Corrosion risk analysis of tube-and-shell heat exchangers and design of outlet temperature control system

This study deals with the high-risk shell-and-tube heat exchangers in the effluent system of hydrogenation reaction of the petrochemical industry.The process of hydroprocessing reactor effluent system is simulated in Aspen Plus to study the distribution of corrosive medium in the three phases of oil,gas and water.The least-squares method is utilized to calculate the ammonium salt crystallization temperature.Then,the heat exchanger with risk of ammonium salt crystal corrosion is identified.Dynamic mathematical modeling of the heat exchanger is established to determine the transfer function.A temperature control system with proportional integral derivative(PID)control of the heat exchanger outlet is designed,and fuzzy logic is used to implement self-tuning of PID parameters.After MATLAB simulation,the results show the control system can achieve rapid control of the heat exchanger outlet temperature.

A Pole Assignment Design Method of Process Control System for Tubular Heat Exchanger

This Paper has first studied the simplified model of tubular heat exchanger which is widely used in the industry and other field.On the basis of reference 2,a new pole assignment design method of pro-cess control system with derivative control action is found.For the above system,the method and the for-mation which calculate the feedback matrix K and gain matrix L is given,and the simulation of the system is made.

Method for Incorporation of Controllability in Heat Exchanger Network Synthesis by Integrating Mathematical Programming and Knowledge Engineering

A method for incorporation of controlling the heat exchanger networks with or without splits is proposed by integrating mathemati-cal programming and knowledge engineering. The simultaneous optimal mathematical model is established. This method can be practically used in the integration of large-scale heat exchanger networks, not only to synthesize automatically but also to satisfy the requirement of struc-tural controllability with more objective human intervention.

Adaptive inverse control of air supply flow for proton exchange membrane fuel cell systems

To prevent the oxygen starvation and improve the system output performance, an adaptive inverse control （AIC） strategy is developed to regulate the air supply flow of a proton exchange membrane fuel cell （PEMFC） system in this paper. The PEMFC stack and the air supply system including a compressor and a supply manifold are modeled for the purpose of performance analysis and controller design. A recurrent fuzzy neural network （RFNN） is utilized to identify the inverse model of the controlled system and generates a suitable control input during the abrupt step change of external disturbances. Compared with the PI controller, numerical simulations are performed to validate the effectiveness and advantages of the proposed AIC strategy.

Bypass Selection for Control of Heat Exchanger Network

Considering the flexibility and controllability of heat exchanger networks (HENs), bypasses are widely used for effective control of process stream target temperatures. However, the optimal location for the bypass is generally difficult to design with the trade-off between controllability and capital investments. In this paper, based on the steady-state model of heat exchanger networks the optimal bypass location was firstly selected by iteratively calculating the non-square Relative Gain Array (ns-RGA). To simplify the calculation process, rules of bypass selection were also proposed. In order to evaluate this method, then, the structural controllability of heat exchanger networks was analyzed. With both the consideration of the controllability and capital investments, the bypasses locations were finally selected. A case study on the HEN in Crude Distillation Unit was presented in which the ns-RGA and structural controllability were used to select bypasses and also to evaluate the results.

Charging System of ECRH High-Voltage Power Supply and its Control System

High-voltage power supply (HVPS) of Electron Cyclotron Resonance Heating (ECRH) for HT-7 and HT-7U is presently being constructed. The high voltage (100 kV) energy of HVPS is stored in the capacitor banks, and they can power one or two gyrotrons. All the operation of the charging system will be done by the control system, where the field signals are interfaced to programmable logic controller (PLC). The use of PLC not only simplifies the control system, but also enhances the reliability. The software written by using configuration software installed in the master computer allows for remote and multiple operator control, and the status and data information is also remotely available.

