Implementation of a dual extended Kalman filter to a falling film evaporator model to optimize the process

• Published in: Chemical engineering science Vol. 298; p. 120303
• Main Authors: Canela-Sánchez, I.J., Escobar-Jiménez, R.F., Juárez-Romero, D.
• Format: Journal Article
• Language: English
• Published: Elsevier Ltd 05.10.2024
• Subjects: Falling film evaporator; Heat transfer; Kalman filter; Optimal Reynold number; Process optimization; Process optimization; Optimal Reynold number; Kalman filter; Falling film evaporator; Heat transfer
• ISSN: 0009-2509
• DOI: 10.1016/j.ces.2024.120303

The performance of falling film evaporators depends on a parameter called film breakdown onset Reynolds number. This parameter defines the Reynold number at which the complete wetting is reached. However, this parameter is difficult to measure. Therefore, in the present work, a dual extended Kalman filter (DEKF) is used to estimate the states and the film breakdown onset Reynolds number of a helical falling film evaporator. Subsequently, optimizations are performed based on the estimated parameter. The results show that the optimal mass flow rate is higher than the mass flow rate at the film breakdown onset Reynolds number, and the improvement of the heat transfer rate ranges from 14.90% to 23.91%. Finally, the results of a simulation at optimal mass flow rate show that the heat transfer rate is maximum at tube 11, it increases from tubes 1 to 11 and decreases from tube 11 to 13. •Outlet evaporator temperature and film breakdown onset Reynolds number estimation.•Dual Extended Kalman Filter implementation in 13 evaporator tubes.•Evaporator optimization based on the film breakdown onset Reynolds number.•Optimal Reynolds number to maximize the heat transfer rate in falling film evaporator.•Heat transfer behavior per tube at optimal condition.