Applied Thermal Engineering 52 (2013) 328e335

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Applied Thermal Engineering

journal homepage: www.elsevier.com/locate/apthermeng

Heat exchanger network simulation, data reconciliation & optimization

Humaad Ijaz, Uma M.K. Ati, Vladimir Mahalec*
Department of Chemical Engineering, McMaster University, W.G. Booth School of Engineering Practice, 1280 Main St. West, Hamilton, ON, Canada L8S 0A3

h i g h l i g h t s

< Linear rigorous model of single or two phase heat exchanger networks.
< Energy balance data reconciliation as a follow-on step to material balance reconciliation.
< Rapid optimization convergence via successive linear programming.
< Site wide energy usage reconciliation and optimization.

a r t i c l e i n f o a b s t r a c t

Article history: This work introduces new heat exchanger network (HEN) model for networks containing single phase
Received 27 July 2012 and two phase exchangers. Rigorous simulation of HEN performance requires sequential solutions of two
Accepted 22 November 2012 sets of linear equations: mass balances and energy balances which are linear in temperatures. This
Available online 8 December 2012
enables data reconciliation via QR factorization as sequential solution of linear mass and energy balances.
Hence, reconciliation of energy balances can be added as a follow-on step to material balance recon-
Keywords:
ciliation, thereby greatly simplifying data reconciliation in process plants. If simultaneous reconciliation
Rigorous linear heat exchanger network
of flows, temperatures and heat transfer coefficients is required, the convergence is attained in a handful
model
HEN model with single phase and two
of successive substitution iteration via QR factorization. Similarly, optimization of the HENs based on the
phase exchangers proposed model converges in two three to five successive linear programming iterations. Excellent
QR decomposition convergence of the proposed HEN model makes it suitable for use in large scale site-wide energy models.
Ó 2012 Elsevier Ltd. All rights reserved.

1. Introduction
q ¼ UAtLM (4)
Optimal design and operation of heat exchanger networks
where tLM, the log mean temperature difference (LMTD), is calcu-
(HENs) requires solution of mass flows, energy flows and energy
lated as
transfer equations for the network. Computations can be either to
evaluate the network performance (simulation), reconcile data
t1  t2
(DR), or to optimize the energy recovery by adjusting the flows tLM ¼   (5)
t
through the network. Classical model of a counter-current heat ln 1
exchanger is comprised of Eqs. (1)e(4): t2

 Here t1 and t2 are temperature differences between two fluids at

qh ¼ mh Cph th;in  th;out (1) each end of an exchanger,

 t1 ¼ th;in  tc;out (6)

qc ¼ mc Cpc tc;out  tc;in (2)

t2 ¼ th;out  tc;in (7)

qh ¼ qc ¼ q (3)
Computations of heat exchanger networks customarily employ
some approximation [1,5] of the heat transfer equation, in order to
eliminate convergence issues associated with log mean tempera-
* Corresponding author. ture difference (LMTD) term. Most frequently used is approxima-
E-mail address: mahalec@mcmaster.ca (V. Mahalec). tion by Chen [2], given by:

1359-4311/$ e see front matter Ó 2012 Elsevier Ltd. All rights reserved.
http://dx.doi.org/10.1016/j.applthermaleng.2012.11.033
 H. Ijaz et al. / Applied Thermal Engineering 52 (2013) 328e335 329

