PRENTICE HALL INTERNATIONAL SERIES [IVTHEPHTYSICAL AND CHEMICAL ENGINEERING SCIENCES. [NEALE AMADBON S ERUSEDITOR, Unni f Howton powsonv Bors ‘A ACO. Sid Unter ove Dai ner of ists [BALaWstR § AMIEL ANDELIASEN Chemical Engineering Thrmodyamics Rgueree Proves: Danis Bisoure Grose, AND ESTERNIRG Stomtic Method of Chemical Proces Desi {Grow AND LOWAR “Chemical Proves Safer. {Gorn nm Stactao Proton Sing in Chonicl Engineering wih Numerical Methods De Proce Flat Mechanics tt ANDLitaInructory Chemical Eaginering Thermals Foun Element of Chemical Reaction Engineering 3nd Ein Hasaa as Sasbatt Computational Methods in Chemical Engineering Hse Base Principe andCalalon bx Chemical gineering. 6h edon Hes ax Manoox Mas Transfer KVte Choma and Process Thermadmamics, 3d eon Nekitan Elecrocheical Sito, 2 edition Pravstra Licimisialth SD DE AZEVEDO Molecular Thermadyamis of Fu Phase Eula rd elton xinnict. Elerochemcal Engineering Principles SHiREKAND Kant Boprovet Engineering StenuasoroUtas | Chemical Paces Control TESTER AND MODELL. Themes and x Aplicaons, 3d eiton “TunTON BH AL W HETNG AKO SHAEIVETZ Anais Sythe Design| of Chemical roceses WAKES Hid Mochancr for Chemical Engnering Chemical Process Control An Introduction to Theory and Practice (GEORGE STEPHANOPOULOS, Department of Chemical Engineering Massachusetts Instiute of Technology pero CII, New Jersey 07632 =z PT R PRENTICE HALL,Contents Preface xvii Part The Control of a Chemical Process Its Characteristics and Associated Problems 1 1. Incentives for Chemical Process Control. 2 1A Suppress he tance of Eterna Disturbances 12 Ensure the Sub af «Process 7 153 Optimize me Petormance oa Chemica Process 10 2. Design Aspects of a Process Control System 12 211 Cusiistion of the Varnes in Chemical Process 12 3. Hardware for a Process Control System 28 1 HMandware Elements of Consol System 28 32 Use Diptal Computers in Process Comal 30CConcding Remarks on Part 33 Thing to Think Aout for Par 39 Reference for Part 38 ‘Proemsfr Part 3 Part II Modeling the Dynamic and Static Behavior of Chemical Processes 43 4. Development of a Mathematical Model 45 “41. Why Do We Need Mathematical Moding fr Proves Comol? 40 442 Shae Variables and Ste Equations for a Chemical, Procert 43. Additonal Blme 4 Dendtime 43 Aadhonal Examples of Mathemasce Modeling 59 446 Modeling Diffeuues 74 “Things to Think About 78 ofthe Mathematical Models 55 5. Modeling Considerations for Control Purposes 80 41 The Input-Output Model 81 52 Depre ofPrestom 86 53 Degrees of Freedom and Process Controllers 89 54 Formulating tbe Scope of Moding for Procees, Control 98 ‘Things to Think About 97 References for Par 98 Problems for Port 11100, Part I Analysis of the Dynamic Behavior of Chemical Processes 111 6. Computer Simulation and the Linearization of Nonlinear Systems 113 1 Computer Simulation of Process Dynamics 1h 162 Linearization oSstams wits One Varable 16 63 Deviation Variables 119 (64 Gnearanton of Stems wih Many Variables 127 ‘Things to Tank About 126 7. Laplace Transforms 128 LL Definition ofthe tapice Tansorm 128 12 Laplace Transfrms of Some Base Functions 20 15 Laplace Travafrms of Denvaties 13? 114 Laplace Tassforms of Irae 129 115 Fina ale Theorem 4 14 Int value Toeorem 14) Things to Think About 14! 8 Solution of Linear Differential Equations Using Laplace Transforms 143 1A Characterinic Example and the Soation 12 Inversion of Laplace Transforms Heaviside Expansion 148 1.3. Examples onthe Solston of Linear ifeentil ‘Equvons Using Laplace Tnsforms 182 ‘Things fo Think About 157 9. Transfer Functions and the Input-Output Models 159 91, Transer Function ofa Proces with Single Ouipat 159 92 Trane Function Matsa af Doses with Male Opus 158 93 Poles and Zeon of Taner Function 167 95 Qualitive Anais ofthe Respome ofa Sytem 8 ‘Things to Think Abot 172 10. Dynamic Behavior of First-Order Systems 173 104. What tea Fistonter Sytem? 173 102 Prose Modeled as First-Order Sytem 174 103 Dynamic Response ofa Pure Capacitive Proves 178 104 Dynami Response ofa Frnt. Ordr Lae Sytem 179 113 rst Oraer Sytem with Varabe Time Consan and ‘Things to Tink About 1861", 2. 18. 14 Dynamic Behavior of Second-Order Systems 186 LLL Wat Isa Second Onde System? 186 2 Bynamie Response ofa Second Order System 187 113 Matcapcy Process s Second Orde Systems 183 11 neremly Secon. Order Processes 207 HSS Steond Order ystems Caused by the Presence of Coates 201 ‘Things to Tink About 204 ‘open Examples of Pays! Systems with TaperentSecoudOrder Dynamics. 205 Dynamic Behavior of Higher-Order Systems 212 121 Capi in Series 22, 122 Dynamic Syuens ith Dead Time 214 5 Dynamic Sues wth vere Response 216 ‘Pingo Tink About 220 Refrnce for Patt 220 Problems or Po Ill 223 Part IV Analysis and Design of FeedBack Control Systems 239 Introduction to Feedback Control 241 15.1 Concept of Feedback Control 241 153 Sype ot Feedback Controllers 248 1553 Measuring Devices (Sensor) 208 {4 Tanumiton Lines 259 1355 Final Cone Elements 253 ‘Things oTaak about 256 ‘Dynamic Behavior of Feedback-Controlled Processes 258 141 Block Digram ae the Closed-Loop Response 258 [42 et of Proportional Conta on the Response of CContlled Prost 268, 16. 1. 18, 14.3 Ee of otal Control Action 273 1 fe of Deseative Control Actos 276 15 Ee of Composite Conel Actions 277 ‘Things oT About 279 ‘Stability Analysis of Feedback Systems 287 15.4 Notion ofSubity 257 152 The Characersic Equation 285 153 Routi-Hurwis Ceterion or Stability 287 1544 Rootes Anais 290 “Things to The About 295 Design of Feedback Controllers 297 161 Outline ofthe Design Problems 297 162 Simple Pectormance Crtena 290 163 Timea! Peformance Critea. 302 164 Stet he Type of Fedhack Conia" 106 5 Contoterosing 10 ‘hing fo Think About 6 Frequency Response Analysis of Linear Processes 317 1A Repos of Fst Or Seo Sn 172 Frequency Resonte Characteristics of Gener Linear System 27 173 Bode Digrams 126 174 Nyguie Pte 28 Things toTink About 347 Design of Feedback Control Systems Using Frequency Response Techniques 344 111 Bode Sabilty Catenion 44 162 Grin and Phase Maris 309 183 Zielr-Nichols Tuning Technique 35219. 2 22. 184 Nyquist Siability Criterion 335 Part VI Design of Control Systems for Multivariable ‘Things to Think About 488 Processes: Introduction to Plant References for Part 1V- 360 Control 459 ‘rolems for art S88 23. Synthesis of Alternative Control Configurations Part V Analysis and Design of Advanced Control for Multple-¢nput, Muttile-Output Systeme 381 Processes 467 Feedback Control of Systems with Large Dead 431 Doptsel Paton snd he Numer of Conoled an ee 223 Generation of Alerntive Lop Contos, 467 194 Process with are Dead Tine 383 334 nemesis Sycen an inensang Une 469 192 Deadtime Componation ‘ington bur a2 193 ContolofStame wih Inveme Response 390 ‘Tings to Think About 399 24. int Decou Control Systems with Mutiple Loops 994 belo DatcN ere tek Keheadet Loops 486 201 CaxadeContoh 393 M2 Sehctve Conte Systems 402 241 Interaction of Cont Loops 487 Re ene coanel 242 Reintve Gun array and te Section of Loops 404 ‘hiner to Tink About 409 243 Design of Nonieracting Comte! Loops 8 ‘Things to Thnk out 08 Feedforward and Ratio Control. 477 214, Log ot eres Cona_ 41 25, Design of Control Systems for Complete 213 Pr o Despning Festa Conve 404 = 21.3 Practical Aspects on the Design of Feedforward Plants 510 Couete 0 a 251 Proce Design and Poets Contl_ $10 244 Reward Feathc Cont 423 252 Hyun of Tene Pa to rode ere: |ACise Sud) 16. ‘Things toThnk About 429 253 Material Balince Conta forthe Hydrodeailation Plot si9 ‘Adaptive and Inferential Control Systems 431 254 Pradoct Quality Control for he Hydrodetylation Plot S24 ive Cool 431 283 Some Comment onthe Contl Design for Complete rental Contol 438 Phas 339 Things fo Tink About 443 Things 10 Tink About 534 References for oY 406 Rofrnce fr Pat VI_837 Protons fr nV. 407 Protons for Port V1" 340,26. 28. 29. 30. Part VI Process Control Using Digital Computers 549 Digital Computer Control Loops 551 21 3 ‘The Digi Computer_352 Compter-ProcesInterfefor Data Acquison and Contol 33? {Computer Control Loops 561 [New Conta Design Problems S66 ‘Things to Tinh About” 508 From Continuous to Discrete-Time Systems $70 21 Sampling Continuous Signals 577 1.2. Reconnection of Cotnuous Signals fom Thee Drarete Tome Vales 78 273 Conversion of Continuous to Diserete Time Movie 38) ‘Tings to Tink About 587 Transforms 589 Definition of = Trnsorms 589 “Transforms of Some Basic Functions 59) oper of Transforms 508 {aversion of cTansforme 59 Things to Tink About "004 ‘Appendia 2880 The Moies =cTransform 606 Discrete-Time Response of Dynamic Systems 608 20.1 Response of Discrete Dynami Systems 609 332 Binete‘Tine Any of Continaou Systems The Pulse ‘rar Fonction 813 293 DacreeTime Azali of Cos-Loop Systems 621 2944 Stabiy Anais of DisreteTme Systems 026 Things to Tak About 531 Design of Digital Feedback Controllers 634 3.1 ig Approximation of Casal Consors 635 302 Efect of Sampling. 638 303 A Dees Cf Dg Conan. 40 505 Desa tGpial Resa Cont Sems_ 650 Process Identification and Adaptive Control 656 SL Proce enifcation 657 312 Prose lenifeton ana Adaptive Control 682 Things toThink Abou "637 Refrence for Port VIE 70 DProbomsfor Por VIE 68 Index 685Preface As its ie suggests, his is an intodtory text tothe theory and practice of chemical process contol Its intended to cover the needs, {3s these pertain tothe scope of basi chemical engineering education (}) ‘ofa first undergraduate course in process dynamics and contol and (2) ofthe first part of an advanced undergraduate or graduate course in process control, ‘Daring the las ten years, academic research and industria practice {in chemical process contol have been shaped by the fllowingimpor- |. The structure of chemical processes has become increasingly com- plex, due to better management of energy and raw materials. As Eonsequenc, the design of control systems for complete plants ow constitutes the fra point of engineering intrest ater than Controller designs for single processing units, Furthermore, the ‘design of a contol system has Become intimately related to the ‘design ofthe process ise 2 Designing a contrl system implies identification of contrat ‘objectives; election of appropriate measurements and manipula- tions aswell asthe determination of loops connecting these nd identification ofthe proper contol laws In other words iis 2 much more involved question than the tadiignal one of contol3.The advent and rapid growth of digital computers has revolution- {aed the practice of chemical process control and fs allowed the ‘nudustial implementation of advanced contra concepts. “Today it i widely believed that education in cheical process com uolhas ao ben aaped to flow made tection. hese are Spice ove Toe presen ext represent an tempt Yo tie the SEES approach to prowess con problems wih the current and furan rond and needs es primary an edcatioal vehi ater thon a prt! guider the sluon of pee inausial proses Here th emphasis bon understanding te nalseof proces contol JMobioms andthe avibtes sr well aon sysomatang he approach {ether solution, Neves 10 sy, several desig ooh and methodol tSorhave sso been inde, bur wih reduced empha Thus i ope thatthe folowing spect wl emerge fe toying hs book "Chemica oes comais sas fay with own inte SUSUEG chatenges I's imately cated fo chemical enact itgscenet and pact, and au sach it the Seger ttfany oer branch of oeacring 2.Thevesgn of con sem nota mathemati pote, bt ‘hoold te pereived aa enpncring tase wih allt atvactve ‘Bitenges and prac! shorter 3.2 tnd undestning of py and chemical phenomena tk ind sae int chemi proceso pertmoant importance or the design of imple and efetive cont schemes. 