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CCB3013 - Chemical Process Dynamics, Instrumentation & Control
1
5/20/2014
Introduction to
Chemical Process Dynamics,
Instrumentation & Control
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CCB3013 - Chemical Process Dynamics, Instrumentation & Control
2
5/20/2014
Chapter Objectives
End of this chapter, you should be able to:
1. Understand the role of process dynamics and
control in industry
2. Understand general concepts
3. Classify variables
4. Understand the purpose of process control
5. Understand control aspects of complete
chemical plant
6. Understand hardware for process control system
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CCB3013 - Chemical Process Dynamics, Instrumentation & Control
3
5/20/2014
Role of process dynamics and control
in industry
Illustration with examples
Example 1 a simple process where
dynamic response is important

Example 2 use of a single feedback
controller

Example 3 simple but typical chemical
engineering plant

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CCB3013 - Chemical Process Dynamics, Instrumentation & Control
4
5/20/2014
Example 1 A gravity-flow tank
Under steady state conditions,
the flow rate out of the tank
must equal the flow rate into
the tank.

What would happen dynamically
if we changed F
o
?

How will h(t) and F(t) vary
will time?


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CCB3013 - Chemical Process Dynamics, Instrumentation & Control
5
5/20/2014
Example 2 Heat Exchanger







We want to control the temperature of oil leaving the
heat exchanger.
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CCB3013 - Chemical Process Dynamics, Instrumentation & Control
6
5/20/2014
How to control?
A thermocouple is inserted in a thermowell in
the exit oil pipe.

Thermocouple wires are connected to a
temperature transmitter that converts the
millivolt output into a 4- to 20 mA signal.

This signal sent to a temperature controller.

The temperature controller opens the steam
valve if more steam is needed or closes it a
little if the temperature is too high.
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CCB3013 - Chemical Process Dynamics, Instrumentation & Control
7
5/20/2014
Components of control loop
A sensor
A transmitter
A controller
A final control element

Process control deal with:
What type of controller to be used?
How it should be tuned?
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CCB3013 - Chemical Process Dynamics, Instrumentation & Control
8
5/20/2014
Example 3 - A typical chemical plant
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CCB3013 - Chemical Process Dynamics, Instrumentation & Control
9
5/20/2014
Concepts of Process Control
Another simple
example:
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CCB3013 - Chemical Process Dynamics, Instrumentation & Control
10
5/20/2014
Block diagram
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CCB3013 - Chemical Process Dynamics, Instrumentation & Control
11
5/20/2014
Need for control
Performance requirements for process plants have become
increasingly difficult to satisfy.

Key factors for tightening product quality specifications:
Stronger competition
Rapidly changing economic conditions
Tough environmental and safety regulations
Modern plants are complex and highly integrated
It is difficult to prevent disturbances from propagating from one
unit to other interconnected units.

Process control has become increasingly important due to
increased importance on safe and efficient plant operation.
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CCB3013 - Chemical Process Dynamics, Instrumentation & Control
12
5/20/2014
- The term process dynamics refer to unsteady
state (or transient) behavior.

- Dynamic studies provide us the behavior of
the process under unsteady-state conditions

Gain knowledge about the process
behavior.
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CCB3013 - Chemical Process Dynamics, Instrumentation & Control
13
5/20/2014
Objectives of Process Control
Maintain a process at the desired operating
conditions, safely and efficiently
Satisfy product quality and environmental
requirements

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CCB3013 - Chemical Process Dynamics, Instrumentation & Control
14
5/20/2014
Process control applications
Large-scale integrated processing plants such
as oil refineries or ethylene plants require
thousands of process variables such as
temperature, pressure, flow, level and
compositions are measured and controlled.

Large number of process variables, mainly flow
rates, can be manipulated.

Feedback control systems compare
measurements with their desired values and
then adjust the manipulated variables
accordingly.
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CCB3013 - Chemical Process Dynamics, Instrumentation & Control
15
5/20/2014
Representative process control problems
Foundation of process control is process
understanding.

What is a process?

The conversion of feed materials to useful products
using chemical and physical operations
PROCESS.

Common processes can be continuous, batch or
semi-batch.
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CCB3013 - Chemical Process Dynamics, Instrumentation & Control
16
5/20/2014
Continuous Processes
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CCB3013 - Chemical Process Dynamics, Instrumentation & Control
17
5/20/2014
Tubular Heat Exchanger
Control problem: The exit temperature of the
process fluid is controlled by manipulating the
cooling water flow rate.
Disturbances: Variations in the inlet temperatures
and process fluid flow rate.