  1
1 0:3275 1 0:3275 0:3275
tCM ¼ t þ t2 (8)
2 1 2
Chens approximation avoids division by zero (which can occur if
LMTD term is present). However, it is still a non-linear and it
provides an approximation the actual heat transferred in the
exchanger.
This work introduces iteration-free algorithm [1] to simulate an
exchanger network performance and for reconciliation of network
temperatures. The algorithm is based on rigorous reformulated
heat transfer equation for a single phase counter-current exchanger
introduced by Goyal [4] and the corresponding two-phase
exchanger model which we introduce in this work.
Section 2 of the paper presents a heat exchanger network model
which enables simulation of the network performance by solving
sequentially mass balance equations followed by the solution of
Fig. 1. F vs. ratio of cold flows with changes in hot flows.
energy balance equations. Section 3 applies the proposed HEN
model to data reconciliation, while Section 4 applies the mode for
on the mass flow rates of the streams can be calculated by the
optimization of the HEN performance.
following equation [4]
Proposed HEN model has excellent convergence properties in all
of these applications, which makes it suitable for use in large scale Uo
production optimization or production planning models. U ¼ " !0:8 #  0:6  (12)
Uo moc Np Uo moh
1þ o 1 þ o 1
2. Heat exchanger model linear in flows and temperatures hio mc Npo ho mh
and its use for network simulation
where Np ; Npo are the tube side number of passes, hoio is the inside
Goyal [4] reformulated Eqs. (4) and (5) by re-writing: film heat transfer coefficient, and hoo is the outside film heat transfer
coefficient. This relationship is illustrated in Fig. 2.
 the LMTD in terms of difference between the inlet tempera-
tures of the hot and cold streams and cold and hot fluid
temperature changes in the heat exchanger 2.1. Simulation of heat exchanger with no phase change
 heat exchanger duty as a ratio to the duty of a base case heat
exchanger with the same geometry; the known conditions of We can use Goyal’s reformulation of the heat exchanger equa-
the base case heat exchanger include flows, inlet and outlet tions to simulate performance of a heat exchanger by the following
temperatures, heat transfer area, and the heat transfer algorithm:
coefficient
1. Compute mass balances (flows) through the network
Let us define a base case heat exchanger with heat transfer 2. Compute the heat transfer coefficient for each exchanger in the
coefficient Uo, heat transfer area Ao, difference in inlet hot and inlet network under these new flow conditions
cold fluid temperatures Dt1o , difference in outlet hot and outlet cold 3. Compute heat exchanger performance factor for each
fluid temperatures Dt2o , difference in hot fluid temperatures Dtho , exchanger in the network
and difference in cold fluid temperatures Dtco . The energy q, 4. Compute energy balance equations; these equations are now
transferred in any exchanger can be computed as a function of the linear in temperatures, since the flows and the heat exchanger
base case heat exchanger duty qo, heat exchanger performance performance factors are known
factor F, and the difference between inlet stream temperatures:

 The data required to calculate the heat exchanger duty are mass
q ¼ F th;in  tc;in qo (9) flow rates for the hot and cold side fluids, mh and mc, as well as their

where
 X
Dt1o
1
Dt2o
F ¼  X  o   o  (10)
Dt1o mh mc
Dtho  Dtco
Dt2o mh mc

     o 
U A moh mc
Dtho  Dtco
U0 Ao m mc
X ¼
oh  (11)
Dth  Dtco
Fig. 1 shows dependence of F on the changes of the mass flow
rates, if heat transfer coefficient does not change with the flows on
either hot or cold side of the exchanger. If the flow regime in the
exchanger is significantly different from the conditions in the base
exchanger, then the overall heat transfer coefficient’s dependence Fig. 2. F vs. ratio of cold flows with changes in hot flows.
330 H. Ijaz et al. / Applied Thermal Engineering 52 (2013) 328e335

temperatures. It is also assumed that the specific heat capacities Cph

and Cpc are known. Hence, the algorithm is as follows

1. Compute flow balances for the network; each exchanger is

modeled by flow balances for the hot and cold stream:

mh;in  mh;out ¼ 0 (13)

mc;in  mc;out ¼ 0 (14)

If there is stream splitting or mixing, the corresponding equa-

tions need to be added.