4 Seven tera conol configuration ar sul posble fr five pecsing ator compete pant. The section of he 2&Ssamone thers te cet guest fo be soe. 5. There cuss plein of aaa ols and design methodolo- fis tha one sould be fiir mith before atempting to tate roves contol problems. “Tn tents divided into seven prs. Ech at inl number of capt nh common gna oieation Pur 1 (Chaplet ino) represents ener introduction tote contol aspects ota seme process. An atempt i made to dfie Site mca y poses con to deny the needs and nents Tnrprecn contol to sale the eign qestions and formula the frobions hat mus be slved and o provide the atonal studying ‘he material that fllows in the subsequent chapters art l (Chapters 4 and 5) introdvoes the reader tothe modeling requirements for proces control It demonstrates how we can constrict Useful models starting from basic principles. and determines the scope nd ifiatis of mathematica! modeling fr proces control purposes art (Chapters 6 though 1) is devoted to the analysis of and dynamic behavior of processing ate, The emphases he on ienihing those proces characte which shape the eae ‘sponse fora vai of processing nite-The suo such as dre ued trio design eflesve conor leputoutpat mode hve Sconemploye though te wc of apace storms Part V (Chapter throgh 6) covers the aap and desig of fed con stem, which repress the onl ches ov tered most afer in chem plat Emphasis has ben ced oh Understanding the eft nich varios fedock cones ave oh the response af ontried pacer, and 0 the ston af the most Apprepte among thm, The suet conto tng hs bet emphases a consequent, the eon wots (eae saues an equeneyrerpons unig methods have tonsa dove Pert V(Chapiers trough 2) tals wht deserin, analy and dein of ore complex sonl stems, with ane contd ou Pu Inpriaar, Chapter 1 situs te conep of edbnck om ensation with Smut petro cope th stone posses be ‘ea meso inverse reponse’ Chaper 20 decries and anaes 3 ‘arc a mutiooy con systems (ih ne contd op) fe counted in chemea proces suchas sae Sp fange.Chape 21 devoted econ fo the analysand dsp of ‘Scdiorvard and rate cntel systems, hile Chapter? makes her ‘serine presentation of aap and inertia conta comes ‘hy they ae needed and bow hey canbe aed. ‘Char 33 trogh 25 conse Part VT ad are devoted to mule ‘variable conta protien, Theemphann hereon gener aera {ive cota confiuraions in sysematc manera secesing ter forth best iisnot meant to coveralasete of avaiable come, 2nd only one engn echague sanncgain aay presente fo ih fection ofthe east interacting opm Simple, onntacting conto Isop are so designe orion eer tems Chaps 23.and 35 oft 2h nroction othe contol dengn pron er empl thea alata lo thy otne systema procedures which en be sed Synthesze contol scheme fr sch compen toms Part Vil (chapers 26 through 3) an ioducton 10 oes. . This example demonstrates vey wid the ed for ubliing the Operon af sytem uring wre ype of tal he presence of ee Sake tne yee oy | from he dese porn)10 conmoeta Crea 1.3 Optimize the Performance (of a Chemical Process Safety and the satisfaction of production specifications are the two Principal operational objectives for a chemital plant. Once these are [chreved te nent goal show lo make the operation of the plant more Droiable Given the fact that the conditions which affect the operation the plant do not remain the same, itis cleat that we woul ike to be She to change the operation ofthe plant (Now rates, pressures, concen- trations, temperatures) in such away that an economic objective {oti is always maximized. This tsk s undertaken by the automatic ‘ontrollers ofthe plant and its human operators Let us ow sce an example from the chemical processing ‘wheve the controller is sed to optimize the economic performance of & single unit Example 13s Optimizing the Performance of Batch Reactor Conder a batch ecto whee the follonng two comectve Fae pic tox acts ar asm oe edhe it stern. Jee cat route fori eats supped By steam wich Bows ‘oma oun ie er (gre 0) The eed pod a ete cae Te ons opener operon Bcc istrmanimisthe prt 8 es ped feat | ss 4 costastcam) cost ofpuchaing A (1. vier ys he psi of ection, ‘Thevonyvarable that we ca change fey inorder to eaximie he Se ie team lw ne Qe seam flow rae which ean ary with Cove | cement Chama css Con! n time, wil ae he temperature ithe bach reactor ao the temperature urn ae the oes ofthe deed and none reactions Ts {oeston is how we shoul vary QU) sth time so thatthe profit © ‘avimie, Let ws examine some Spec poise with esos 10 0, 1L1f QU is given te last possible value for the entire reaction pesto tthe tempers othe seating ature ill he The Fg value thats possible. Insta, when xis ree wil ba ‘ph eds of B but we wil also py ore forthe steam. As tine fnes on andthe concnestin of B icra the ld of Caso Increases. Consequently tovard he end of he reaction period tae Temperature must decreas, aecentating + Getese in te st fiow ate 21 be sea dow rate i ep ait lowest value bs, 010) =0) for {he ene eatin period fn ne wil ave no steal Above no producion of Wie seers fom these two exzeme cae hat Q() will ary between ‘slows and hides vats ig ecto ed How sod ‘vary fomaniniae the profits not el and request sla of he he seam Dow rate mast follow o opimize the profit. Therefore a contol rst enced ‘ich wilt) empath ben ea ow te for vey tie Gring the Featon period and 2 ast the valve Gnuerted i the sean i) 29 thatthe ser fw rate takes is best vale [ar compaed in 0) Such Problems ae known a otal conta probiems, Of seo te Fue tat Opin otenaage ‘This example indicates that the control of the steam flow eae is not ‘sed to ensue the stability of the reactor orto eliminate the effec of ‘external disturbances onthe reactor, bat to optimize ts economic pet= formance,Design Aspects 2 of a Process Control System 2.1. Classification of the Variables ina Chemical Process “The variables (flow rats, temperatures, pressures, concentrations.) sssocited sith a chemical process ate divided into two groups 1. Input variables, which denote the effect ofthe surroundings on {he chemical process. 2. Ouput variable, which denote the effet of the process on the surroundings Example 21 For the CSTR rear dace in Example 12 (Figure 17) we Bove pa variables: 4, Ts Fy To: Fal) Outpt variables: cx TA Ta V Notie that he eMuent flowrate F can be considered ite as inpst or fut, Ibee incon valve onthe eget steam Sha its Dow ‘ate cen te manpulstd by conver te varable Fs an input, ice the opening ofthe valve fared external there, Fi output re 2 Desgnéepc ota Pnser Conese 13 Example 2.2 For the ank beter disused in Example (Figure i) we have Input variables: F, Ts Fe(F) Output variables: RYT ‘The input variables canbe further clasiied into the following ate- oie: 1. Manipulted (oe adjustable) variables, i their values can be adjusted freely by ihe human operator or contol mechanism 2. Disturbances, if thee valves are not he result of edustment by an ‘operator ora control system “The output variables are also classified into the following categories 1. Measured output variables, if their values are known by directly ‘measuring them 2. Unmeasured output variables, if they are not or cannot be mest- uted directly Example 23 Suppo thatthe nt seam inte CSTR ester (Figure 1.7) comes ‘om an upstream un over wich we hve no conta Then Fy and Tre diarbancen Ite cola flow ate is contd by © conta “Salve hen ira maniplate vara whe Tira dntrance Aso, ‘ow ate of the eflestyeam i conoid by 2 aie, Fie 8 ‘manipulated variable; otherwise ran oatpUt ea “The concentaton cy canbe a measured variable fan anager gat ‘ehvomatoprap,slfaredspecvometer ie) i ached to the fle Seam. Im many sbdateal plants such analyz are nok avaiable ‘ey apm a te ow ai fe poor mens Example 24 For the tnk beater system (Figure 1), the puts Fan Tare iaurtanes, while Fe and Fare manipulates tapas. The output var fies ¥ apd Team te measured nny an they re sonadered meattedee 21 lp an opt aries aren emi re, ‘According to their dzect measurably, the disturbances are cless- fied into wo categories: measured and unmeasured disturbances. Example 25 ‘The dsurbances F and; ofthe tired tank heer (igre 11) are casi eased tus they are considered measured dsturbances. On the ‘ther tend, the ed componson for sdailion column, at exaction ‘i rentors and he ike not sormaly measured and consequat is ‘considered an unmensred dinturnce. As we mae ter, uameasured ‘Sitrbaeesponeate more fica conol preblems Figure 2. summarizes all the classes of variables that we have around a chemical process. 22. Design Elements of a Control System Let us look next at the basi questions that we must ask and try 10 answer, while attempting to design a contol sytem that wil sais the Control needs fora chemical process, Dotine contro! oboctves ‘The contra element in ny contol configuration isthe process th we want 1 control: The first question raised bythe contol designer Question 1: What are she operational objectives that a control ys fem iselled upon to achieve? (owe 2 Denpr Aspect feces Corel Siton 15 ‘The answer to this question determines the contol objectses. They ‘may have 1 do with: Ensuring the stability ofthe process ‘Suppressing the influence of external disturbances, or (Optimizing the economic performance of plant, or A combination ofthe above [At the begining the control objectives ate defined qulitasively subse- Example 26 For the CSTR sistem disused in Example 12 (Figure 17), the con- wo abjecive(quakauvely deine) isto ensue the Sabi of the Idle unuble steady sue But uch quale description of he ‘ontrl objectives at well forthe Gaga oa costal tem and ‘ost be guastiied A ghanitatve traaatin of the geltaie conte! ‘bjective regis th the temperature (an output variable) not devise ‘ore thar Sk from its somo values the woatabe tad ste. Example 2.7 For the steed tank heater of Example 1, the cont objectives ae rani the temperate ofthe outlet (7) aad the volume ofthe fad (in the tank a Sesed values, Forts tmp the quantfietion of {Re contre objectives edict sod waghforant tha ‘where T, and ¥, ae sven, deste ves Example 2.8 For the batch eactr of Example 3 the qualitative coma bjeive is the matimizauon af the rai The guasttauve Ssepion ofthis shjecve she comple. trues the slain of mexnieaton probion,which wl yt the valu ofthe senn Now rat, QUO, at each fanen darng the enton peri Whatever our control objectives ate, we need some means to moni- tor the performance ofthe chemical process. This is done by measuring the values of certain processing variables (lemperaures,pressutes, con centrations, ow rates, ec). The second question that aries i=16 ConvllachameslPocts ChrscetesanAuceed obime Pan Question 2: What variables should we measure in onder to monitor the operational performance ofa plan” Wis selfevident that we would like to monitor directly the variables that represent our contol objectives, and this is whats done whenever possible. Such measurement are called primary measurements. Example 29 For the ak ester sytem (Example!) our onl objectives are to teepthe volume and te tmperatre of the gid the nk at Sse level thats ep Ter md v=h CConsauenty out ft atempt ro install measuring devices that wil ‘monitor and eirety Forth resent system tis ssp by sas ‘ermocoupe or T)ands difretal pressure cel (or 7 1 sometimes happens that our contol objectives are not measurable ‘Quantities: that they Belong to the class of unmeasured outputs In Such cases we must measure other variables which can be measured tasily and reliably Such supporting measurements ae called secondary “Then we develop mathematical relationships bermeen the unmeas- ‘red outputs and the secondary measurements thai ‘unmeasured output = secondary measurements) ‘which allows us to determine the values of the unmeasured outputs {once the values of the secondary measurements ace available). In a Subsequent chapter we will se that the mathematical relationship between measured snd unmeasured outputs results from empirical, txperimental, or theoretical considerations. Example 210 Consider ple dsilntion cole separating a binary mist of pentane and besa nt wo product streams af pestane (stint) ad Fetoe osioms: Our soa obective ito maint he