime response with the response obtained earlier.

Fig: Code and its output

Now we plot experimental vs simulated response to step change and derive conclusions
from the same.

● The experimental results and the model response

are in good agreement.
● A bump test experiment similar to this one might be
used to assess the first-order response to a step
change in input temperature.

Fig: Experimental vs simulated response to step change

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 Feedback Control

● Open Loop Process

The following transfer function
depicts how a change in the voltage
V driving the steam valve opening
influences the tank temperature T.

The transfer function below shows

how a change in inflow temperature
(d) influences T.

Fig: Block Diagram of Open Loop Process

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 Feedback Control

● To regulate the tank temperature T around a given setpoint Tsp, we can use the following
feedback architecture to control the valve opening (voltage V):

Here, the following PI controller calculates the

voltage V based on the gap Tsp-T between the
desired and measured temperatures.

The following is the required command and the

output obtained.
Code Output
Code

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 Feedback Control

Now to check the performance of ITAE controller, we close the feedback loop and simulate
the response to a set-point change.

Plot:

With some overshoot, the response

is fairly quick. The gain margin is
small, as evidenced by the stability
margins

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 Bode Diagram

Command

Plot:

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 Bode Diagram

On reducing the proportional gain Kc, the stability is strengthened at the expense of
performance.

Code

Plot:

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 Step Response

Code

Plot:

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 Feedforward Control
Changes in inflow temperature creates disturbances, To reject such disturbances, an alternative to feedback
control is the feedforward architecture shown below:

Flow diagram: Feedforward Control

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 Feedforward Control

Straightforward calculation shows that the overall transfer from temperature disturbance d to
tank temperature T is

Perfect disturbance rejection requires

Code

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 Feedforward Control

Plot of Tank Temperature vs Time

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 Combined Feedforward-Feedback Control

●
●

In general, feedback control is beneficial for setpoint tracking, although feedforward control can aid in the
rejection of measured disturbances.
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 Combined Feedforward-Feedback Control

Use connect to build the corresponding closed-loop model from Tsp,d to T. First name the input and
output channels of each block, then let connect automatically wire the diagram:
Code

To compare the closed-loop responses with and without feedforward control, calculate the
corresponding closed-loop transfer function for the feedback-only configuration:

Command
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Now compare the two designs:

Code
Plot:

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The two designs have identical performance for setpoint tracking, but the addition of feedforward control
is clearly beneficial for disturbance rejection. This is also visible on the closed-loop Bode plot

Code
Plot:

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 Interactive Simulation
Here we have given the step input disturbance and we will check the data for 4 conditions discussed in
further slides. The command for this simulation is : heatex

Fig : Simulink model for the heat exchanger temperature control.

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 Open
Open loop
loop response
response Joint
Joint Feedback
Feedback And
And Feedforward
Feedforward Response
Response

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Feedback Response Feedforward Response

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Task 2

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Task 2 Results

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Task 2 Results

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Conclusion: Faced:
Difficulties

● Task 1 was not particularly difficult because the directions and order were clearly described in the
reading material provided. It was only in a few circumstances where relating the code's functioning
process proved troublesome.
● In Task 2 , it was quite challenging to get to an equation of a certain order which has got some
background of heat and mass transfer.

Conclusions:
● We studied temperature control in a heat exchanger process, model for this project and
implemented it in MATLAB and SIMULINK.

● We created an open loop, feedback, feedforward, and combined feedback and feedforward heat
exchanger simulation model. And we also plotted the bode diagrams for different frequencies.

● For task 2 of this assignment, we successfully generated a second order plus deadtime model.

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Thank You!

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