International Conference on Chemical, Environmental and Biological Sciences (ICCEBS'2012) Penang, Malaysia
Dynamic Analysis of a CSTR using Aspen
Dynamics
SarathBabuAnne andPraveen KumarBommineni
Abstract—Present study is aimed at carrying out dynamic
simulation of a continuous stirred tank reactor using Aspen Dynamics
which is useful for finding required control structure to the process,
controller parameters, controller interactions and response of the
system for various disturbances in feed as well as
products.Exothermic reaction of ethylene and benzene carried out in
a continuous stirred tank reactor (CSTR) to form desired product
Ethyl benzene and the undesired product diethyl benzene is
studied.Two controllers (temperature controller and level controller)
are used in the present simulation. Temperature controller maintains
the reactor temperature at the set point value by manipulating the
coolant temperature. Level controller operates in such a way to
maintain liquid level in the reactor according to set point value by
manipulating the valve position.
The response of the process has been found to be faster in the case
when controller with tuned controller parameters compared to that
with default parameters. The response of the process was found to be
better when controller with Ziegler-Nicholos tuned parameters were
used in the case of servo problem, whereas Tyreus-Luyben controller
tuning parameters were found to be better in the case of regulatory
problem subjected to a ramp disturbance. It has also been observed
that disturbance in temperature had effect on reactor liquid level.
Contrastingly, disturbance in level had no effect on temperature.
Keywords—CSTR, Aspen dynamics, Z-N and T-L control
settings.
I. INTRODUCTION
D YNAMIC simulation is useful to design the control
structure of the process, study the performance of the
controllers by subjecting the system to various disturbances
and to optimize the control parameters with a view to develop
an economic process.
PID controller uses ideal algorithm in Aspen Dynamics to
determine the controller output [3].
 dE D 
1
OP = Bias + Gain E P +
 τI ∫ E dt + τ
I D
dt 
 (1)
Where E P -Proportional mode error, E I = Integral mode error
E D = Derivative mode error,
τ I = Integral time,τ D = Derivative time
Sarath BabuAnne is with the National Institute of Technology, Department
Of Chemical Engineering, Warangal(phone: (91-870)2462610;
mail: sarat@nitw.ac.in).
Parveen Kumar Bommineniiswith the National Institute of Technology,
Department Of Chemical Engineering, Warangal (phone: 91-9703184141;
e-mail: pravenbr@gmail.com).
The Ziegler-Nichols(Z-N) closed-loop technique is one of
the most popular methods for tuning controllers. This
technique gives approximate values for the controller’s gain,
integral time, and derivative time required to obtain a one
quarter amplitude response.The gain that gives these
continuous oscillations is called the ultimate gain, K U . The
period of the oscillations is called the ultimate period, P U .
The following expressions are used to calculate the
controller settings from the ultimate gain K U and the ultimate
period P U.
TABLE I
APPROXIMATE DECAY RATIO SETTINGS:
Controller
Gain Integral TimeDerivitive Time
type
P 0.5K U 1E+06 0
PI 0.45 K U P U /1.2 0
PID 0.6K U P U /2 P U /8
In Tyreus-Luyben (T-L) settings K C =K U /3.2 and τ I =2.2P U.
II. PROBLEM DEFINITION
In the present study dynamic simulation of a continuous
stirred tank reactor has been carried out using Aspen
Dynamics. Required control strategy is developed for the
process and controller parameters were tuned using Z-N and
T-L settings[5].
Exothermicreaction of Ethylene and Benzene to form
desired product Ethyl benzene and an undesired product
Diethyl benzene (DEB) is considered[1].
FEED:
The two feed streams to the reactor are at 298K and 1 atm:
1) 0.2 kmol/s of pure ethylene and
2) 0.4 kmol/s of benzene. The excess of benzene is used to
keep the ethylene concentration low so that the formation of
DEB is suppressed.
