Presented by:

Dr. Chua Bee Lin

 Dr. Chua Bee Lin

Office: D9B.11
Ext. No: 5424
Email: beelin.chua@taylors.edu.my
1) Why process control
2) Why process modelling
3) Examples
4) What can engineers do
5) Process variables
6) Illustrative Example Stirred-tank blending system
7) Feedback control
8) Justification of Process Control

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 1. Product Quality
Lecture 1

2. Production Rate
3. Safety
4. Environmental protection
5. Economics
6. Equipment protection
7. Monitoring/Diagnosis
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 Introduction to Process Control
 Objective of process control-maintain a process
at the desired operating conditions, safely and
efficiently, while satisfying environmental and
product quality requirements.
Lecture 1

 Representative process control problems:

Process- The conversion of feed materials to
products using chemical and physical operations.
 3 types of common process:
1. Continuous
2. Batch
3. semibatch

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 Process variables
Controlled variables:
The process variables that are controlled. The desired value of a
controlled variables is referred to as its set point. The controlled
variables are also called output variables.
Manipulated variables:
The process variables that can be adjusted in order to keep the
controlled variables at or near their set points. Normally, the
manipulated variables are flow rates
Disturbance variables:
The process variables that affect the controlled variables but can
not be manipulated. these are also called "load" variables and
represent input variables. 6
 1. Continuous Processes
a) Tubular heat exchanger
-Process fluid is cooled by cooling water
-Controlled variable exit temperature of the
process fluid
- Manipulated variable cooling water flow rate
Lecture 1

-Disturbance variable inlet temperatures and

process fluid flow rate
b)Continuous stirred-tank reactor
(CSTR)
-exothermic reaction-need to control reactor
temperature
-Controlled variable -reactor temperature
- Manipulated variable flow rate of coolant
- Disturbance Feed conditions (composition, flow
rate, temperature)
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 c) Thermal cracking furnace
-Crude oil is broken down into petroleum
fractions by the heat transferred from a
burning fuel+air
- Controlled variable-furnace temperature
- Manipulated variable fuel flow rate and
fuel/air ratio
- Disturbance variable -crude oil
composition, heating quality of the fuel
d) Multicomponent distillation column
Controlled variable -distillate composition
Manipulated variable -flow rate
Disturbance variable feed condition
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 2. Batch and Semi-Batch
Processes
a) Batch and semi-batch reactor
-reactions are allowed to proceed for a specified
time or until a specified conversion is obtained.
Lecture 1

-used in chemical plants, bioprocess (glucose is

fed to a yeast or protein.)
- Controlled variable -reactor temperature
- Manipulated variable coolant flow rate

b) Batch digester in a pulp mill

-digester is used in paper manufacturing to break
down wood chips to extract cellulosic fibers.
- Controlled variable -lignin content
- Manipulated variable temperature and pressure of
digester
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 c) Kidney dialysis unit
-medical equipment used to remove waste
products from blood
-blood flow rate is maintained by a pump.
- Controlled variable-temperature in the
Lecture 1

unit
- Manipulated variable flow rate

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 Major steps in designing and
installing a control system
1. Formulation of control objectives- based on the
objectives for the plants and process constraints
 Example- control the temperature of the tank,
Lecture 1

minimize energy consumption

 Constraints (upper and lower limit on mv)
2. A dynamic model of process is develop
 Theoretical based (physical and chemical
principles- conservation laws, rate of reaction)
 Empirical model- experimental data
3. Devise an appropriate control strategy

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  Meet the control objectives while satisfying
process constraints.
 Based on process understanding and
experiences
 Computer simulation is used to screen
alternative control strategies and to estimate
Lecture 1

the controller settings.

4. Select the control system hardware and
instrumentation
5. Adjust controller setting
 Use the preliminary estimates from the design
as a starting point.
 Trial and error procedures.

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Lecture 1

http://www.shiningstuff.com

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Lecture 1

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http://www.controlguru.com
A simple heating system
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 The control systems appear to have three basic elements
Desired value

controller

Final element Sensor

Process
Inputs Outputs

CONTROL : To maintain desired conditions in a physical system by adjusting

selected variables in the system.
FEEDBACK CONTROL makes use of an output of a system to influence an input
to the same system.
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  Process Design
Lecture 1

 Measurement

 Final Elements

 Control Structure (algorithm)

 Control Calculations
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 Laplace transforms: Introduction
to the Laplace Transformation
Lecture 1

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 General Modelling Principles
 The model equations are at best an approximation to the
real process.
 Modelling inherently involves a compromise between
Lecture 2

model accuracy and complexity on one hand, and the cost

and effort required to develop the model, on the other hand.
 Process modelling is both an art and a science. Creativity is
required to make simplifying assumptions that result in an
appropriate model.
 Dynamic models of chemical processes consist of ordinary
differential equations (ODE) and/or partial differential
equations (PDE), plus related algebraic equations.