production of {ditt seam with 98 mol pentane inthe pence of chan the eed composition. Iris carat or firs ection ew wea composition analyz 10 smeatre the concentration of pentane Inthe dst and then sa {Redbck cone fo manipulate there ratio, 0 at we an Heep the Aisi 99% n pentane Fis ost scheme bow a Figure 228A ‘Sernatve conte mse to wea campostion analyzer monitor the {ncentation of pentane inthe fe, Thea fasorward rangement ‘fe ean chngs tbe ven vais to achieve our objective, TS conta Asoc ola Procts Cont Siem yes 22 “Tie trent sem oh ii cmponio tine sion auc ora) ne18 Conolote chemics Process: Charactnsics andAssocata Problems Pant schemes hown i Figure 22 Both of the cont stems soe above depend onthe compostion sear, I sponse ta sath easing ‘Svcs ae either ery coy o of Vr low ey for on eae ‘evionment (ing gute en oF ot peoviding secuae meson ‘en Sahn ean men one ee ‘rou ye lng te eg often gu ea, wig ag "hermocouple. Then using the mater a ey tales ard he {rv the chim andthe thera euieram toooehns ‘tween laud and vapor nrcams, we Can develops maternal ee ontip tht gives ws te compostion ofthe dine he enpers of soe sled ays ae Knows, igure Zac shows sch? onl sie ig empetrtue aha)merh) ‘cata or inter the componion of pentane nthe austere Valo ofthe cont oct . ‘The third class of measurements that we can make 19 monitor the behavior of a chemical process includes dtect measurement of the ‘external disturbances, Measuring the disturbances before they enter the Drocess can be highly advantageous because it allows us to know a Dron’ what the behavior ofthe chemical process wil bea thus take ‘emesal control action to alleviate any undesired Consequences, Feed. forward contol ues diet meastement ofthe disturbances (ee Fig ure 14) Select manpulted variables ‘Once the contol objectives have been speifed and the various measurements identified the next question relates to how we elec change in the proces: ‘Question 3: Wha are the manipulated variables 0 be wed 0 con trol a chemical proces? Usually ina process we have a numberof availabe input variables hich can be adjusted feey: Which ones we select to use as manip, lated variables is crucial question 8 the choice will acct the quality ‘ofthe control actions we take Example 211 ‘Toon the eve of liguid in tak wean adjust lier the fw at ofthe ne stream (Fgue 13) ore Mow ate othe ote seam {ac uh Whi eters a important goeion that we il Sn vse 2 Desgriepateta aces Conlin 19 ‘Select the control coniguaton After the control objectives, the possible measurements, and the available manipulated variables have been identified, he final problem 1 be solved is that of defining the conrol configuration. Before we ‘efine a control configuration, fetus look a some contol systems with ‘iferent contol configurations. ‘The two feedback cone systems in Figure 1.38 and b constitute two different contol configurations Ths the sane information (mes surement of liquid level) flows 10 diferent nranipulated variables [vey F (Figure 138) and F, (Fiore 136). Similarly, the feedback contol system (Figure 12) and the feedforward contol wystem (Figure 1.) for the tank Beater eoasttue two distinctly eitferent control coofiqura: tions. For these two contol systems we use the same manipulated triable (Le, Fa) bu diferent measurements. Thus forthe feedback system of Figure L2 we use the emperatore ofthe liquid inthe tank, ‘whereas forthe fesdforward sytem of Figure we measure the term: perature ofthe inlet Tn the examples above we 1 fer either nt ce that two control configurations 1. The information measurement) owing tthe same manipulated vatiable, or 2. The manipulated variable 1o which the same information lows ‘Thus forthe two feedback control systems in Figure 3a and b we use the same information (measurement ofthe iqud evel) but differ- {ent manipulated variables (F or F) On the coatrary, fr the contol Sjstems in Figures 2 and I, we have efferent measurements (Tor TT) which are used to adjust the value ofthe same manipulated varshle Fo. ‘Later, we will study other types of control configurations, but for the time being we can define a control configuration (or contol structure) follows ‘Acontol configuration isthe information structre that is sed to connect the available measurements tothe avalable manipulated vanables Wis clear fom the previous examples that normally we ill hve ‘many different contol configurations for given chemical proces, ‘hich raises the following question: Question 4 What isthe Best contol configuration for a siren chemical proces contra situation?20 conmolotachemeaaces CrracestcsandAsscsiedPobons Pat! ‘The answer to this question is very critical forthe quality of the control system we are asked 1 desi, Depending on how many controlled outputs and. manipulated inputs we have in a chemical proces, we can distinguish the control configurations as either single Input, single-ouput (SISO) oe maliple- “Input liplecutput (MIMO) conto systems. For example, for he tak heater system (@) IF the conto objective (controled output isto keep the liquid level ata desired valve by manipulating the efizent low rate, we have a SISO system. (@) On the contrary, our contol objectives are (more t ‘Keep the level and the temperature ofthe liquid at des ‘by manipulating (more than one) the steam flow rate and the cizent flow rate, we have 8 MIMO sytem In the chemical industry most of the procesing systems are mult- pleinput, multiple-output systems. Since the design of SISO systems Simpler, we will start fist with them and progressively cover the design (OfMIMO systems Let us close this section by defining three general types of cont configurations. 1. Feedback control configuration: ses direct measurements of the controlled variable to adjust the vals of the manipulted variables (Figure 23) The objectives to keep the controlled vari- pt st t Foti entry gue 23 Geter race etch onal eons t ' { { ' 1 { 4 1 ' ' ' t ie ' ' ' ' ' ' t u TH op 2 Denon sept ota oct Cotte 2 Page 2A Generac inet cnt cotati. ables at desired levels (set pots). Examples of feedback control fare shown in Figures 12 and 13. Tnerenial contol configvation’_ uses secondary measurements (Gecause the controled variables cannot be measured) fo adjust the values of the manipulated variables (Figure 2.4). The objec: tive here is to keep the (unmeasured) contoled variables at ‘desired levels “The estimator uses the values ofthe available measured out pus, together withthe material and energy balances i the process, 1 compute m ‘the unmeasured controlled variables. These estimates, in tir, are used by the controler to adjust the values of the manipulted Yatiables. An example of inferemal contol configuration is shown in Figure 22 Feedforward conrol configuration: uses dscet measurement of| the disturbances to adjust the values ofthe manipulated variables (igure 2.5). The objective here is to keep the values ofthe con: twolled output variables at desired levels An example of fedfor= ward control configuration is shown in Figure lt22 Conolctechics Paces: Caranmites en Asneuted ober Pant age 28 Genel re of fred cont eoniutons Design the controler In every contol configuration, the controle isthe active element ‘tat receives the information from the measurements and takes appro- brat contol ations to adjust the values ofthe manipulated variables. For the design ofthe controller we must answer the following question: Question S: How isthe information taken from the measurements ted fo adjut the values of the manipulated variables? ‘The answer to this question constitutes the conrol law, whichis implemented automatically bythe controle. Example 2.22 Let we consider the problem ofconoling the tempernture T of guid n'a tank (Figure Li) when the Inlet temperature 7, chMnE. ‘Assume ta he int ad ove ow ies re equ Our measurement wil be the gud tempersare and the manipulated varable the ate of eat input Q,provige by seam, The question is How should Q change tn erdr to eeptempersare T constant, when T, changes? In her ‘fords, we wan fo develop the cont aw. “Asume ht the ese hasbeen operating or some ie an that the tial temperature hasbeen kept conan tT, whe the volue of te {und bar remaiod constant at value YW sa ta the Heater has been opertng a steady sate (where nothing changes). Under tee ‘onion the energy balance around the task is 0= FpedTu~ 7) + ep where Fan ae the inet (route) ow ate, density ofthe ii, rae 2 besor Aap ta ots Cans 23 and the quits het capacity, respectively: Ty Tin and Qy ae te oreespondig steady tate values. Suppose that deny; creas 8 Showa Figure 26 Ifaatbing done on Q, the emperatare 7 wl sat ‘ing with me. How T change th mel be ven y the anit | erg balance around the a ta Vp, Foot =D Ee rrr +0 a Sebo fom 2) ad ke Yo BEG Tarr Tel-P-T@-2) 22) Noe that d(T ~ T= dT, since 7,» constant. "The diference = T= T, ences the evar ot deviation of iui’ temperature rom the ese valve 7, We want ode thier 200 by manipulating aporepeatey the vue of heat input Q. Toe simples entre! lewis fo regu that @ chang’s proportionally to te enoe rr Qs-ar-T)+0. en “This tw is known a proportional cnr and parameter a i called Proportonal gain, Sabsttate cq 2) to (23) sed take ar) # pe = Fre poston anaes they ae needed «0 Inyour open, whch sem csr to como the two CSTR cn stn a Fate Pe ov oe equine oneCSTR em it taes the same conver? Expl uae Consiger a tubular citaltie reactor whee an endotirmic reaction ‘A takes place (Fyure PLT). The eacng mitre i ead wth ‘heam fomieg ea jace toon the bul reactor. The team ofthe ‘aw mate icles a chem Cbich oon the catalyst over ‘od of five days At the cunt deeys, the conversion of Ato B ‘ecrensey. We can make up orth drereas y increasing the tempera tere f the reoing rare, which san be achieve by evening the apply of ea to ie reir throgh higher presure Steam. Let 8 ‘Shame tha the eacior thermal along length Figure PLT , 1 ey mes 7 swsnesodzamcnesPeoans 41 shows the temperature in he ete ding te reaton prio tha imeimiac the ptt fom hepa fe bu (3) Formate the opinion ple ht ls the tenpertre bro of Fgre Poa ston (0) Beveopedbackconl st that wl elt he emp {trot the actors that shows a Fr PLT Wha een © bam conel () Draw como sem that wc itl computer fr he inp elsion fie eck tn In (ce meng 140 Tw aid ses ih ow ae and Fan tempos Tape ow though wo separate pipe which converge ingen (Fare PLS. We want o mans onsantthe fow rte Ftd the temperature 7 ofthe lgld seers Teun om the itiag of he fiat wo areas (@) deity the contol objectives, dsubance, avilable mesture- sents, and manipulated vrais. tht ¢ SSO ort MIMO 9 (0) Bevel a conta system tha ies oly edhak conte {©) Develop conta syscm tht wes ol dorm conta (8) Develop two diferent cota ster onus both dba hod ‘eaforard controlerModeling || the Dynamic and Static Behavior of Chemical Processes What ges oni the modelers hod nt purely frmalizale, either ix strates. ortntaxonote ews thas ttre, has tele tha con be taught and earned. ut mais aoa personal ouch a ony ‘merle atin deeper oniderton fl nd ata In order to analyze the behavior of a chemical process and to answer some of the questions raised in previous chapters about ts Contal, we need a mathematical representation of the physical and ‘homical phenomena taking place inf Such a mathomatcal ropro- Sentation conettutes the model of the system, wa the activites leading to the constuction of the model wil be reterred to as mode! fal step shouldbe approached wit cart “The purpose ofthe folowing two chapters Is 1. To explain why we need to develop a mathematical description (regal of a chemical process as a prerequist tothe design of its controler44 NestraineDmancandSitcomesrotCnmealPenee Fant 2. To describe a methodology forthe modeling of a chemical proc- using the balance equations ang provide examplas of Implementation 8. To-determine the scope and te cifcuties ofthe mathematical rmodaing fr process control purposes It should be noted