2. Calculate heat exchanger transfer coefficient U for each

exchanger (Eq. (12))
3. Calculate heat exchanger performance factor F for each heat
exchanger (Eqs. (10) and (11))
4. Solve energy balance equations (Eqs. (1)e(3) and (9) simulta- Fig. 3. Vapor fraction of sample crude as function of temperature.
neously for all exchangers in the network)

If there is fouling in the heat exchangers, it can be described by

where Hv is the heat of vaporization.
cleaning factor CF [7]:
Heat transfer in the exchanger comprises of an area with liquid
Ufouled 1
CF ¼ ¼ (15) and an area with two phase fluid
Uclean 1 þ Rf Uclean
A ¼ Al þ Alv (18)
where:

 CF is the cleaning factor A ¼ b1 Al þ b2 Alv (19)

 Ufouled is the fouled heat transfer coefficient determined iter-
atively by Eq. (12)
 Uclean is the clean heat transfer coefficient known from base
operating conditions
 Rf is the fouling resistance
2.2. Simulation of heat exchanger with or without phase change
where Al is the area for the heat exchanger containing only liquid,
Alv is for the exchanger containing both phases. Eq. (11) can be
updated with the heat exchange area. b1 is a ratio of the heat
transfer rate of Goyal’s reformulation (Eq. (11)) and of the hot
stream calculated by Eq. (16). Similarly, b2 is the ratio of Goyal’s
heat equation and the enthalpy of the cold stream also calculated
by Eq. (16).

This section introduces a model of a heat exchanger with or 2.2.1. Example 1: simulation of heat exchanger network
without a change of phase on either side of the exchanger. For Heat exchanger network shown in Fig. 5 consists of one cold
mixtures consisting of many components, such as crude oil, the stream and seven hot streams. The example is taken from Goyal [4].
vapor fraction g can be accurately represented as a linear function of The network has been simulated in Aspen Plus. Thermodynamic
temperature in the region of interest. For instance, dependence of the data from Aspen Plus model have been used to derive parameters
vapor fraction on temperature for a sample crude oil is shown in for energy balance equations in the model presented by Eqs. (1)e
Fig. 3. Over 50e100 K temperature ranges the dependence of vapor (17). Heat exchanger data (heat transfer coefficients and heat
fraction on temperature is practically linear. For a given fluid, the transfer areas) are given in Table 1. Linear heat exchanger model
bubble point tBP and the dew point tDP of the fluid are known. without a change of phase and values computed by the sequential
Enthalpy of the fluid can be represented by piecewise linear rela- simulation algorithm are also presented in Table 2. Estimated
tionship, where the inflection point corresponds to the bubble point values of unmeasured variables are presented in Table 3.
(see Fig. 4). It is assumed that from the plant operating data we can
determine which heat exchangers are likely to contain fluid under-
going phase change. Such exchangers (with phase change) can be
modeled by two exchanger models, one having liquid flow only, and
the other having both liquid and vapor phases. The heat transfer rate
of an exchanger can be calculated from the change in enthalpy, DH:
q ¼ DHm ¼ ðHout  Hin Þm (16)
Inlet and outlet stream enthalpies for both hot and cold streams
can be calculated from the inlet and outlet stream temperatures, t

8
>
>
>
> Ho þ Cp ðt  to Þ t < tBP
< Hv ðt  tBP Þ
H ¼ HBP þ tBP < t < tDP (17)
>
> ðtDP  tBP Þ
>
> HDP þ Cv ðt  tDP Þ
: t > tDP
Fig. 4. Linear enthalpyetemperature profile.
 H. Ijaz et al. / Applied Thermal Engineering 52 (2013) 328e335 331

Fig. 5. Heat exchanger network adapted from Goyal [4].

3. Data reconciliation
Crowe et al. [3] introduced use of projection methods for data
reconciliation, which was later extended to non-linear systems by
Swartz [9]. Swartz proposed an iterative procedure to reconcile
data for heat exchanger networks by applying QR factorization
introduced by Crow et al. HEN simulation algorithm introduced
above can be applied to data reconciliation by: (i) reconciling flows
first, (ii) computing heat exchanger performance factors for every
exchange in the network, and (iii) reconciling the temperatures.
u. Then a set of linear balance equations for a steady-state process
can be written as
Ax x þ Au u ¼ 0 (21)
where u is a (p  1) vector of unmeasured variables and Ax (m  n),
Au (m  p) are matrices of known constants [6,8].
The presence of measurement errors does not allow the balance
equations to be satisfied exactly. Hence, the data reconciliation
problem must solve the following least-squares problem