Dynamic Simulation of the Aircraft Environmental Control System

The dynamic research of aircraft environmental control system (ECS) is an important step in the advanced ECS design process. Based on the thermodynamics theory, mathematical models for the dynamic performance simulating of aircraft ECS were set up and an ECS simulation toolbox (ECS_1.0) was created with MATLAB language. It consists of main component modules (ducts, valves, heat exchangers, compressor, turbine, etc.). An aircraft environmental control system computer model was developed to assist engineers with the design and development of ECS dynamic optimization. An example simulating an existing ECS was given which shows the satisfactory effects.

Heat exchanger network synthesis integrated with flexibility and controllability

Over the last three decades,flexibility and controllability considerations for heat exchanger networks(HENs)have received great attention,respectively.However,they should be simultaneously incorporated in HEN synthesis to allow the economic performance to be achievable in a practical operating environment.This paper proposes a method for simultaneous synthesis of flexible and controllable HEN by considering their coupling.The key idea is to add the bypasses with optimized initial fractions and positions to explore such coupling,and consequently enabling HENs to be operated successfully over a range of disturbance variations.These are implemented by identifying and quantifying disturbance propagations,and then examining the sensitivity of bypasses to the entire HEN.In this way,the superstructurebased mixed integer non-linear programming(MINLP)with objective function of minimizing the total annual cost is formulated.A case study is used to demonstrate the application of the proposed method.Quantitative measures and dynamic simulation show the ability to provide the satisfactory flexibility and controllability of the obtained HEN.

Optimization of a Heat Exchanger Using an ARM Core Intelligent Algorithm

In order to optimize heat transfer in a heat exchanger using an ARM(advanced RISC machine)core intelligent computer algorithm,a new type of controller has been designed.The whole control structure of the heat exchange unit has been conceived on the basis of seven functional modules,including data processing and output,human-computer interaction,alarm,and data communication.The main controller and communication controller have been used in a combined fashion and a new MCU(micro control unit)system scheme has been proposed accordingly.A fuzzy controller has been designed by using a fuzzy control algorithm,and a new mode of heat transfer for the heat exchanger has been implemented by combining the fuzzy controller and the PID(proportioning integral derivative)controller.Finally,the model has been applied to an actual heat exchange station to test and verify the performances of the new approach.

Two-tier control structure design methodology applied to heat exchanger networks

Because of its paramount importance in the successful industrial control strategy of a given heat exchanger network(HEN),the control structure designs for providing appropriate manipulated variable(MV)and controlled variable pairings have received considerable attention.However,quite frequently HENs with such control structures face the problem of hard constraints,typically holding the HENs at less controlled operating space.So both the MV pairings and the above control pairings should be considered to design a control structure.This paper investigates the systematic incorporation of the two pairings,and presents a methodology for designing such two-tier control structure.This is developed based on the sequential strategy,coupling an indirect-tier with direct-tier control structure design,wherein the intention is realized in the former stage and the latter is implemented for further optimization.The MV identification and pairing are achieved through variations in heat load of heat exchangers to design the indirect-tier control structure.Then the direct-tier control structure is followed the relative gain array pairing rules.With the proposed methodology,on the one hand,it generates an explicit connection between the MV pairings and the HEN configuration,and the quantitative interaction measure is improved to avoid the multiple solutions to break the relationship among all the control pairings into individuals;on the other hand,a two-tier control structure reveals control potentials and control system design requirements,this may avoid complex and economically unfavourable control and HEN structures.The application of proposed framework is illustrated with two cases involving the dynamic simulation analysis,the quantitative assessment and the random test.

Stability Analysis of Network Controlled Temperature Control System with Additive Delays

This paper presents,using Lyapunov-Krasovskii functional technique combined with reciprocal convex lemma is considered for a networked control temperature control system with additive time-varying-delays.In the stability analysis,a new LK functional is assumed,and take the time-derivative of the(LK)functional,using reciprocal convex combination technique was employed to obtain less conservative stability criteria.Finally,the proposed stability analysis culminates into a stability criterion in the LMI(linear matrix inequalities)framework.The results obtained are in accordance with the theoretically obtained in the temperature control system and they are closer to the standard benchmark temperature-control system.