thatthe subsequent chapters donot constitute a compote eatment of al the aspects on mathematical modeing, butit Istmtes to ose of erect for process conta Development @ of a Mathematical Model Consider a general processing system wit its associated varibles as shown in Figure 21. To investigate how the behavior of chemical, proces (ie is outputs) changes with time under the influence of hanges in the external disturbances and manipulated variables and consequently design an appropriate contrller, we can use two diferent approaches |. Experimemal approach: a this case the physical eavipment(s) ‘of the chemical process is available to us Consequent. We ‘change deliveraely the valves of various inputs (Sntrbances, ‘manipulated variables) and through appropriate measuring dev iees we observe how the outputs (temperature, presses, om ‘aes, conceattations) of the chemical process change ith ime, ‘Such a procedute i time and effort consuming and it sally {uit costly because a large number of such experiments most be performed, 2 Theoreial approach: 18 quite often the case that we have to Pow ane —— [ire _ thetime period. |_| thetime period | te ime period at ar aja Fy + 0.1eD 82) a from be eam ose lito he sal aig eine [sien | where @ ~amoust of et tented fom the steam othe aid pee {ni of ie ad un of heat anfer ace, “A wevesssetonl aren ofthe ine abe "Sverage(ased cna) velo ofthe ui D zexteral diameter of he anes tobe both ies ofc (17) by A Se and eting = Divi Oana r=0, pe 9 Tua et onchange10 osuegineDrencané Siac Bahr Cnmea Reeser Pa wets roa? spout eave «wy ae tna 41) wean sbi @ bye =r ante pena? pot Zenon ZaeD ure (4% “Tiss the equation of ate that modes the Beavir of i's semper {ere tute aril) along te leg of he exchanger. Sina (9) 88 al diferent equation we 8) tha he echangr has bees modeled he darbuted parameter ye. Note that Ui te overall Het ase htficeat between seam and be gue in the tbe, and Ty th {rperture of nturatd seam, Example 4.13: Mathematical Model of an Idea! Binary Disilarion Column Considers tinary mitre of components A and B, to be separated inxs wo product teams sing comvemona lation The mite i fed the comp sa saturate Hud (eat its bubble point {Ee ay / Figure), witha mola ow rate (mol/mi) Fand moa ‘Soon ot component A, The sverhead vapor sam it cooked #56 Comey condensed, an then tloweint the refx dum The cooing ‘tbe ovecead vapor i acomplshed with cooing water, The aud fom te sehux drum x pry pumped tack inthe column opty.) tte molar Dow ae Fr (fie stream) andi pay removed a the “ittte pdr with aro w rte Fy Let call Map te gd ‘ot thereon drum and the moa ation of componet As teed othe tet drm, Its en hat 5 the eompostion fr ‘oth there nd distill reams. ‘Ae base ofthe dtilton column, qld product stream (he ovis product) x removed ith 2 Row rate Fy and a cOMpostOS (nota acon of 8) 4 baud steam wi a molar flow rte i 0 ‘Strom fom he boom of he olson aed ar as bee heated wi Steam, it reurs to te Bae ofthe csluma The composition ofthe ‘iran tc to cofuma seam e-Lt Mg be the gui ol ‘hee ofthe clu, ‘The cola contains N ways numbered fom the boom of the column tothe op Let Mb he bud noldp on the th. The vapor fap on each ay wl be asomed wo be nepipble. gure tla we se the rnc ows in and out ofthe fed Sinai Figre 411 nde show the materi os rte 9p (8) 26 ftom tisha, he Figure 41 fers o any oer ty. ‘To simpiy hese, we mil make the following aston: Pe 1, Yoo dap on each wil be ep 2 The moar beats of vaporization of bt components A and Bare ‘pec sah es a we conden eer 4 Renew eat pic a ofa tomes om he Cl othe soundings re tar eben Soacaeead 4.Thertve von @ of he wo components remains constant tbrowpowt he clu 5.Each nyse 1 Be 008 ec (e she vapor ening cach yin eglitelen wth he done a) ‘Te fist ve assumptions ply th sd theres 0 need fr ener balance around each a: ‘The lat to assumptions imply tat x spe Yapor-tgu eit. slum relationship can be used to ene the mas faction of A te ‘vapor levi the thy (3) with he mle acon 9 he Ha lebing heme uy —— Tei ow whereas the relative voailty of the two components A and B n72 Aecing He DamcardSinc Bator etCrameatocascs Pant “Te ial asumption tht we wil make ae the flowing: 4 Neges te dams of he condenser a th ble ear Uther to nie hcat exchange) connate processing systems Sh ter ov riht an as sch they have a namie behave oe Flame 41) Therefore. aunt modeling shoul ice the Ente equations which dice the namic boavo of camdeser Nos Jane foreach ey and ase hat te Tolar Dow reo the gd ining ach ty eed the Teun fhe tay tough the anew forma HAM) PNB afe aan Let w now develop the state equations tat wl describe the dypaeie eta a' asian clr, Te fanart dani eft Inns and mas of component But he question i Wat ithe eae {Tou ch we wil ae the balances? From a pac pint of view, Fig it Mose ea of he ity sition elma: 0) ed ‘Sin Oh ope spt cr bt Chap-4OnaeemertlaMseneates Most n the boundary af he ase ofits is otined by dashed ties in Figure 40 Such boundary ary otf the puts ane out of pret! gaicance forth overall em aha een at ass ‘ese ste ow acon dt ad on ch ‘ange with tie, ne cao ing how the vase of praca i ance, sch 39 andy, ung nth ine Therefore we ae fred to Brae he ne and ch Thor we ve ee ao Fe Feed ay (=P ‘otal mas: MM Bs Lt Boa Lym Wow Fs shy (423 mass 6 Fy ty Vag= em Vom Bt Las by (4228) pA MM Bes Lanes Vana La Vor Component a SMA eye nas Vein Lay iy (4200) Top ray i= totam: SO Fas ys Lu Yoo Faby (428) Ga Fas Vou ba Vaw Fu-Ly (238) Component A: HMOs peg + Vy late Vad (42 Mets eg Translate Yow (420) Boom ey =p Tonia fp teF Fett, hy compen AOE Lae y= tins= Hs (424) (it =2 tans aa oat mine eb Yate tty ae cos) “ Compan 4868) aa Vaes= bar ¥o) 289 a, barn 42%) Rete am ‘Total mass: Mao) sy, py (4.260 Mal tee Component A: MIB). vay, (Fy + Foxe (4.266) Ma) yt Fide (420) cot oral mass: M0). 4 yg, “2% Touma a) ‘Component A: SM) «4. -. (4.27% Metabo Faty (20)74 eins te Oamicand Sine BtworetChemes Processes Pant ‘Aili cqutions above ate at eputions and dscrie the dynamic tenor ofthe dation come, The ste artals ofthe mel ae Lig holdup: Ml Mo, Mp Mst Men and Me Liga concenration: XX vs 9X0 and Ne “To complete the modeling ofthe calm, quationn we need the fiowing relationships on tothe sae 1 aul relionsis: ape afie B A20) "Ty de Me 2. Him elation Francs we formula LefMl) tebBevafeonN (420 Wien al the modeling equation above are solved we Find Row the ‘ton rte and conentatons of he to product teats (ile, bot om) chang with, the presence of ehages nthe varios inp sarah "The modeling step outline above indie thatthe overall procedure maj be cious and ao simplifying assmpions AL mes the eating the sion of the coresponding ations may be cumberome. For the binary diilion eon we bv tome stm 2N + 4 snlner teen equations (tate euation) and 20 «1 alesrac equations (eqilbriem, and hydraulic reatonship) 4.6 Modeling Difficulties, “The modeling examples discussed in previous sections ofthis chapter should have alerted the feader to a series of dificulies that we may fncounter in our efforts to develop a meaningful and realistic mathe- ‘atical description of «chemical process. Example 6.14: Difficulties inthe Modeling of « CSTR. Considering te mathematica modeting ofa CSTR (Example 410) ‘ne following dats ase |. Detrnine withthe died accuracy the vals of varios parame- ‘heap Band te veal eat aster coeticet 2 Almoush the specific beat apace, y and cy, have Deen consid. {hed conta, they are poner Toncions of he temperate T Co. Beatomarote Mansa Med 7 andthe concentztion cy Hove do we desde ht this dependence it ‘tea (otha we can te constant values a inthe cxampe) ot ‘ong (in which cae the modeling becomes very complies)? ‘Therameguetons ane for the desis pat abd the est of rescion (3/1) Daring he operation ofthe CSTR, ling. fouling nso on will ale the vale ofthe overall eat wantrcefisent How can count for his fle inthe mathemati ode 4. We have considered istorde ince to deeribe the reaction ‘ate Is tis core ‘We can classify the dificultes encountered during the mathematical ‘modeling ofa process in thee categorie |. Those siting from poorly understood chemical or physical phe- 2 Those caused from inaccurate values of various parameters 3. Those caused from the size and the compleity of the resulting model Poorty understood processes ‘To understand completely the physical and chemical phenomena ‘occurring ina chemical proces i virtually imposible. Even an accept able degree of knowledge ist times very difficult Typical examples ‘include Multicomponent reaction stems with poorly Known Interactions “among the various components and imprecisly known Kinetics Yapor-liguid or liguid-lgud thermodynamic equilibria for ml Licomponent systems ‘Heat and mass transfer imteracsions in distilation columns with nonideal multicomponent mixsurs, aeotrpic mixtures, and soon Example 4.15 ‘Consier he Midize aay craking proce shown in igre 4.12 An oil fed composed of eat hytocaon mses is med ith ‘Gtayt and emesflaed Bed weacor Te lang molecules et 00 ‘he src ofthe ctl dare cached int igh proget meus (Gch gasoline) wich lene the eactor rom the tp While cracking taking place, carbon and ctr besty unesched orsne atte ‘eposted onthe ura ofthe cata Teding tote deactivation. The tlt thes then into epencratr where the mtr deponted | ‘suri 8 buoea with ar Then, the regenerate aie return othe escort has Ben med with rea od78 Woteina he ojamemeSitetaverat Oecd oceset atl oe ee) Fee 2 i cae cick (FCO. “To model he wo unis, the lloing information mst be valbe 1, The reaction ate ofthe cracking proces 2The ate ih which carbon a ay ate ate posted om {Becta his wil termine the te o cays deactivation 4 The dependence of the tro res above othe temperate ofthe {eacor and he guy of th fed igh or ex) 4 Therte with bch carbonaceous mateal depeied 08 the cate ‘urn inthe regenerator ands dependence os emg information i ot oly fic asi, but a ccna contentions Forexanole in Figure 413 me Sotho model iat ssc the fe ofthe Reavy a ed rte the ‘Sie tempertne We nonce ta the quate behavior pei By ‘aye eu eins reaeratn ae Sided eda iti well tnova how poorly undersons he uid mechanical charset Grvech aise we Tie mag et tery oe owe 4 Devecpmant ota Mion Mos ” Impcocisely known parameters ty of accurate values forthe parameters ofa models 1 quantitative analysis ofthe Behavior of proces. nfrtunatly. thi isnot lays posible. Typical examples includ the preexponential constant ofa kinetic rate expression It should also be pointed out thatthe values ofthe parameters do not remain constant overlong periods of time. Therefore, for effective modeling we need not only accurate values but alto some quantitative description of how the parametric values change with time. Typical ‘examples of changing parameters ae the activity ofa catalyst ad the Coverall heat transfer coefficient of heat tranafer eysems. (heat exchangers, jacketed reactors, ete). “The dead time is also a critical parameter whose value is usually mprcisely known and varying. As we will ee ina late section, poot Knowledge of the dead time can lead Yo serious sablity problems for the process. When no relisle values forthe parameters are available, we resort ‘o experiments onthe real process in an effort to estimate some “good ‘values for them, The experimental procedures wil be discussed further in Chapter 3 ‘Size and comploxty ofa model In an effort to develop as accurate and precise 4 mathematical ‘model as possible, its size and complexity ineeat significant Example 4.16, Consider a distiation cola with 20 tye eb, and» con- denser The fed ia two-component intr. Then 8 we hae ee in sample 3, the mathematea! moe! omposed of 2 +4200) +4 = 4 diferent equation and 20+ 1=200)+1 = alee equtons ‘The sie ofthe moe! fr sucha simple sytem i already pobibitve Since the common dsl syste ncloe feds wih mor ha 10 omponens and poses fpr suis of aye ity lea hat such ah ‘tensive modeling sould ead to cumberiome and hardtonte model “Therefore, care must be exercised thatthe size and complexity ofa ‘model do not exceed certain manageable levels, beyond. which the ‘ode! loses its Value and becomes les atractve78 Mecing me Dramicand sta Behav Charcal roe Pa THINGS TO THINK ABOUT 1. What sa mathematical model of phys procs and what do we mean (then we ul bout mathematica! modeling? Te Figure 41 we se two diferent curves that relate the temperate ao the a rat ofthe reactor forthe sta eracking unit iced ample i eth erm model” appropriate fr each of hese carve? {Let ws recall thatthe seam tables give the temperature at whch water {usd and mater vapor are teqeirum for given peste They abo {ove te spec alc for ential. esropy, ad volume of bot baud ind vapor phase, Do thee table of Values cosiute a materia too 4 Consider the gps shown in Figure QS These graphs were progeny oia'hg concentration of Bsn the rari AB, overtime, anda ‘nous emperors o these graph present mathematical ode!” Pee tt '5. Why do you needa develop the mathematical model ofa proces you want eon? (6. What are the sate variable, and wha ate the sate equations? What are ‘hey sie or +7. tow many sate vstles do you need to deeibe a ye that is com- posed of Wf phases aN components? 