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Models can be classified based on how they are
obtained:

• Theoretical models: are developed using the

principles of chemistry, physics and biology
• Empirical models: are obtained by fitting
experimental data
• Semi-empirical models: are a combination of
theoretical model and empirical models.

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 Uses of Mathematical Modelling

 To improve understanding of the process

Lecture 2

 To train operating process

 To develop a control strategy for a new the process
 To optimize process design/operating conditions
 A Systematic Procedure for Developing
Dynamic Models
1. State the modelling objectives and the end use of the model.
They determine the required levels of model detail and model
accuracy.
2. Draw a schematic diagram of the process and label all process
Lecture 2

variables.
3. List all of the assumptions that are involved in developing the
model. Try for parsimony; the model should be no more
complicated than necessary to meet the modelling objectives.
4. Determine whether spatial variations of process variables are
important. If so, a partial differential equation model will be
required.
5. Write appropriate conservation equations (mass, component,
energy, and so forth).
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 A Systematic Approach for Developing
Dynamic Models (cont.)
6. Introduce equilibrium relations and other algebraic equations
(from thermodynamics, transport phenomena, chemical
kinetics, equipment geometry, etc.).
7. Perform a degrees of freedom analysis to ensure that the model
Lecture 2

equations can be solved.

8. Simplify the model. It is often possible to arrange the equations
so that the dependent variables (outputs) appear on the left side
and the independent variables (inputs) appear on the right side.
This model form is convenient for computer simulation and
subsequent analysis.
9. Classify inputs as disturbance variables or as manipulated
variables.

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 Modelling Approaches

 Physical/chemical (fundamental, global)

 Model structure by theoretical analysis
 Material/energy balances
Lecture 2

 Heat, mass, and momentum transfer

 Thermodynamics, chemical kinetics
 Physical property relationships
 Model complexity must be determined (assumptions)
 Can be computationally expensive (not real-time)
• May be expensive/time-consuming to obtain
 Good for extrapolation, scale-up
 Does not require experimental data to obtain (data
required for validation and fitting)

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 Conservation Laws

Conservation of Mass
 rate of mass  rate of mass  rate of mass 
Lecture 2

    (2-6)

accumulation   in   out 

Conservation of Component i
rate of component i  rate of component i 
  
 accumulation   in 

rate of component i  rate of component i 

   (2-7)
 out   produced  25
 Conservation of Energy:Stirred-Tank
Heating Process
(constant holdup)
Lecture 2

dT
V C  wC Ti  T   Q (2-36)
dt
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Assumptions:

1. Perfect mixing; thus, the exit temperature T is also the

temperature of the tank contents.
2. The liquid holdup V is constant because the inlet and outlet
flow rates are equal.
3. The density  and heat capacity C of the liquid are assumed to
be constant. Thus, their temperature dependence is neglected.
4. Heat losses are negligible.
 Example 1: Process Dynamics –
A Chemical Mixing Scenario
 chemical mixing example:

• Two process streams are mixed to produce one feed to reactor.

• After mixing, the blended stream (stream) is fed to a heating vessel before
being sent to reactor.
• The process is running at steady state
 Concentration of A in Volumetric flowrate of A in
Stream 1 = 1 g/L Stream 1 = 10 L/min
Stream 2 = 4 g/L Stream 2 = 20L /min

Scenario:
At 3pm, shift changes at the plant
new operator misread the flowmeters and he
Lecture 1

switches the flow rates of the 2 streams

Volumetric flowrate of A in
Stream 1 = 20 L/min
Stream 2 = 10 L g/min

At 3.30pm, shift supervisor run to the control

room to find out the source of the problem of the
reactor.