Regulation Conditions Influence on the Thermic and Exergic Efficiency Factors Size with the Heat Exchanger of a Coiled Type

The thermal engineering research has been executed for the threecircuit heat exchanger of a coiled type, that provides the thermal loads regulation for the heating and hot water supply systems. A processing curve of the warmth supply regulation at a combined heating and hot water supply load, was used at that. It is important to know the processes running inside the apparatus for the technical characteristics improvement of the threecircuit heat exchanger of a coiled type. The task solution will allow save the materials consumption for the threecircuit heat exchangers of a coiled type manufacturing in the future.

Theoretical and experimental studies of gas preparation system for pressurization and reactive control system of launch vehicle

A new gas preparation system(GasPS-RCS)is proposed to solve two tasks:(A)to heat helium gas for tank pressurization;(B)to prepare gas for the Launch Vehicle(LV)Reactive Control System(RCS)at the LV orientation and stabilization sections of the LV on passive parts of the flight trajectory,to provide conditions for launching the Liquid Rocket Engine(LRE).The system includes a gas generator based on hydrogen peroxide,a separator for water separation,heat exchangers independent of the LRE,and gas-jet nozzles.The proposed new system allowed to reduce the length of pressurizing gas lines and reduce the increased helium gas consumption during the heat exchanger warm-up interval of the LRE during its launch.A special advantage of the proposed system is the possibility of ground testing of heat exchangers without an operating LRE.A mathematical model based on the first law of thermodynamics was used to perform a comparative analysis of GasPS-RCS with traditional pressurization and RCS systems.To validate the mathematical model,the experimental studies of helium pressurizing of a liquid nitrogen tank were conducted.The results show that the deviation of experimental and calculated values for pressure is 1.1%and for temperature up to 2%.According to the results of comparative analysis,the GasPS-RCS is 259 kg lighter for the first stage and 80 kg lighter for the second stage of the LV.

Stability and weighted sensitivity analysis of robust controller for heat exchanger

This study presents a parametric system identification approach to estimate the dynamics of a chemical plant from experimental data and develops a robust PID controller for the plant.Parametric system identification of the heat exchanger system has been carried out using experimental data and prediction error method.The estimated model of the heat exchanger system is a time-delay model and a robust PID controller for the time-delayed model has been designed considering weighted sensitivity criteria.The mathematical background of parametric system identification,stability analysis,and H∞ weighted sensitivity analysis have been provided in this paper.A graphical plot has been provided to determine the stability region in the(Kp,Ki),(Kp,Kd)and(KuKd)plane.The stability region is a locus dependent on parameters of the controller and frequency,in the parameter plane.

Constant temperature control of tundish induction heating power supply for metallurgical manufacturing

The tundish induction heating power supply(TIHPS)is one of the most important equipment in the continuous casting process for metallurgical manufacturing.Specially,the constant temperature control is greatly significant for metallurgical manufacturing.In terms of the relationship between TIH load temperature and output power of TIHPS,the constant temperature control can be realized by power control.In this paper,a TIHPS structure with three-phase PWM rectifiers and full-bridge cascaded inverter is proposed.Besides,an input harmonic current blocking strategy and a load voltage feedforward control are also proposed to realize constant temperature control.To meet the requirement of the system,controller parameters are designed properly.Experiments are con?ducted to validate the feasibility and effectiveness of the proposed TIHPS topology and the control methods.