1. We know tat when two phases are at thermodynamic equilibrium, the Chemical potas of evry component (1 phase Ts equal 1 the ‘hemicl potently ofthe tate component in phase Martin Feb Qo ‘Express he elim elaionsip above in terms ofthe mole concentra ‘ions ofthe 8 components nthe two phases, The ansher fo This question ‘wit demonstate ta you tat me dono ned the concentrations of the ‘omponcnts in both pases inorder to describe the tem, ‘Wee a lationship that willie youth mol othe pec ntay of ‘cp 4 Dewopentt eateries Mes cy 2 mutcomponent guid at emperature T and pressure 9, wth known mpoaon forthe 8 components 10, Repeat qertion 9, but with as insted of aud. 11, Consider the fas drum of Examples 47 and 4 Develop an expesion forthe density of the vapor phat, sing the van der Wau equation of sxe State ao a expression forthe deny of the bau phase 12, When ie system at steady ste? 15, Wat ihe main reason for he presence of dea ime in proces 14, Do you know of any systems that do at pokes ded tie? 15. How would you Find be den time of system 16, In Figure Q4.2 we see the bevir of the concentration at he ote of mo ewe Qua 17, What are the asemptions lending {0 equimolar vapor flow ses (se. Poca bint) dilation clam” 1 ny tan we nee he ee tls rhb el lation ‘column of Example 4.13? a 1. Wat ate amp leigh iii elton and how is it derived? = 20, Col 0 an ea tine bre hovered apr ad se dite ‘product? If yes, why? i ‘ Conse pin Eamle 43 Stow hat he dead ine cn be comput from the following equation ial “ {freeones ie sr Fe vl flow raf he aud drupe ie a2 ncn fine The ave equrton soe at ot Ea {Stewie vom fow me attuned ioteeemantModeling Considerations § for Control Purposes “The mathematical modeling of physical and chemical phenomena, ‘encountered in procesing systems of interest o chemical engineers 8 form of scientific art. Like every type of at it doesnot conform to, nor ‘bey clearly specified rules and fecipes. It is an expression of ll the ‘ducational background and_ previous practical experience of the ‘odeler, Therefore, previous sotions have generated more questions {o the reader than anewers to specific modeling problems, he or she Should not despair. Good and efficent modeling is acquired slowly with everinereasing ability in this chapter we attempt 0 focus the mathematical modeling on contol purposes and needs Thus We will examine the following issues: 1. Starting from the tate-ariables model, how one can develop an Inputcoviput model whichis very convenient for contol put- poses? 2 Using the mathematical model ofa process, how can one deter- mine the degrees offeedom inherent in the process, and conse. ‘Quel, ideaty the extent ofthe contol problem to be solved? “We wl lose this chapter with some general guidelines tha will help the control designer to formulate the scope of modeling for contrat purposes, wo 8 Medina Coneeratons fer Cons Pupeaes 81 5.1. The Input-Output Mode! Every chemical process and its astociated variables can be described pictorial as shown in Figure 5. The main lock represents the proc: fs, while the arrows indicate the inputs and outputs ofthe proces. 'A’mathematcal mode! that is convenient and wsefl to 8 control system designer should conform with the picture above, (ie, Be such that given the values ofthe inputs i provides directly the valves ofthe ‘outputs In particular, the model should have the following general {orm fr every output output ~ finput variables) Using Figure 5. the relationship above implies that My My oad dyes de) FORE =A Zooc tm Such a model, describing directly the relationship between the input and output variables ofa process, is clled an input-output model 1s 8 very convenient form since it represents dretl the cause-and-effect Felationshipin processing systems. For this eason tis also appealing > process engineers and contol designers. “The mathematical models we learned to develop in Chapter 4 using state variables are not of the direct input-output type. Nevertheless, they constitute the basis fo the development of an input-output model, ‘This is particulary casy and straightforward when the sate variables «coincide completely with the output variables of process. In such ease ‘we can integrate the state model to produce the igpul-output model of the process Input-Output Model forthe Stirred Tank Heater Consider again the sired tank beater discused in Example 4 sasume that f= F, which ysl r= 0, leving the ttl oe82 Meaing ie rameard Sta BehavarefCharca roca Pa ‘lance atte only equation ofthe state model, rere a) ‘The amount of heat @ supplied by the seam is ven by (O- UM Ts) ‘where U i the overall heat transfer cefsen, the arc of eat ‘ani ad the enpesnture ofthe sem Ine (4.3) repiace By (5, Ue) (5 Wrenn a ae Dorel ne Darel teks oo leg 1B et aelee LB ee uation (5, the mathematical model ofthe ied tank heater with Tbe sate vara, whe and Taf the wp ables Ueto see how we can develop the corresponding input-output model ‘At stendy sae eg 3) yielas veanaL r+ ATs 6 here Tn Ta are the sendy tat values of he corresponing anble Sabiract (53) fom (3. and ake aT a ton om th eoreiponding ted state values. ‘Te solion of (3.3) is Toecetees ffe[meela 60 Assuming sha ily the Beater is at wendy ste, fe, at C20, T= we easy nd that c,=0.Tettore eg 3.4 ves, rose fe[ineara . uation (3.8 expresses the relationship ewes the inate (7, 3) and the output (79, and constues the tput-owput made fr the tank ‘ener This reaionshp algo depicted patra i Figure 82. Example 5.2: Inpt-Ousput Model for a Mixing Process onside agin the process of miing of two steams dncased in Example stl (Figure 8) Assume that Fs P= Pe sich implies tat Aaij=0 (ie. 1 constant) The hel ot slaons ae dependent oF The concestaton, which impli hat (8M, 8M) =[aihy AR, he the ate equations fos (ta) and (414) ar ede 1 the (5) (so) At steady ste es (56 an (5.6 led 0 (Fe Elen Bena Bey, om 0 BE 15.70)ah cp f —©-8 ay ne Seale Pare 3 inp ott motel fa ming pes Sabu (572 fom (5.4) and (5.7) fom (5.0) and ake pace (ove 5 Motkng Cnsceatante ConvlRenes 85 ie tem i intaly Ge, a = 0) at steady te, then cit =0)=0 TH =0)=0 and it rest o)= 60 uations (595) and (3.9) eepreen the input-output model forthe siaing procs tnd shwn schemata in ge 3. Remarks 1m Examples 5.1 and 5.2 the output variables coincide with the sate variables of the two processes, Consequently. in order to ‘develop the input-output model we need ony solve ‘uve. Take as an example the bina (Example 419 and Figure 410, For tis system we have: Sate variables igi holes: My, Ma ooy Mpsn Min Mao and My Liguld concentrations: ¥en usw Koad ky Output variables: Disa produ: fow rate and composition: Fo and xy 5 9, Fieg, Fi Ber ayeBey Ben 0 atoms produc flow rate and compotion Fy andy Boor Lr lrsce a ‘We notice that we have many more sate variables thn outputs ue For such sate, the development of the iput-ouput als hee ch hy Cy TT, Tanda ein aries einem uite involved and iicut: Figure 84 depict pital the Fos input-output model hat we woud ike o develop for he binary Cyeeyn tne attn mens Sheen ene tlaton cota. ao 2. In subsequent chapters we wil study the method of Laplace ot transforms, which allows a much sinpler development f apa TetTy TeteTe Titty @=0-0 ‘output mols from the eesponing sate models te, BE and ‘hen tS en cuncerve Lol ruyecerses [ol na (3) be 69)85 MosingiieDjeamcansSic Serer cheresocuses Pa 5.2 Degrees of Freedom ‘The degres of freedom of @ processing sytem are the independent variables that must be specified in order to define the process com Dletely. Consequently, the desired contol ofa process wil be achieved whom and only when al the degrees of redo have been specified: ‘A pood understanding of how many degres of feedom ae inherent in a proces, and which they are, is very crucial forthe design of effective coniroles, Fora specified system, its mathematical mode is the basis for Finding the degrees of feedom under both dynamic and ‘atc conditions Let us start with two characteristic examples. Example 5.3: Degrees of Freadom in a Stirred Tank Heater “The mathemati! model of + are tank eater (Example 44) is ven aay an Zeek As Bern ax nen sa 4) and (4.5 ae solved smutaneouly we ca ind how Agu evel) and 7 (iguid temperature) chang wi time when The foputs (TF, Q) ange Le us sk though the lowing wo questions 1 Is soation ofthe equations posible? 2 Itsaluon is pss, how many sltons xis? “To anmer these qoetons lt us count equation and variables umber ofequtions=2: cs) nd (4.3) number oariabes =6) AT FF. Teand Q ‘We nave assume that 4,9 and ae pcamters with given constant umber of variables > numberof egetons ‘Conseuenty the nse othe fst quston is: yes, thee eis atest ‘ne anton t the equallans modeling the tank ates, With espe! to the second guction we esl conclu that hee san vine numberof tsistone sce we con ape arbitra the valve of oar variables (Oey and solve eq (44a) 28d (4.3) Tor the Femaining wo Fa The arity specifi varisbes ae the ders of fowdom their number sven by be Fllowieg obvious relish = (numberof vaables)~ (umber of equations) Suppor that we spec the vas ofthe ou vases FT Fs and (a. Then we can intepate eas (44) and (450) and find how f and T 0.5 Mong Crain Corte Pemsee a change with ime. If we give diferent values Fi of Tn oF For Q; we find that ad T change diferent tan belo. Consent 98 stam hand T'ichange te pescribe manner, we should mot hve 8) Arges of fiedom fe. taraies hat ean take arty values). Tha {SSice tothe concsin at er toapcta moc complete the umber of degree of edo shold 2, Example 5.4: Degrees of Freedom in an Ideal Binary Distillation Column [Consier the model fra deal inary sation slum developed in Example 13. We have ‘sursons onan 7 uli ennai G0 8! Wma reason 2 hun be ety 42254225) acs ron he fp (20h 290). laces rand he bom ty [ne 3 (6 AN-3) Bane arene ey eg a 4259) 7” Batons rand he ru dom ee 0) iin rand colume bse 7 amber eri oo Te Roof NDB gud composons OUTESINE tpeteomption “The numberof degrees af feedor fo the el binary diilion co Jaan 1-9-6 “Tat is me ned to specify the values of variables before we ca solve the model ofthe ban stilton ‘The observations made and the conclusions drawn from the two xamples above can now be generalize for any. processing system described by a set of E independent equations (éiferential and/or lgebrac) containing V independent variabies. The numberof degrees ‘of freedom for such s system is given by JaVrE88 NedingiheDame an Stal Sehvart hemes Pocases According 10 the value off, we can distinguish the following cases: Cave 1, Wf = 0, we havea system of equations with equal number of ‘variables. The solution ofthe E equations yields unique values for the varabies. In this ase we say thatthe proces is