Min
3.1. Data reconciliation via QR factorization x ðy  xÞT S1 ðy  xÞ
s:t: Ax x þ Au u ¼ 0 (22)
Consider the following measurement model

y ¼ xþ3 (20)
Table 2
Ex. 1 & 2-simulation & DR results of measured variables.
where y is a (n  1) vector of measured variables, x is a (n  1)vector
Tag Aspen Plus Linear model Measured Reconciled
corresponding to the true values of the measured variables, and 3 is
simulation simulation values values
a (n  1) vector of random errors. The measurement errors are
Flows (kg s1)
assumed to be normally distributed with zero mean and known
FA1 108.7 108.7 107.8 108.2
covariance matrix S (n  n). FA2 26.6 26.6 26.0 26.0
Partially measured processes are solved by decomposing the FA5 24.6 24.6 24.7 24.8
reconciliation problem into two sub-problems. In the first sub- FA8 48.9 48.9 47.0 46.9
FA9 12.3 12.3 12.5 12.5
problem, the measured variables are reconciled, followed by the
FA12 38.1 38.0 39.1 39.0
calculation of the unmeasured variables. Let the variables be clas- FA13 17.6 17.6 17.8 17.8
sified into two sets, measured variables x and unmeasured variables FA17 45.1 45.1 44.8 44.7
FA20 21.7 21.7 22.3 22.3
FA26 37.3 37.3 38.1 38.1
Table 1 FA28 11.3 11.3 11.3 11.3
Exchanger areas and heat transfer coefficients. Temperatures (K)
TA1 305.4 306.7 306.9 308.5
Heat exchanger Area (m2) hoio ðW m2 K1 Þ hoo ðW m2 K1 Þ TA2 464.3 464.7 461.1 467.8
HX1 297.3 641.6 840.4 TA5 522.6 523.2 516.9 526.8
HX2 297.3 749.5 755.2 TA8 370.6 367.3 369.8 367.3
HX3 418.1 283.9 658.7 TA9 537.6 537.6 535.7 535.2
HX4 220.2 369.1 1419.6 TA12 370.6 367.3 370.7 367.3
HX5 891.9 539.4 1470.7 TA13 566.5 566.5 567.8 567.2
HX6 891.9 266.9 391.8 TA17 610.4 610.4 610.6 609.1
HX7 167.2 641.6 721.1 TA20 370.6 367.3 373.4 367.3
HX8 269.4 414.5 670.0 TA26 547.0 547.0 547.4 549.2
HX9 18.6 579.2 709.8 TA28 583.2 583.2 580.6 580.6
332 H. Ijaz et al. / Applied Thermal Engineering 52 (2013) 328e335

Table 3
b ¼ R1
u T b
1 Q1 Ax x (31)
Simulation & DR results of unmeasured variables.

Tag Aspen plus Linear model Estimated

simulation simulation values 3.2. Non-iterative data reconciliation algorithm
Flows (kg s1)
FA3 108.7 108.7 108.2
Sequential simulation algorithm described in Section 2 can be
FA11 48.9 48.9 46.9
FA16 87.0 86.9 85.9
used as a basis for data reconciliation via QR decomposition: (i)
FA30 21.7 21.7 22.3 reconcile flows, (ii) compute F for each exchanger, and (iii)
Temperatures (K) reconcile temperatures.
TA3 336.5 334.4 335.1 Consider mT as the vector of measured flows, mM as the true
TA11 409.5 405.5 406.7
values of the measured flows, and ST as the covariance matrix
TA16 416.9 412.8 413.5
TA22 525.0 523.9 525.6 comprising standard deviations of the nth flow measurement:
TA30 540.6 539.0 538.9 X 
TA31 504.0 502.1 502.5 ¼ diag s21 ; s22 ; .s2n
T

