Numerical simulation of the thermal control of heat exchangers

The temperature control of outlet air by changing the water flow rate in a single-pass water-to-air cross-flow heat exchanger is investigated. The conservation laws are applied to finite control volumes and an implicit formulation is used for transient numerical solutions. Conjugate forced convection heat transfer from the tube is solved to calculate the temperatures of the air and water coining out of the heat exchanger. In the simulations the outlet air temperature is controlled by changing the water flow rate entering the heat exchanger using a proportional-integral (PI) controller. The range of controllability of the heat exchanger was studied first. Then disturbances in the form of step changes in the inlet air temperature, the airflow rate, and the set point temperature were separately introduced. The effects of the limiting-condition constraints and different control parameters on controlling the outlet air temperature are presented. The results show that the control behavior can be simulated numerically and that this control methodology is effective within limits.