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CCB3013 - Chemical Process Dynamics, Instrumentation & Control
18
5/20/2014
Continuous stirred tank reactor
(CSTR)
Control problem: If the reaction is highly exothermic, it is
necessary to control the reactor temperature by
manipulating the flow rate of the coolant in a jacket or
cooling coil.
Disturbances: The feed conditions (composition, flow
rate, and temperature).
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CCB3013 - Chemical Process Dynamics, Instrumentation & Control
19
5/20/2014
Thermal cracking furnace
Control Problem: The furnace
temperature and amount of excess
air in the flue gas to be controlled by
manipulating the fuel flow rate and
the fuel/air ratio.
Disturbances: The crude oil
composition and the heating quality
of the fuel.
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CCB3013 - Chemical Process Dynamics, Instrumentation & Control
20
5/20/2014
Multi-component distillation column
Control Problem: Distillate
composition can be controlled
by adjusting the reflux flow rate
or the distillate flow rate.
Disturbances: The feed
conditions
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CCB3013 - Chemical Process Dynamics, Instrumentation & Control
21
5/20/2014
Process variables
Three important types: (Control Terminology)
1. Controlled variables - these are the variables which
quantify the performance or quality of the final
product, which are also called output variables.
2. Manipulated variables - these input variables are
adjusted dynamically to keep the controlled
variables at their set-points.
3. Disturbance variables - these are also called "load"
variables and represent input variables that can
cause the controlled variables to deviate from their
respective set points.

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CCB3013 - Chemical Process Dynamics, Instrumentation & Control
22
5/20/2014
Process variables
Specification of controlled variables,
manipulated variables and disturbance
variables is a critical step in developing a
control system
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CCB3013 - Chemical Process Dynamics, Instrumentation & Control
23
5/20/2014
Batch and semi-batch processes
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CCB3013 - Chemical Process Dynamics, Instrumentation & Control
24
5/20/2014
Control problems
Batch or semi-batch reactor: The reactor temperature
is controlled by manipulating a coolant flow rate.
Batch digester: The end point of the chemical reaction
is indicated by Kappa number, a measure of lignin
content. It is controlled to a desired value by adjusting
the digester temperature, pressure, and/or cycle time.
Plasma etcher: The unwanted material on a layer of a
microelectronics circuit is selectively removed by
chemical reactions. The temperature, pressure and
flow rates of etching gases to the reactor are
controlled by adjusting electrical heaters and control
valves.
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CCB3013 - Chemical Process Dynamics, Instrumentation & Control
25
5/20/2014
Control problems
Kidney dialysis unit: The blood flow rate is
maintained by a pump, and ambient
conditions, such as temperature of the unit,
are controlled by adjusting a flow rate.

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CCB3013 - Chemical Process Dynamics, Instrumentation & Control
26
5/20/2014
Control Terminology(2)
set-point change - implementing a change in the
operating conditions. The set-point signal is changed
and the manipulated variable is adjusted appropriately
to achieve the new operating conditions.
Also called servomechanism (or "servo") control.
disturbance change - the process transient behavior
when a disturbance enters, also called regulatory
control or load change.
A control system should be able to return each
controlled variable back to its set-point.
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CCB3013 - Chemical Process Dynamics, Instrumentation & Control
27
5/20/2014
Illustrative Example:
Blending system
Notation:
w
1
, w
2
and w are mass
flow rates
x
1
, x
2
and x are mass
fractions of component A
Assumptions:
w
1
is constant
x
2
= const. = 1 (stream 2 is pure A
Perfect mixing in the tank
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CCB3013 - Chemical Process Dynamics, Instrumentation & Control
28
5/20/2014
Blending system
Control Objective:
Keep x at a desired value (or set point) x
sp
, despite
variations in x
1
(t). Flow rate w
2
can be adjusted for this
purpose.
Terminology:
Controlled variable (or output variable): x
Manipulated variable (or input variable): w
2

Disturbance variable (or load variable): x
1
Design Question
What value of is required to have ?
sp
x x =
2
w
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CCB3013 - Chemical Process Dynamics, Instrumentation & Control
29
5/20/2014
Overall balance:


Component A balance:


(The overbars denote nominal steady-state design values)
At the design conditions, .
Substitute in Eq.1-2, and , then solve Eq. 1-2
for :

Equation 1-3 is the design equation for the blending
system.
sp
x x =
sp
x x =
1 2
0 (1-1) w w w = +
1 1 2 2
0 (1-2) w x w x wx + =
1
2
= x
2
w
1
2 1
(1-3)
1
SP
SP
x x
w w
x

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CCB3013 - Chemical Process Dynamics, Instrumentation & Control
30
5/20/2014
If our assumptions are correct, then this value of will
keep at .
But what if conditions change?