Then the flow measurements can be reconciled by the first sub-

The unmeasured variables u and matrix Au in Eq. (22) are problem
eliminated by a projection matrix, P [3] to solve the reconciliation
problem. This is made possible by pre-multiplying matrix Au with P, Min T 1
mM ðmT  mM Þ ST ðmT  mM Þ
which has the following property
s:t: PM AM mM ¼ 0 (32)
PAu ¼ 0 (23)
where the rows of matrix AM are either þ1,1, or 0, depending on
Thus, the reduced set of constraints involving only measured whether the corresponding stream flow is input, output or,
variables is the following respectively not associated with the process unit for which the flow
balance is written [8]. Similarly, the matrix for the unmeasured
PAx x ¼ 0 (24) variables can be created and the projection matrix determined via
In this method, QR factorization is used for the construction of QR factorization. The solution to Eq. (32) can be calculated by
the projection matrix [8]. Consider the case when the columns of X h i1
the m  p matrix Au are linearly independent. The matrix Au is b M ¼ mT 
m ðPM AM ÞT ðPM AM ÞSM ðPM AM ÞT ðPM AM ÞmT
decomposed as the product of the orthogonal matrix Q (m  m) and M

upper triangular matrix R (m  p). (33)

  and the unmeasured variables can be estimated via
R1
Au ¼ QR ¼ ½ Q1 Q2  (25)
0 b M ¼ R1 T b
u M1 QM1 AM m M (34)
R1 is a nonsingular p  p upper triangular matrix. Q in Eq. (25)
Similar equations apply to reconciliation of temperatures from
can be partitioned into Q1 and Q2 based on the dimensions of R1.
Eqs. (1)e(3) and (9). The procedure is illustrated by Example 2.
Multiplying Eq. (26) with [Q1Q2]T on both sides results in
" # " #   3.2.1. Example 2: non-iterative data reconciliation
Q1T Q1T R Process flow diagram of the heat exchanger network is given in
T Az ¼ T ½Q1 $Q2  1 (26)
Q2 Q2 0 Fig. 5. There are 62 process variables of which only 22 are
measured. The algorithm steps are:
Since Q is an orthogonal matrix, Eq. (26) becomes
" #   1 Reconcile measured flow rates
Q1T R1
T Az ¼ (27)
Q2 0
Fx ¼ ½F1 F2 F5 F8 F12 F13 F17 F20 F26 F28 
Eq. (27) shows that Q2T
is the required projection matrix as its
rows span the null space of ATu [3]: 2 Calculate F for each exchanger. If changes in flows are small,
the then overall heat transfer coefficient need not be updated.
Q2T Au ¼ 0 (28) For large changes in flow, update the overall heat transfer
coefficients.
The reduced data reconciliation problem is to minimize the
3 Calculate and reconcile measured temperatures
objective function in Eq. (22) subject to the constraints, Eq. (24).

Min Tx ¼ ½T1 T2 T5 T8 T12 T13 T17 T20 T26 T28 

x ðy  xÞT S1 ðy  xÞ
s:t: PAx x ¼ 0 (29) Measurement values and reconciled values for the measured
flow rates and temperatures are included in Table 2. Estimated
The reconciled values for x can be obtained by values of the unmeasured variables are shown in Table 3.
X h X i1 Even though this algorithm is not completely rigorous, since it
b
x ¼ y ðPAx ÞT ðPAx Þ ðPAx ÞT ðPAx Þy (30) assumes that reconciliation of temperatures has no impact on
reconciliation of flows, the algorithm produces results that are
The solution bx can be substituted in Eq. (23) to obtain the esti- almost the same as the results from the algorithm that simulta-
b for the variables u.
mates u neously reconciles mass and energy balances.
 H. Ijaz et al. / Applied Thermal Engineering 52 (2013) 328e335 333

Fig. 6. Heat exchanger network adapted from Swartz [9].