CSTR volume has been taken as 100m3 , and the reactor
temperature has been taken as 430 k.
The reactions taking place are:
C 2 H 4 + C 6 H 6 → C 8 H 10 (ethylbenzene)
C 2 H 4 + C 8 H 10 → C 10 H 14 (di-ethylbenzene)
C 6 H 6 + C 10 H 14 → 2 C 8 H 10
All the reactions occur in liquid phase and are assumed to
e-
be irreversible.
Temperature in the reactor is the main parameter which
needs to be controlled in order to control the product
composition. The following two controllers are used:
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 International Conference on Chemical, Environmental and Biological Sciences (ICCEBS'2012) Penang, Malaysia
1) Temperature controller to maintain reactor temperature at
set point value by manipulating medium temperature or
heat duty.
2) Level controller to maintain liquid level by opening or
closing the valve.
III. METHODOLOGY
3.1 Steady State Simulation
The steady-state design results can be used to yield valuable
information that gives reasonably reliable indications of how
effectively the reactor can be dynamically controlled.
The first step in simulation is developing the flow sheet by
adding the necessary equipment and connecting the input and
output streams. All the parts of a flow sheet will be specified
(reactor, control valves, and pumps) at this point, so that a
dynamic simulation can be performed after the steady-state
simulation is completed. In order to carry out only steady-state
simulation, pumps and control valves need not be included in
the flow sheet.
Fig. 1Aspen Plus Steady state flow sheet
The key element in temperature control of chemical reactors
is to provide sufficient heat transfer area or some other heat
removal mechanism so that dynamic disturbances can be
safely handled without reactor runaways.
Two valves at the inlet of feed streams are installed. These
valves are used to manipulate flow rates into the CSTR.
Another valve is installed at the outlet which is used to control
liquid level in the reactor. These valves are less useful in
steady state simulation but when steady state flow sheet is
exported to dynamic simulation under pressure driven mode
their role comes into picture.
After specifying the necessary stream and reactor
specifications, the steady state simulation of the reactor can be
carried out. In the present simulation Chao-Seader property
estimation method has been chosen.
When the steady state simulation is exported to dynamic
state, it is required to specify the reactor geometry (length or
diameter), and mode of heat transfer (constant duty or constant
temperature). For an aspect ratio of 2 (i.e., L/D=2), the reactor
length has been calculated as 8m for a diameter of 4m.3.2
Dynamic Simulation
The steady-state simulation now can be converted into a
dynamic simulation mode. Basically the additional
information that must be provided is the physical dimensions
of all the equipment, and heat transfer options. The design
details given from the steady state simulation for different
equipment in the flowsheet can be used to achieve this.
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Dynamic simulation can be carried out based on heat
transfer option that has been specified in order to export
steady state simulation. Either constant duty or constant
temperature can be specified. When constant duty is specified
heat duty will be the controller output and when constant
temperature is specified controller output will be the
temperature.
When steady state simulation is exported to Aspen
Dynamics, it is required to choose either simple flow driven
simulation or rigorous pressure driven dynamic simulation.
Pressure driven simulations include pumps and compressors
where needed to provide the required pressure drop for
material flow. Control valves must be installed where needed,
and their pressure drops need to be selected. For flow driven
simulations no such arrangements are required.
When steady state simulation results are exported to Aspen
Dynamics, the default control structures are automatically
installed on some control loops. Usually level, pressure and
temperature controllers included wherever appropriate. These
control loops are modified or even replaced with other suitable
control loops available in Aspen Dynamics.
The impacts of installing various controllers on reactor
control have been studied under dynamic simulation. Possible
control structures and controller interactions are observed.