exact) specified. Cave 2. ff > 0, we have more variables than equations, Multiple Solutions result fom the equations since we can specily arbitrarily f ofthe variables. In this ase we sy thatthe process is wnderspcifed by Faquaions (ewe ee Fabel egutions to have 2 unget Case 3. ff <0, we have more equations than variables and in general there is n0 solution to the equations. In this case we sy thatthe ‘system is overspeed by Fequations (ue, we need Io eemove J eQust ‘ons to have a solution forthe system). Remarks 1. is clear ffom the analysis above that sloppy modeling of a ‘process may lead 19a model that does ot include al the relevant ‘quations and variables or includes redundant equations and ‘ariables. In either ease we have an erroncous determination of the depres of reedom, which may imply incorrectly that We have fninfinite numberof solutions or no solution at al ‘The presence ofa contol loop in chemical proces introduces an ‘iditional equation between the corresponding measured and ‘manipulated variables, hus reducing by one the iil number of ‘degrees of freedom forthe proces. Example $3 ‘The tized tank heaters mode by two egutions containing ix ‘are, thes yieling four degrees of feadom (Example 3). Ths i treet the flew rate Fis termined ya pum, valve and 0 On. {eat soppore that isnot he as and that he bg ows ou om the tank ely nde the hyrosate peso the gud in te tank To Us cane there ian adaitonl equation relating F tok (eg, F=AVR), Example 56 Consider agin these tok heater, but om under eedbsck cos: wel (igre 53). Con! loop t matin heigl level ata deed {Shy mesg ee hd ad ang eat he The lgued tthe Gente vlc by maniplating he ow of sen ad that ‘he low ofheat Q. Contequratly, contol lop 2 introduces aeatonship (hap 5 Meding Concertos or Comal Puposes 89 mye Figwe SS Fedack ops ofa irda eee eisclear om the analysis above hte we ontop trode ‘wo adonl equations, ths vedi the dees of fendam byt 5.3 Degrees of Freedom and Process Controllers Ingenera, carefully modeled process will posess one or more degrees offeedom, Since fr J > Othe proces will have an infinite number of Solutions, the following question arises How do you reduce the numberof dress of freedom to zero s0| ‘hat you ean have a completely specified sysem with unique behavior? ‘1s clear that for an underspecified system with f degrees of freedom, we ned to introduce f additional equations to make the system com. Dletly specified. There are to sources which provide the additional ‘suations: (I) the estersal world and (2) the comtol system. Let us "examine them closer sing the stirred tank heater ab our example Recall fom Example 5.3 that the steed tank heater possesses four egies of feedom. Therefore, we need four additonal relationships, Independent ofthe modeling equations [eqs (4-4), (&:)}. These are ‘provided from the following considerations |. The fed flow rate F; and fed temperature T ae the main two sturbancee forthe stirred tak etter and they are both spec. Fied by the external word (eg. the unit that precedes the tank heater). Although the equations that specify Fand 7, may not be Known to us, nevertheless they exst and remove two degrees of| SresGam. Thus we have 40202 cemainine demnee efedm90 Masking te Dyromicand Site BenmaratCemealRaceses Pani 2. Acceptable operation of the tank heater requites that the liquid level and liquid temperature inthe tank heater be maintained at or < bounding value where variable x= low ate, temperature, presure, volume, compos Vion, and 50 on, Tis lea, therfore, that if we have ieatiied the variables which define quantitatively our contol objectives, she mathematical model ‘hat we wil develop must describe how these variables change with ime, ‘is, it wil ip us determine what balances are needed forthe deve ‘pment ofthe mathematical mode. Example 59 Conse he ied task ester discus in Example 44 1 Hfou conta abjective ito keep he ii evel at desired al, {he anise saab of ren he olome of the ui a he tank (or euuialealy the Regt of the gud evel) and conse. ‘urndy oe med only consider tbe tal mats ance, Te it nef neet te ow ste ofthe nt sen, whe he ‘Misiputed vals tobe considered are the outflow rte F nthe int Row ete F ‘ont oer bdsm acne ee he emp ‘State vee the impestar she level of the ian the unk Ths imps hat we need wie th ta mass and enerey ‘Sianns The Surunces of neve sre he emperatre nn he ERPS orine nit seam, while ne avalable manipulated ar ‘owe 8 Nodein Coracaore or Conte Pate 95 5. Finally. four contol objectives arto kep the temperate of tbe fiesta a he id evel tne vaay, nave 8 Example $10 Consider te continuous mixing proces disused in Example 41 igre 48) We an dsingseh te flowing conrl stations 1. Afour conta objective whee he concentaton ofthe fen Svea ia ata deed vale, the sate varies of nterent te he ‘lume ofthe mixture inthe lank ands concentaton in A ‘Theelvaa lances are thon on total mast and on component A Thesturance of iterest ar (OF cuh Fé (OF Crh abd Fs The avable aniplated vasubls ae FP SPs ot toe rao bike 2 Ion ihe other han, our control objectives ae to kee the compo ‘ition andthe empecature of eMuem seam at desea values we ted consider al thre state Varbls (en, P73) and formate Ail thvee balances (tl mas component A al neg) In this {ase the important distutbaces ate yy PT ny Fan Ty “The wvalale taniplated variables re FF, the Tt Fury and 0 Expected disturbances and ther impact ‘The external disturbances which are expected 10 appear and affect the operation of a process wll influence the mathematical model that, ‘ne need 10 develop. Furthermore, disturbances with a very stall ‘impact on the operation ofthe process canbe neglected, whereas distur- bunces with significant impact onthe process must be Included in the ‘model. This will determine the compleity of the mode! needed: tht, ‘that Balances and what state varables should be included in the model State variables that are affected very litle by the expected distr- bunecs can be eliminated from the model and, together with them the ‘corresponding balances. Example S11 {et return othe sized an ster (sample 44. ihe eed Dow ‘ate (istrbane) sot expected to vary signet the volume ote ligaid inthe tank wil remain almost contant In thi sxe Bf A dhe = 0 and we can nei! the oa mass balance and the Soeited wate arable h'The mathematical mode of inter fr C= "rol purposes is gven bythe tual energy balance alone fq (50), With temperature the ony sate vara ‘Remarks. Note tat ifthe eed temperature Tent expected to vary Sica bul thee flow ate Fs exposed to chang subtatall, ‘he matematal model cannot be simplied ws above bt It il be a96 Madang tO ymca Sc twortChemealmocaies Pan Similar reas to those above canbe deduced forthe CSTR sytem example 410) Ht the fed ow rei nt expected fo change stn ‘tty, the model canbe simplified (le. dO) a8 ven y ‘es ey and 100) Physical-chemicl phenomena in a process ‘A good understanding of the physcal~chemical phenomena taking place in a proces can lead to significant model simplifications for ontrol purposes. Such simplifications can be done by excluding from the balanees (model those terms that have small contributions, Example 5.12 Let us eur to the comtineous mining pres cused in Exam pe AIL Assume that forthe partulr components A and B ofthe mi {Sr the Beata auton doe ot depend sical onthe compos: ‘on ofA aad 81a tus ease ee Example 410) [As ~ Aff} “102 AR} =O andthe oa energy bale eg, ea be simplified 1 the follow pov Di aphotti=T9epF ltr T)20 In other words, ne se that he nature ofthe mixing phenomenon lens to Farhermore, suming that fom al poste disturbances ony the feed compoiions cx and cy, afe expected to change siifcatly twhereat the fend fw ates Fad Fen eed temperatures an Ts “Trecxpectedo remain almost he same, we cas omit om the mathe il mode the total mass and energy Balances and fom the xe of wate ‘able volome and tempertare Ty Thus the implied dal ‘ven only by the Blane om component Ae (18) Example 5.13, Coir agin the CSTR discussed in Example 410 fhe Ret of encore pri eation A= i very saland the temper ‘ore ofthe fed steam i ot epeted wo change siguiente ee erator ofthe easing mitre wl not charge appeal. this eae {he reactor canbe asuned thermal We can exude the tl ene) {mlnoce om he utensil nel an the tomperatire fom the se fsa varable Examples 5.9 through 513 demonstrate very simply but vividly how the mathematical model ofa process can be simplified when We ake hae Moola Consett CnelParosee 97 {nto account various considerations relate to the nature ofthe process nd the characteristics ofthe contol problems. “The contro designs ways looks out for such simplifications, THINGS TO THINK ABOUT 1. What ian iapt-outpat mode, and how can you develop i fom a sate ‘node When ths pose? 2 Describe a procedure that would allow you to develop the input-output model fran dal, binary sition column, 4 Define he concep of depres of eedom and lt i ote solution of cuatons with V variable, 4 How many degrees of fcedom do you have ina stem composed of F pes with C components Resl Gibb ue). How many deyes of teedom do yeu ave ina matem compored of P Dhases wih C compacts ifthe man ofeach phase nsven ies i Ms "Mh } (Reel Debens ele) 6. How does he numberof dees of feedom afc he muber and the ‘election of the onl ates in a chem proces? ‘Why dome csi that d disturbances reduce the numberof degrees of Freedom by 4. Wy cana conta sytem not be designed for an overspecified process ‘Can you have she desired operation fran underpecified proces? I yes ‘plan why no, expan how ean you he underpin, 10, Consider sytem mode by the following st of sat guaions: fc mma my did) = |. Fe Sera sn ms madd dd) andy ate the sate varibet sms and my a the ‘Rarpolied varabie and dy dy andy are the external iurbances (3) How many depres of eedom doe the yee poe? {b) How many contol objectives car you specify a mos (©) Consider his s)tem a tay sate. How many gress of feedomt foes poses?98 Macing a Oyameana Suter st Chemearocasses Pat 1, A system ie deeibed bythe allowing eo state equations Ps 4 fon ord ds) and Ea fama ds Fd mn dod) ti > Find the desres of fear fo the sytem tits dynamic state and sendy fe Ar thy xual? In, hy? Wht are the mpctons om contol 12, What are the principal contro considerations hat fet the ap of math ‘ati modeling of sbemicl poses? fons affect he athe! mods: In wha sented the conte consign ie ofa chemieal proce What are the wil general quanstativecepresntations ofthe contol hjsuvee In arms of what variable ae they expe” 15, How can the expected impact ofthe disturbances simplify the mel ofa Drove? Givean exempe oer han that iacssed ia eX 16, Givecxamples to demonstete how you cn simplify the model ofa process by dvegnaing pycal sod chemical phenomena with ited impact fon the bebo fhe process you should take during he development ofa mathe nial proses contol purpose. ‘tain mode fe REFERENCES FOR PART IL Chapter. Three exceptional references with a large aumber of process ‘modeling exampes te |. Proces Dynamic nd Contra Nol. by. M. Deus, reatice- Hal Engewood Cis, NJ. (97D, 2 Proet Modding, Sinalain, and Contr for Chemical Engines by W. TLopben MeCran- Mil Book Company, New Yok 97), 3, Dynamic Behavior of Process, J.C. Fey, Prentice-Mall, Ine Eng stood Ci NI. (972, For the development ofthe dynam material and energy balances, the reader ‘Soul io conrlt the following book. om which Examples 410 and are ape 4 Inaction 10 Comical ngincsring Analyst, by TW. E Russland M. MBean, ah Wey & Sonne, New Yor, 972 Punt! adeingee Orame ane Sanc Baber Choma Rocees 9 Adina reference for materi and entry blancs ae: 5 asic Principles and Caleuaions in Chemical Engineering, Sr yD. M-Himenetos, Premice Hal ne, Englewood Cif NJ (974 (6 Elementary Principles of Chemical Proves, by RM, Fader and RW. Rousseau John Wiley & Sons, Inc, New Yor (978, For the modeling of specific unit operations and reactors, there exit ‘umber of textbooks tat he rede oul use. Not all model sade in these tks are convenient for process conta prposer, ba they could elp you to develop simple an wll modds Among ll he salable references te foowing constue «pata ist For the modeling of chemical reactors 1. Chem Recon Engine, by O. Leven John Wily & Sons toc New Yor (960) & an imroduction to Chemical Engng Kini and Reactor Desi, Cais obn Wey & Sons In. ew ork (OT. en 9. Elementary Chemical Recor dna, Wy RAs Prec Hal,In, Englewood Cy 03.90), 10. Chal and Cate Retin Engineering, by 5.3. Caer MeGras- FH Book Company New Yok (070. For the modeling of transport proceses 11, Danio Phenomena, by RB. Bed, W Stewart, od EN. Liphifoot, Ion We & Sons Ine, New York (1960 12 Mass Tanger Operations, 2 by RE, Treyba, McGraw Book Company, New Yor 6. 