3.3. Simultaneous data reconciliation for mass and energy balances process flows. The entire set of mass flows and (energy balance,
and heat transfer coefficients heat transfer) equations was reconciled by QR decomposition.
Reconciled values were then used to compute the new values of the
3.3.1. Example 3: simultaneous DR without change of phase coefficients in the linearized equations and the process was
Here we consider an adaptation of the DR problem presented by repeated until convergence. Even though successive substitution is
Swartz [9] with the process flow sheet shown in Fig. 6. The model used, the algorithm converged in 3 iterations. The measured data
has 16 measured variables, 18 unmeasured variables, and 24 and reconciled values are presented in Table 4. Heat exchanger
constraints, resulting in 6 degrees of freedom. These process cleaning factors when U is updated are presented in Table 5.
constraints include mass and heat balances around the heat
exchangers, splitters, and mixers. 3.3.2. Example 4: simultaneous DR with change of phase
Data reconciliation was carried out with and without updating Consider again the complex HEN process flow sheet given in
the heat transfer coefficients. Heat transfer Eq. (9) was linearized, Fig. 5. One stream is heated by seven streams at various junctions.
including also the linearization of the heat exchanger performance Phase change occurs in the cold fluid at heat exchanger 5 and 6.
factor F since it depends on the flows. Initial values of the coeffi- Now the model has 22 measured variables, 59 unmeasured vari-
cients in the linearized equations were computed from measured ables, and 61 process constraints. Heat exchangers 5 and 6 are
described by equations presented in Section 2.2. The base case,
measured data (generated from Aspen Plus simulations) for inlet
Table 4
Ex. 3-HEN error free, measured, and reconciled values. flows and temperatures of each feed stream, and the resulting
reconciled values can be found in Table 6. Solution was obtained in
Tag Error free data Measured Reconciled Reconciled
5 iterations. Heat transfer rates are shown in Table 7. Note here,
values values values
(U not updated) (U updated) results show that partitioned HX5-B had the largest magnitude of
Flows (kg s1)
error, approximately 6.7%. True areas for heat exchanger 5 and 6
FA1 108.7 108.2 108.2 108.2 were both 891.9 m2. A separate Aspen Plus simulation was per-
FA3 65.2 64.9 64.9 64.9 formed that included partitioned heat exchangers for carrying only
FA6 43.5 43.3 43.3 43.3 liquid phase and both vaporeliquid phase streams. Estimated
FA8 37.3 37.2 37.2 37.2
values of the partitioned heat exchangers and Aspen Plus results
FA11 11.3 11.4 11.4 11.4
FA14 17.6 17.2 17.2 17.2 are shown in Table 8.
Temperatures (K)
TA1 305.4 306.3 306.1 306.1
TA3 343.8 345.0 344.7 344.8
TA4 390.3 390.8 391.5 391.5 Table 5
TA5 413.2 410.0 414.4 414.4 Heat exchanger cleaning factors when U is updated.
TA7 402.2 402.3 401.8 401.6
Heat exchanger Cleaning factor
TA8 547.0 553.0 548.4 548.6
TA11 583.2 585.6 583.8 583.9 HX1 0.998
TA13 566.5 565.3 563.2 563.1 HX2 0.998
TA14 446.5 440.7 443.4 443.7 HX3 0.999
TA15 408.8 411.4 409.4 409.3 HX4 0.996
334 H. Ijaz et al. / Applied Thermal Engineering 52 (2013) 328e335

Table 6 Table 9
Ex. 4-HEN error free, measured, and reconciled values. Optimization results.