Control Question. Suppose that the inlet concentration
x
1
changes with time. How can we ensure that x remains at
or near the set point ?

As a specific example, if and , then x > x
SP
.

2
w
x
sp
x
sp
x
1 1
x x >
2 2
w w =
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CCB3013 - Chemical Process Dynamics, Instrumentation & Control
31
5/20/2014
Some Possible Control Strategies
Method 1. Measure x and adjust w
2
.
Intuitively, if x is too high, we should reduce w
2
;
Manual control vs. automatic control
Proportional feedback control law


K
c
is called the controller gain
w
2
(t) and x(t) denote variables that change with time t
The change in the flow rate, is proportional to
the deviation from the set point, x
SP
x(t).
( ) ( )
2 2
(1-4)
c SP
w t w K x x t ( = +

( )
2 2
, w t w
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CCB3013 - Chemical Process Dynamics, Instrumentation & Control
32
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Control Method 1
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CCB3013 - Chemical Process Dynamics, Instrumentation & Control
33
5/20/2014
Method 2
Measure x
1
and adjust w
2

Thus, if x
1
is greater than , we would decrease w
2

so that .
One approach: Consider Eq. (1-3) and replace and
with x
1
(t) and w
2
(t) to get a control law:


Because Eq. (1-3) applies only at steady state, it is not
clear how effective the control law in (1-5) will be for
transient conditions.
1
x
2 2
w w <
1
x
2
w
( )
( )
1
2 1
(1-5)
1
SP
SP
x x t
w t w
x

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CCB3013 - Chemical Process Dynamics, Instrumentation & Control
34
5/20/2014
Control Method 2
Method 3. Measure x
1
and x, adjust w
2
.
This approach is a combination of Methods 1
and 2.
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CCB3013 - Chemical Process Dynamics, Instrumentation & Control
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Control Method 4
Use a larger tank.
If a larger tank is used, fluctuations in x
1
will
tend to be damped out due to the larger
capacitance of the tank contents.
However, a larger tank means an increased
capital cost.

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CCB3013 - Chemical Process Dynamics, Instrumentation & Control
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Classification of Control Strategies
Table. 1.1 Control Strategies for the Blending
System

1

x w
2

FB

2

x
1
w
2


FF

3

x
1
and x

w
2


FF/FB


Method

Measured
Variable

Manipulated
Variable


Category

4

-

-

Design
change

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CCB3013 - Chemical Process Dynamics, Instrumentation & Control
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Feedback Control
Distinguishing feature: measure the controlled
variable.
It is important to make a distinction between
negative feedback and positive feedback.
Engineering Usage vs. Social Sciences
Advantages:
Corrective action is taken regardless of the
source of the disturbances.
Reduces sensitivity of the controlled variable
to disturbances and changes in the process.
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CCB3013 - Chemical Process Dynamics, Instrumentation & Control
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Feedback Control
Disadvantages:
No corrective action occurs until after the
disturbance has upset the process, that is,
until after x differs from x
sp
.

Very oscillatory responses, or even
instability
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CCB3013 - Chemical Process Dynamics, Instrumentation & Control
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5/20/2014
Feedforward Control
Distinguishing feature:
measure a disturbance variable
Advantage:
Correct for disturbance before it upsets
the process.
Disadvantage:
Must be able to measure the
disturbance
No corrective action for unmeasured
disturbances
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CCB3013 - Chemical Process Dynamics, Instrumentation & Control
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Justification of Process Control
Specific Objectives of Control
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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CCB3013 - Chemical Process Dynamics, Instrumentation & Control
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Economic Incentives - Advanced
Control
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CCB3013 - Chemical Process Dynamics, Instrumentation & Control
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Hierarchy of process control activities
1. Measurement
and Actuation
2. Safety, Envi ronment
and Equi pment
Protecti on
3a. Regul atory
Control
4. Real-Time
Opti mizati on
5. Pl anning and
Scheduli ng
Proces s
3b. Multi vari able
and Cons trai nt
Control
(days-months)
(< 1 second)
(< 1 second)
(seconds-minutes)
(minutes-hours)
(hours-day s)
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CCB3013 - Chemical Process Dynamics, Instrumentation & Control
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Major steps in control system development
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CCB3013 - Chemical Process Dynamics, Instrumentation & Control
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Conclusions
You have been introduced to:
1. the role of process dynamics and control in
industry
2. general concepts of process control
3. classification of variables
4. the purpose of process control
5. control aspects of complete chemical plant
6. hardware for process control system