19, Heat and Mas Trane, 2a et by ER. G.Eskert and R.M. Drak, ‘Mecrawti ook Company. New York (959). Formoreon reaction equilia and phase eguira the ear may consul the folowing books 16, traduction o Chemleal Enginering Thermodynamics, 3 by 3.6 Smith and H.C. Van Nes, MC il Book Company, New York (979), 1S. Chemical Engmering Kins, 2nd, by JM, Sith, McGee Hil Book Company New York. 970. Foran extensive dicusion ofthe mathematical modeling ofan el. binary ‘silation column and fs noidcal maticomponentcfusn the eer can onsut he books by Dou (Ret Layben (Ref 3} and cy et SA100 Neng Dyraric nd Sune Bunoverat Cpu Poseees Pant intersting dcuson of he dificuis encountered during the modeling of ‘hemiclprossss can be found 16, “Cig of Chemical Process Control Theory.” by A. Foss, AIC J 19,2099). 17, “Advanced Conte Pace inthe Chemical Paces Industry: A View fom indus by W Lee and. W.Weeknan, Je, AICRE J, 22,77 (1978), (Chapter. For adiiona sty onthe degrees of feedom and tei impact fn the devgn af proses contol systems, he ender Should consul teflon Automatic Control of Process, by BW. Mul inners, Sertaton Ps (195). 19, The Chemicel Engineers Handbook She 3-H. Perey (8), MeGram- il Book Company, New Yor (1976 est Educational Po PROBLEMS FOR PART Chapter & Consider te two systems shown in Figure PIL System | ie om ‘Stem 2 by the fc that he eel ohgui in tank? dos ot at the ‘nt ow ae om tak which the ease for stem 2 {@) Develop the mathematical mol for ech ofthe wo syiems. (©) What are the nate warabiy for etch system, and what pe of alae equation ave you use? (Whi mathematical mode easier salve, tat fo stem 1 oF Assume ta the low ate ofan eluent seem fom ata is popot ‘foal to the Myron igi pressre ha causes thew’ of gui ‘The eoeesectnal area of tank Iie 4, (snd tak 245 (POE oh ytomel The flow rates Fy, Fy and Paris Fig Pat Ming Oyamc nd Site ehawratCoaics Recess 107 112. Develop the mathematic! mal for he sytem shown in Figure PIL2 ry ‘What ae the state varies for hs system and what type flat equations have yoo we? Al the Now rte are Woluntse ad the ‘sratctionalafens of the tice asks re yd, espe Uvey Te flow ate Fs constant an doe no depend ony shila ‘ther fsa flow rts are proportional fo the earesponding Ryo ‘sae gui presures tht case the Bom ewe 2 Consider thet sired tank heaters shown in igre PUL. (a) Iden ee ate variable ofthe system (0) Determine what balaces you shoul perform (6) Develop esate mol that deserbes te dynamic behavior of the (@) How mould you expe the heats sven by the two steam Rows terme of ther varias? “The ow eso the eset reams ae assumed ob proportional to {eligi sate pessre that sues the ow ofthe gud The coh ‘esto ara ofthe wo tanks ate 4, and 42 (8) andthe lw aes are ‘olumetic No vapor i prodeced ether ote fist rte second “nan ate the beat exchange ates fore to steam oil102 MoteingteDvacanaSite Beare Chomiewocases Pa A. Dothestme work asin Problem 13 forthe sted tank heater oystem ‘Show i Figure PIA For tank I, he slam is injec ie in the Hud water Water vapors produced inte wecond unk and 206 the croneseconal res of the two tanks. Assume that the eet fom {ats are proportional ote igaad uae pressure tat autes heir om “iis the beat aster ae forthe team cl we Ld TS Consider the miting proses taking place in a omotank sytem (ewe PIL). {i osc the tate varies ofthe sytem. {6} Betrmine wha balances you soul perfor {0} Develop the sate model at describes the dynamic behavior of te proccss tat the heat of soliton ae song fonctions of {he campos (How tr tbe model simplified it functions of te composition? ‘Assume that the flow ae re volume and the composons at ‘oles per volume The efgent flow aes ae roporuona othe aod ‘nic pres tht cases their flow, abd 4 are the rosesectonal ‘Seas or the wo anand se etwas ear he sea c eats of rotton ae very weak 114 Develop the sate sae! for the atch mixing of 140 tons (ire rt) tually. he onk empty. The vome of he an is MatengheOarc nd Sate eraotctCnmiedPoceees 108 (0?) The fw rte ae volumetric andthe conentions are in males pervolume, {5 How ong doe i tae tf wp hea (©) Show how would you nd the composton and temperature of the ia ne ak arn te ht hk ged wp. Assume tha the fw rates are volumes the compotion n moles per vlume, ad tht the heat of auton depends the ompoion, Pages Develop the sae mode fora batch eater whee the lowing ree ‘ons take pace aap All reactions are endothermic and have fistader Kneis. The reat Ing mature is heted by stam of 150 ps, which ows though ache send the reactor wth ante of Q (bri Consider the continuous sized tak sector sem shown in Figure PIL Seam 1 wamistare fA and with compotion and my (oles/olume) and hs a volumewre ow rie Fv and 4 epee ‘Whe Ty Stream 2 pure R The reactions taking plc re: Reaction Ae RE B, Reaction 2: B28 A Py oF mB catenin Fees Both reactions are endothermic and have econorderreaton |) 0 thigorer (ection 2 Knees Hest is ppd fo the reaction fae ‘are by steam which Now troagh a oi Immersed nthe factors ‘content, with heat anaes (2 Wat rth sate sas Geng the mata ste of the104 Woteicgme Dyan arate Bower eFChomeProcetes Pan (0) What are the ances tat you should consider? (B Deveop mestte mous forthe STR yen. (G) Bow ean you spit the state model fs = 107 for «tre ‘ang of temperate? (@) Belin the memptons hat shuld be made in order to have a otermal recor 119° Develop ie state model oth wo CSTR stem of Figs PULE. A iin rencion A= wih fisorder kinetics thes pce. Ase ifthermal onions Flow ats F tperd pumps ad ths ae Independent of the corespond gee LS 1110 aaig flow condos ee ob ety is ‘ir9y, develop tat model A simple exothermic ection AB ith Rnvower hnece thes pce, Du tothe very le tent of Teucion, mote ly wich Howe ountercrent tthe eacion mit ‘Srearoond the tue ofthe raco,f aed coolant To Keep the ‘entln temperature asseplable ves. Asume conan emperature {Geihe mele salt song the Teagth of he reactor. The resction ke) ‘Bice n te cous phawe. The ow fates are volumetric and the ‘ompostios are m moles pe volume The imeraal ameter ofthe tebe dn) and its length (a) tse sytem amped parameter (esrb by ordinary ieee {al equation) or 4 divbated parameter system? Develop the (oy Bons ihe reactor possess det time tetnen inputs and output? Papi. Page P19 rdsu Bahar CamelPeceis 108 Figure PILLO shows implied repretenaion a drum bile. Fe ater enters the Ber mith a ow rte Fy (mat) and emperatare sands ested by on amount of ent Q tBtu) which supplied ty burned feu. The generated seam flows ou fom the top of he wile, witha low ete Fs (ash) ands posure P(g) & ple fRedckconrl system ha been nals seep evel ofthe mer nth drum bole consian by manipulate fw ate af he ec. (G) What are the tate varisblsdeciing he system? (©) What alnces are aporopiate forthe rum bor syste? (©) Develop the sate model ofthe sytem, Far the feedback contol system, sea slaonsip ofthe form F=f (hone) 1142 Consider pipe of agth £ Gin) wth an itera hater D Gin Water fows through ihe pipe wih a volumeticfow rate F Lat ps be the presiore tthe earance ah pipe and ps te pressure at teenie (a) density the aproprte state variables o deeb the tes (©) What are the relevant lance for the sytem, (6) Develop he state model forth laminar Tow sytem, 1.13 Consider turbance inthe fw system ofthe Problem 12, At ne {iin oniig conc mai nae ater, cating» conentiaton cx mol/vame asthe water Ete the pipe. Assuming that A doc oa isso teenth he ppc (@) Develop a nate model tha desis bow te cameenton OPA henge ith time aod alone he leg oe pipe (2 Show ha the stem psec ead ine betwen input an outpt sdcompute the vals of ede tine ML14 A tigi scam i minute of to components A an B and bas + Yolunetic (volume/) Now ate F temperature Tae press Tet crand cs be the mole fncons oF and Bin the fii seam Hes ‘sted tate pes se ante Be po pase ot the mintre A and Bohl there n vapor poset ‘The quid seam passes trouphan bees expanson valve108 Meselng te Byam arate Bere Chieccties Pant nd is “she ino ash drum (Figure 46). The presure p inthe ‘Tumis ssumed to be lower than the bubble pont pressure ofthe ite intrest a esl two pases at equa with each bier appease the ash rm vapor pase witha composition Ys Shaye tiotae actions) wich bedrawn wits wolumetc flow ae SSLY'igid phase wih compotion = aod (mola factions) ‘Elst ulna Selumete How rate L. Let 7 be the temperature ofthe feo phases tequila i te ash rom. (Gy Wnt se the fundamental dependent quantities whose values esr the natural sine of the ash dr? (oy What rete boundais ofthe sstem() around whch yu wil perform the various balances? (e) Wistar the relevant balances? (3) senes the bance equtons, wha ada elation o 908 ‘ec to compe the sate model for he ash ra (olden the ste yarns andthe inp variables (manipulations, itrbances of the stem. (©) Develop te complete stnte mol of the astm Chapter 5 Lis Staning with the sine adel forthe two systems of Problem TL I}, deveop the eoresponding npu-ouipt modes. Ao 1146 For ach ofthe following systems, ind {Gy Toe camber of depres of eso (8) The sumer ef indepenent coma objectives you can speci (6) The input-output mode. _Shten A: The thes ank sytem of Figure P12 (Probie) Stem The two sed tak Deters sytem of Figs PILS rote 114, S\sem C: The twotank ming process of Figure FILS (rob- ico. 7 For he CSTR sytem of Figure PIL? (Probl 18), Sd (a) Te number of depres of edo, (8) The numberof independent onto obetvs that you can pei. (2) Forte sumber ofconalatjnives you ave specie, 6 308 ave a equal numberof sanipolted varies so that you cm there your contrat objecves? (a) den wha you woul se fo conta obetvs {© Show hor you wold form the corespoading input-output model Bard nt develop is anata form. Fal edengtbe Dei an Sia wcrcrmmest Pcie 107 8 De the a ne i ble Lf te no CSTR en gure PILS (Probie 119). 