Tag Error free data Measured data Reconciled values Tag Model values Aspen plus values
Flows (kg s1) Flows (kg s1)
FA1 108.7 107.8 108.2 FA8 33.2 32.4
FA2 26.6 26.0 26.0 FA12 17.2 17.8
FA5 24.6 24.7 24.8 FA20 57.7 57.8
FA8 48.9 47.0 46.9 Temperatures (K)
FA9 12.3 12.5 12.5 TA31 522.1 524.6
FA12 38.1 39.1 39.0
FA13 17.6 17.8 17.8
FA17 45.1 44.8 44.8
FA20 21.7 22.3 22.3
FA26 37.3 38.1 38.1 5. Conclusion
FA28 11.3 11.3 11.3
Temperatures (K) In this work we have presented a new model for computation of
TA1 305.4 306.9 308.5
heat exchanger network performance. The algorithm enables
TA2 464.3 461.1 467.8
TA5 522.6 516.9 526.9 simulation of network operation and reconciliation of flows and
TA8 370.6 369.8 367.3 temperatures as single pass, non-iterative solution of mass and
TA9 537.6 535.7 535.7 energy balances. Process plants routinely reconcile mass balances
TA12 370.6 370.7 367.3 in order to monitor production. The proposed algorithm introduces
TA13 566.5 567.8 567.8
energy balance reconciliation as an add on step which requires
TA17 610.4 610.6 610.6
TA20 370.6 373.4 367.3 solution of a set of linear equations. Such approach makes data
TA26 547.0 547.4 547.4 reconciliation much easier to implement than the current approach
TA28 583.2 580.6 580.6 of simultaneous reconciliation of mass and nonlinear energy
balances. When applied to optimization or to simultaneous data
reconciliation of flows, temperatures and heat transfer, the network
4. Optimization model converges rapidly via successive substitution in three to five
iterations. Excellent convergence properties make the model suit-
Maximum outlet temperature from the network shown in Fig. 5 able for use in large scale site-wide models that include energy
can be attained by adjusting the flows through the parallel recovery networks.
branches carrying the cold stream. Optimum values of the flows
through the branches have been computed via sequential linear Acknowledgements
programming (SLP) by using linearized form mass and energy
balance equations. Table 9 shows the optimal values of the outlet Support on NSERC Canada and Ontario Centre of Excellence is
temperature and the corresponding flows through the branches. gratefully acknowledged.
SLP converges in 4 iterations. Maximum attainable temperature
TA31 is 522.1 K computed by our model. Computed values of flows Appendix A. Data reconciliation via QR factorization for
are different due to a constant heat transfer coefficient used in the iterative model
Aspen Plus model, while our model updates the coefficient to
account for changes in flow, and physical properties computation is Mass and energy balances (Section 3) can be linearized and used
more accurate in Aspen Plus. to solve data reconciliation problems as

Ax x þ Au u ¼ c (A.1)

Table 7 where all constant terms from the model linearization are
Heat exchanger duties. grouped into a constant vector c with a (p  1) vector of
Heat exchanger Error free data (kW) Estimated values (kW) unmeasured variables u. Ax (m  n), Au (m  p) are the Jacobian
HX1 7396.5 7423.0
matrices containing the partial derivatives of the nonlinear func-
HX2 8648.6 8907.1 tions f with respect to x and u, respectively and (xk,uk) is the
HX3 4742.4 4801.7 solution at the previous iterate.
HX4 5367.3 5504.0

HX5-A 7337.7 7870.6 vf

Ax ¼
vx
xk ;uk
HX5-B 11877.5 11392.3
HX6-A 5210.7 5534.7

HX6-B 1681.0 1684.1 vf

Au ¼
HX7 1179.2 1212.3 vu
xk ;uk
HX8 1283.9 1357.6 
HX9 1089.9 1061.7 c ¼ Ax xk þ Au uk  f xk ; uk

The presence of measurement errors does not allow the balance

equations to be satisfied exactly. Hence, the data reconciliation
Table 8
Heat exchanger areas.
problem must solve the following least-squares problem

Heat exchanger Error free data (m2) Estimated values (m2)  T  

Min
HX5-A 428.3 431.1
b
x x S1 x  b
xb x (A.2)
HX5-B 463.6 466.6
HX6-A 589.9 588.6
HX6-B 301.9 301.2
s:t: Ax x þ Au u ¼ c (A.3)
 H. Ijaz et al. / Applied Thermal Engineering 52 (2013) 328e335 335

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[3] C.M. Crowe, Y.A. Garcia Campos, A. Hrymak, Reconciliation of process
h i1 flow rates by matrix projection, Part. 1: Linear Case, AIChE J. 29 (1983) 881e
X
b
x ¼ x ðPAx Þ ðPAx ÞSðPAx ÞT ðPAx x  PcÞ (A.4) 888.
[4] O.P. Goyal, Speedy analysis of heat-exchange processes by elimination of trial
and error, Chem. Age India 26 (1975) 465e470.
and the solution to the unmeasured variables can be given as [5] W.R. Paterson, A replacement for the logarithmic mean, Chem. Eng. Sci. 39
(1984) 1635e1636.
b ¼ R1
u T 1 b
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