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  What happened to the exit concentration (Ca)
from the heating vessel over the past 30 min?
Lecture 1

20 L/min

10 L/min

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• model the mixing tee and the blending tank
• using an unsteady-state mass balance
• Reasons- shift change and the error made by
the operator.
• Balance of component A: (g/min)

v=volumetric flow rate= L/min

Ca=concentration of a =g/L
V x Ca = L/min x g/L
=g/min (Rate of A)
 20 L/min

10 L/min

• Before the change:

• After the change:

• So, the net change is feed concentration to the heating

vessel is decreased from 3 to 2 g/L.
• To analyze how the exit concentration from the heating vessel (Ca) varies
with time, we perform an unsteady state mass balance on component A

Ca3
• The volumetric flow rate v is constant into and out of the heating
vessel at v3. Thus the volume of the fluid in the tank V is constant.
𝑉 𝑑𝐶𝑎
• Rearrange the equation + 𝐶𝑎 = 𝐶𝑎3
𝑣3 𝑑𝑡

𝜏
• The coefficient of the derivative term is the residence time of the
heating vessel τ, which in this process is 5 min.

• Rearrange and solve this equation:

 A plot of the exit concentration from the heating vessel is shown

Ca

Modelling the mixing process enables us to determine the

concentration of component A in the stream (1,2,3) being fed
Lecture 1

The control objective is to blend the two

inlet streams to produce an outlet stream
that has desired composition.

Notation:
• w1, w2 and w are mass flow rates
• x1, x2 and x are mass fractions of component A
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 Assumptions:
1. w1 is constant (stream 1)
2. x2 = constant = 1 (stream 2 is pure A)
3. Perfect mixing in the tank
Lecture 1

Control Objective:
Keep x at a desired value (or “set point”) xsp, Flow rate w2 can be
adjusted for this purpose.

Terminology:
• Controlled variable :x
• Manipulated variable :w2
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• Disturbance variable : x1
Lecture 1

Control Question. Suppose that the inlet concentration x1

changes with time. How can we ensure that x remains at or near
the set point xSP ?
As a specific example, assume that x1 increases to a constant
value that is higher than its nominal value (x1  x1) andw2  w2 ,
then x > xSP.

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 Method 1. Measure x and adjust w2.
• For example, if x is too high, we should reduce w2;
• Manual control vs. automatic control
Lecture 1

• This method can be implemented as feedback control law

 Method 2. Measure x1 and adjust w2.

• Thus, if x1 is greater than x1, we would decrease w2 so that

w2  w2 ;

Feed forward Control:

Lecture 1

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 Method 3. Measure x1 and x, adjust w2.
• This approach is a combination of Methods 1 and 2.
Lecture 1

Method 4. Use a larger tank.

• If a larger tank is used, fluctuations in x1 will tend to be damped
out due to the larger capacitance of the tank contents.
• However, using a larger tank is an expensive solution due to the
increased capital cost.

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 Table. 1.1 Control Strategies for the Blending System
Method Measured Manipulated Category
Lecture 1

Variable Variable
1 x w2 FB
2 x1 w2 FF
3 x1 and x w2 FF/FB
4 - - Design change

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 • Distinguishing feature: controlled variable is measured
and disturbance variable is not measured
• Advantages:
 Corrective action is taken regardless of the source of the disturbance.
Lecture 1

 Reduces sensitivity of the controlled variable to disturbances and

changes in the process.
• Disadvantages:
 No corrective action occurs until after the disturbance has upset the
process, that is, until after x differs from xsp.
 Very oscillatory responses, or even instability…
 Slower-acting control
– disturbance works through process before its effects are detected
(reactive control)
Hence, perfect control is not achievable
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 Negative feedback Positive feedback
Desirable situation where The controller makes
the corrective action things worse by forcing
taken by the controller the controlled variable
Lecture 1

forces the controlled farther away from the

variable towards the set set point.
point.

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 Distinguishing feature: disturbance variable is measured
and controlled variable is not measured
• Advantage:
 Corrective action is taken before the controlled variable
Lecture 1

deviates from set point

• Disadvantage:
 Must be able to measure the disturbance.
 No corrective action for unmeasured disturbances.
 Fast
– acts before the disturbance has affected the process (anticipatory)
– Theoretically perfect control
– But need to know process dynamics and measure all disturbances
– It is applied to deal with major disturbances
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 Specific Objectives of Control
Lecture 1

• Increased product throughput

• Increased yield of higher valued products
• Decreased energy consumption
• Decreased pollution
• Decreased off-spec product
• Increased Safety
• Extended life of equipment
• Improved Operability
• Decreased production labor

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Lecture 1

 “Process control” Marlin Chapter 1

 “Process Dynamics and control” Seborg Chapter 1

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 Lecture 1

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