Alternative ventilation strategies in U.S.offices:Comprehensive assessment and sensitivity analysis of energy saving potential

Mature technologies exist to reduce the heating,ventilation,and air-conditioning(HVAC) energy associated with ventilation and use ventilation proactively to save energy.This study investigated the energy use impacts in U.S.office buildings of multiple alternative ventilation strategies that combined:economizing,demand controlled ventilation(DCV),supply air temperature reset(SR),and/or a doubled ventilation rate.We used energy simulations in a Monte Carlo analysis,sampling 17 building inputs and varying locations to match the climate zone distribution of the U.S.office stock.Results indicated the possibility for significant savings compared to a baseline that ventilated constantly at a minimum rate in both a small office type with a constant air volume(CAV) HVAC system and a medium office type with a variable air volume(VAV) system.In 95%of instances,HVAC source energy savings were 5-25%in the small-CAV office(median:11%) and 6-42%in the medium-VAV office(median:27%).In the small-CAV office,DCV typically saved the most energy,usually from heating,and heating degree days and occupant density were decisive influences.In the medium-VAV office,economizing and SR were most important,DCV usually only had minor impacts,and zone temperature setpoints,along with climate indicators,were the critical influences.Other than infiltration,envelope characteristics did not strongly influence energy impacts.The untapped primary energy savings of alternative ventilation strategies over the 74%of U.S.office floorspace reasonably represented by our modeling was estimated at 36 TWh per year,with an annual value of U.S.$ 1.25 billion.

An Efficient Method for Heat Recovery Process and Temperature Optimization

Flue gas heat loss accounts for a significant component of theoverall heat loss for coal-fired boilers in power plants. The flue gas absorbsmore heat as the exhaust gas temperature rises, which reduces boiler efficiencyand raises coal consumption. Additionally, if the exhaust gas temperatureis too high, a lot of water must be used to cool the flue gas for the wetflue gas desulfurization system to function well, which has an impact onthe power plant’s ability to operate profitably. It is consequently vital totake steps to lower exhaust gas temperatures in order to increase boilerefficiency and decrease the amount of coal and water used. Desulfurizationperformance may be enhanced and water use can be decreased by reasonableflue gas characteristics at the entry. This study analyzed the unit’s energyconsumption, investment, and coal savings while proposing four couplingstrategies for regulating flue gas temperature and waste heat recovery. Agraded flue gas conditioning and waste heat recovery plan was presentedunder the condition of ensuring high desulfurization efficiency, along withthe notion of minimizing energy loss owing to energy inflow temperaturedifference. Numerical results show that the proposed methods improved thesystem performance and reduced the water consumption and regulated theboiler temperature.

Study of Corrosion on Film Properties of High Strength Cu-Sn-Zr Alloys in Tap Water

Corrosion has been reported to occur in the copper tubes of heat ex-changers in multiple-circulation hot water supply systems. We have been investigating the applicability of high-strength Cu-0.65 mass% Sn-0.014 mass% Zr-0.020 mass% P alloy to counteract this corrosion. Immersion tests, electrochemical measurements, and field tests were performed. Excellent corrosion resistance of the alloy was established under conditions with flowing water due to the formation of composite films containing tin. The alloy is expected to be better than copper as a corrosion-resistant material for heat exchanger tubes.

分体式自清洗工业废气余热回收装置设计

为解决化纤生产废气余热回收装置运行一段时间后因污垢层积而换热效率下降的问题,提出一种分体式自清洗工业废气余热回收装置。设计了分体式换热器,采用PLC控制刷洗机构、拉板小车和高压喷头,实现了换热翅片管排的自动分合和清洗功能。测试结果显示,分体式自清洗工业废气余热回收装置能维持较高的换热效率,较原有整体式装置效率提升大约5%,清洗时间由10h缩短为2.5h。该余热回收装置可提高能源利用效率,降低生产成本,减少维护时间,为低品位热能回收利用提供了参考。

PEMFC空气系统流量和压力协同控制策略设计

为提高质子交换膜燃料电池(PEMFC)空气系统的动态响应性能,避免局部缺气而导致其输出性能降低等问题的出现,针对空气系统存在流量和压力耦合的问题,分别采用PID、前馈解耦控制和模型预测控制(MPC)对空气系统进行控制,通过仿真和台架测试,验证控制算法的有效性。结果表明,两种控制算法相比较PID均具有较好的控制效果,空气流量和空气压力均能快速跟随设定值,PEMFC发动机的输出性能平稳。