1119 Fo the ash den tem of ible IL Ge ao Figure 48) i (0) The eure ape endo, 7 (0) The number of iaepenen coma abjeives you a spi (6 leafy 4a of esata ober ne ting om 8 Peale afew (Seow tow you wold develop input ode et rom, but ono denvetacoaplte sayin 1120 A simple chemical ection. A — B, with inorder ini ta Disc mn COTA The eon ofthe ear ete an ay Slaton column whore the uted A cna te ved of wth acomponn orf ced to ever afr i has ened weed Cue PL owe the mise a the CSTR oh tema (tent he enamel pendent val tht erie he nat cnn ofthe pn (e) What ae he rev alas, ad wha ate Boundaries ofthe Sem rund which yeu wl prom he alas (0) Forms ate rleast lane santos {8 cml he ste variates o te pat 21 Consider te smal pan described in Problem 1.20 (Fabre PIL) (a) Determine the number of degrees of fedom othe plant. {6 IF(number of dees of Gecdom) > 0, how would 904 spi the ‘ional equations need to vender am exacly speci #0 (Ge, number af depres of eedom =| (6) How maty disturbance sperfeations Go You have and ow apy ontrlabjcetves can you enti108 MesengineDaneansSttctahearol Crea Pocesees Pal (@) Specify the contra objectives hat have a practic! meaning forthe Bist ( Deveop simple input-output model forthe plant without pe forming the required analtc computations 1122 Develop the stte mode! foram ides! inary bath distilaon extn ‘rth ideal pater (FguePIL12) AU 0 the compostion of the Tnial minaret ex 8nd malar Garona) aed otal mss (mots, (a) Lit al sumptions tat you make for modding the system (8) Identify the relevant alee equations (0) In addon fo the balance uation, what other rationshipe do You needa complete teste model? (q Stow how you ean find the time when the composion ofthe ‘verhead prod has eached a composition (mala ation). (c) How many ees of feedom does these poses? (6) How many eontlabjecives an You spect? Adina question: (Does he vapor flow rate remain constant the heat inst Q ‘emai constant with time? (0) What abou Fe doce i remain constant? Under what conditions vost jou change i? Qu 1123 Develop the sate model for gat absorption column (Figur PILLS) ‘ih Nien refer units The fw rte (ot) of the elena Steam ie witha compen elation) py wl the compan tow ofthe eluent gr ream should be (mola acon). The ow fae ofthe gu absorbing sear iF l/r ad ats entrance it Istrexofeomponert A rac NostegibeDinicandSiaicBehmarctchmcaPecests 109) Pee PLS 124 Develop the sate mode for + mulicomponent (C compoaeat) ‘oniea itlaton cola with N tay Une the ger eaten ‘ure developed in Bample 4.13 fo the sea binary lation. (a) tate your asumpions (6) Inco the dynamics ofthe condenser aod reboler considering .eapetvel. (0 ht eltonsios do yo net aditon wo he nace au (How many degre of fredom det the system poset? (6) How many conta objectives an you speci?Analysis of the || Dynamic Behavior of Chemical Processes In proces conta. he process aréaraycally complex but relies Simple to con im prasice These proces act quanti ke rahi me ob uate and fr cetan quanta ie purpose the an be modeled in term of spe ais eames so combine thon tere Brot In Part we study the dynamic and stati behavior of several, ‘simple processing systems, Undorstanaing the dynamics of such sim- ple eyetems allons fo analyze the behavior of more complex sys toms such as the chemical processes. “The analysis limited o near dynamic systems. This may soom ‘ncompatioie wih the Tact that most of the chemical engineering Dproesees are modeled by noningar equations, However, Inoar tec ‘iques are vary valuable {allowing reasons: 1), ‘on of tem can bo ‘parating eo bya linear systom near some ‘advances in the bnear convat ‘os Conal RS Fomand MM. Deeb AICME yp Ser 12, No 397,nz prajeacibeDaric Seber Creal Preccsee Part thaory permit the synthesis and design of vary effective controers ‘ven for noniinear processes, Fundamental, therefore, isthe concept of linearization and the procedure for approximating noniear systems with linear ones ‘hin wil be studio’ In Chapter 8. “The Laplace vanstorms, wich wo wil discuss in Chapter 7 offer a vory sip and elegant procedure for the sokuton of inet dtaron- tal equations (Chapter 8) and consequently forthe analysis of tho Denavir of tear systoms. Inthe remaining chaptors of Parti! we wit siscuss: 1. The dovelopment of simple input-output modes for chemical ‘rocesses, using the Laplace transforms (Chapter 8) 2. The dynamic analysis of varous typical processes (Chapters 10 ‘trough 12) Computer Simulation 6 and the Linearization of Nonlinear Systems In onder to find the dynamic behavior ofa chemical process, we have to integrate the state equations used to model the process. But ‘most ofthe processing systems that we wll be interested in are modeled by nonlinear diferental equations and itis well known that there sno ‘eneral mathematical theory for the analytical solution of nonlinear ‘quations. Only for linear ditferentil equations are closed-form, ana- Inte solutions available ‘When coatfonted with the dynamic analysis of nonlinear systems, ‘here are several things we ean do, suchas: 1. Simulate the nonlinear system on an analog or digital computer and compute its solution numerically, oF 2 Transform the nonlinear system into @ linear one by an appeope ae transformation ofits variables, oF 3. Develop a linear model that approximates the dynamic behavior ‘ofa nonlinear system in the neighboehood of specified operating conditions. Alternative 2 can be used in very few cases, whereas alternatives 1 sand 3 aren principle, always feasible. In this chapter we discuss the Computer simblation of nonlinear processes very briefly because iti a tule tobe covered primarily na course on numerical analysis. More Emphasis wil be given on the approximation of noalinear models by Tinear ones. Ic should be noted tat all the theory forthe design of contol systems, available from past work, is based on linea systems,4 ‘Araiyas ol he Dyraric Bahawor ot Chemeal Processes Par ‘and that very small advances have been made toward the development ‘ofa contol theory for noalinear systems. 6:1 Computer Simulation of Process Dynamics Nonlinear differential and/or algebraic equations cannot, in general, be solved analytically, and computeraided numerical solutions are required. Numerical solutions are also prefered for the equations ‘which can be solved analytically, when the analytic solutions are very ‘complex and provide lit insight inthe behavior of the sytem, Telus consider two processes we have already modeled’ the continue ‘ous sired tank reactor and the dea, binary disilation column, ‘The mode forthe CSTR (see Example 4.10) is given by eqs (4.8), (4.9) and (4108). These constitute a st of nonfineareQustions fot which there is no analytic solution available Therefor, tn order 10 sudy the dynamic behavior ofthe CSTR, we must solve the modeling ‘vations numerically using a computer. ‘The model forthe idea, binary dsilation column (se Example 413)is composed of 2N +4 nonlinear diferental equations and 2N-+1 nonlinear algebraic equations ‘1s not only the nonlinearity ofthe equations but also the sizeof modet (24 inferential and 21 algebraic equations for a modest IO-tay eoluma) ‘hat necessitates «numerical solution in order to study the dynamic behavior ofthe column, ‘Today, computer simulation is used extensively to analyze the 0. Then aei-[eea- [ema on transform ofthe func Now, if a=s>0 or 5 a, which yes finite Al fone Laplace tansforms so that we will not tet ther existence every time we need them. 4. The Laplace uansformat Has f(0+ ashKOl= aL} ALLA 3) where ay and a are constant parameters The proofs strighfor- ward isa linear operation aa purenine[.tasio sation Sree ieee neers130 nove hie 7.2. Laplace Transforms of Some Basic Functions. Let us now apply the Laplace transformation on some hase functions that we will ve repeatedly inthe following chapters. Exponential function “This function is defined as fe" forrz0 Then ae ro) crete [em at aed os Ramp function (gue 7-18) “This function is defined as flt)~ at for 1 = Owith a = constant (ow? tapce Transom 131 Then aan 06 “Tigonometric functions Consider the sinusoidal funeton tt) = sin wt. Then isin ot) o ot [teem 1 4 Simian, it canbe proved that eos of) «5 os) Note. In the proof shove we have used the Euler identiSoe Se eee ete fers For the proof of (7.8) use ‘Step function (igure 7.16) ‘This function is defined by [4 freso 4 \0 fore <0 ni Laps vasorm 4p ction tin A) <4 on Proof: We notice tht discontinuity inthe value ofthe function exi tre Osuch that f(t =) is undefined. The definition of Laplace tans- orm from ea (1) requitesthe knowledge ofthe function at f= 0. The ‘rawiack is overcome if we conser the more precise mathematical ‘efiniton ofthe Laplace wansformation from ea (7-1 inf! nora “AO “Thus forthe step function, the upper limit T= 20 but the lower iit Ist sOs (icra very small but finite postive Ue) instead of =, Hence for step function we have ante [ae a ‘Tansiates functions Consider the function /() shown in Figure 72a. If this function is 0, The temperature of de liquid inthe tank will, start ineessing and we want o know how itchanges with ime. In other ‘words we must solve eg (53) "Equation (5.3) isa linea equation with constant coefficients. We can vse Laplace transforms to solve i. Let us examine the solution proce ‘ure “Take the Laplace transforms of both sides of 9. (3.3 42 )saur AT) LUT) UT)- TOI aT =} TH)+ KTH) —D. Recall that 7(0) = 0, THs) = {sep function of 1'F] = 10/5 and Ty =0-Then eq (81) becomes To) (32) “The faction 7) whose Laplace transform is given by the right side of eg (8.2) sour Solution, Ii easy t0 show that Sore 8 4 a From Table 7.1 we find easly th ‘The function with Laplace transform If unt step fnetion. The fanction with Laplace transform I/fs+a) te. Therefore, fom eq (8.3) we find that re Ba-ey 64) (0) given by ¢q (4) the solution to our iil diferent equa- tion (53). Indeed taking the Laplace of eg (84), tyes eg (8.3). The procedure by which we find the time function when its Laplace trans- form is known is called the inverse Laplace transformation and i the ‘most critical sep while solving Kear differential equations using {Laplace transforms. To summarize the solution procedure described in the example above, we cam iden the following steps: le 1 Take the Laplace tanto ofboth sie ofthe dierent eqs on Use es. (710 (11) and (76) t develope Lapa transforms of he varios derives Then endtons pea forthe etal equnon are incorporated ints ep tanormt fthe eas 2. Sate te venga equton in rms ofthe Lape transform of the unknown function. ™ 5. ind tin neo a ss Laplace aso he he nde ate euaon ssn nsep 21a eon secret ian codons Step 3s the most tedious. Given a general expression suchas (Pease bxs+e) B+ as bis +63) itis not obvious at all what the function x(0) that ha the foregoing Laplace transform. In Section 82 we wil study particular method ‘ogy forthe inversion of Laplace transforms by partial factions expan x 18.2 Inversion of Laplace Transforms: Heaviside Expansion ‘As pointed out above, the critical point i finding the solution to & diferenia equation using Laplace transforms is the inversion of the Laplace transforms. tn this section we wil dy a method developed by Heaviside forthe inversion of Laplace transforms known as Hea side or partial fractions expansion, “Assume thatthe Laplace ansform ofan unknown function x(t) is ven by 2) 70) 6 where Q(s) and P(s) are polynomials in sof order m and 1, respee- tively. The inversion of Laplace transforms using the expansion 1) Paral factions s composed ofthe following thre steps: 1. Expand the Q(5)/P(s) into a series of factions, 92, Cr, POs) (3) FAs) ns) wy where 18), (o)ou-< (8) are low-order polynomials such as first order, second order and 30 on, XUs)= x)Tn vamon 0) 2.Compute the values of the constants Ci, Ca Ce from ca 80), 2. Find the inverse Laplace transform of every ps the unknown function (1) ven BY woe ofS] Se oS where £" symbolizes the inverse Laplace transform of the “upression within the Brackets. The inversion of each ration can be done rather easly by inspection using tables of Laplace transforms for typical fonctions suchas Tables 7. and 6. “ime ein fe) arae Boake) heb a9 et tenoie4 raw oKe ae wy ae coma war 2 Bee cota) Tare ‘ie =a 2 mor seo et snior er ee ee oe eee ee ee ee When (+) is given as the ratio of two polynomials (69. (8) its ‘expansion into a Series of fractions is governed by the form andthe foots of the polynomial in the denominator, P(s). In genera, we wil ‘intinguish two cases 1 Polynomial P(s) has m distinc (all differen) ros, real or com= plexor 2.PolyaomiatP(s) has multiple root. We will examine each case separately using characteristic examples. Distinet real roots of he polynomial P=) Consider the Laplace transform f the function x() ven by $a PaBias 42 PO) eo The polynomial in the denominator is of third order, Pis)ns?— 28542 and has thee ro, Diet past pa? ‘Therefore, Bis) = 5-289 54226 =e + IKE = 2) and eq (8.1) becomes fen HOSED as) Expand (88) into partial rations and take xls) SE 69) Canes res rere where Cs, Cs, and C, are unkown constants 1 be evaluated From eq (8.9) it is lear that one Sets) tS] fd using Table we find tat (= Cie!" eh Ce (810) hich sth inverse Laplace transform of the expresion in (8.7). ‘Let us see now how we can compute the constants, Cs, and Cu