TABLE II
DETAILS OF TWO CONTROLLERS
Control
LC TC
ler
Type of controller Proportional only Proportional Integral
Controlled variable Reactor liquid level Reactor temperature
Manipulated variable Valve position Heat duty or medium temp
Controller action Direct Reverse
Default controller
valuesK C =10,T i =60 K C =10,T i =20
Fig. 2Aspen Dynamic state flow sheet with control structure
Direct acting control system increases the output signal as
the input signal to the controller increases. On the other hand
as the input signal to the control structure increases the output
 International Conference on Chemical, Environmental and Biological Sciences (ICCEBS'2012) Penang, Malaysia
signal from the controller must decrease for the case of reverse
acting control strategy. The direct acting control law has
negative gain and increase/increase (or decrease/decrease)
term is commonly used to represent it. For the reverse action,
increase/decrease (or decrease/increase) term is used and
controller gain has positive sign[6].
The reactor flow sheet includes two (LC1 and TC) single-
input/single output (SISO) control loops. Therefore this
control structure is a multi-input/multi-output (MIMO) or
simply multivariable closed loop system.
In aspen terminology, the process variable or controlled
variable is denoted by PV, the set point is represented by SP
and the controller output or control variable or manipulated
variable is abbreviated by OP.
Fig. 3 Level controller faceplate
Fig. 4 Temperature controller faceplate
In above diagrams default set point value is the steady state
value of the process variable (PV). Reactor liquid level is the
PV for level controller and reactor temperature for
temperature controller. Bias signal is the output from the
controller when the error (SP-PV) is zero. From Fig. 3 and
Fig. 4, it can be seen that error is zero for both controllers.
Therefore, aspen dynamics has set the value of OP as the bias
value.
3.2.1Servo performance
Disturbance in reactor liquid level or reactor temperatureare
given and effects of the disturbance on process and control
loop interactions have been studied.
3.2.1a Servo performance on level controller: A disturbance
of +20% and -20% in reactor liquid level is given at time t = 6
hours by changing SP value in level controller faceplate.
Response time taken for PV to reach new steady value, effect
on temperature of reactor observed.
3.2.1b Servo performance on temperature controller:+10%
and -10% disturbances in reactor temperature are given by
changing SP value in temperature controller face plate.
Response time taken for PV to reach new steady state value,
effect on reactor level and duty arereported in Table-V.
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3.2.2 Regulatory Performance
Step disturbance in feed temperature for both ethylene and
benzene streamsgiven and its effect on reactor liquid level,
temperature and ethyl benzene purity in product has been
studied. 10% and -10% step disturbancesin both feed
temperatures are given [2]. In stream specification sheet
variable has been changed from fixed to free variable and after
changing value again the variable is specified as fixed. Effect
of changing the feed streams has been reported in Table-VI.
1. Tuning of Controller(relay auto tuning test)
Tuning isessential for all process controllersto obtain
optimum controller parameters. By conducting Relay Auto-
Tuning test theultimate gainand ultimate period are
calculated[4].For this test, the feedback controller is
temporarily replaced by an on-off controller (or relay). After
the control loop is closed, the controlledvariable exhibits a
sustained oscillation that is characteristic of On-Off controller.
The ultimate gain and ultimate period can be obtained from
the following. Ultimate period P u is equal to the period of
oscillation for the process output.Ultimate gain K u =4d/πa
where d is relay amplitude set by the user and
a is measured amplitude of the process oscillation.
IV RESULTS
4.1Steady state Simulation results
Steady state simulation results for CSTR are shown in
TABLE-III. The mole fraction of ethyl benzene in the product
is 0.4741.
TABLE III
STEADY STATE SIMULATION RESULTS
Parameter Values
Outelet Temperature 430K
Heat Duty -12467358watts
Reactor volume99.99m3
Residence time 1967 sec
4.2 Dynamic Simulation results
Process response has been first studied with default
controller parameters for both temperature and level
controllers and without any disturbance. Response time for the
process variables to reach steady state has been observed.
From the results it can be observed that the system response is
very poor with the default controller values.
Fig. 5 Temperature controller response with default controller values
 International Conference on Chemical, Environmental and Biological Sciences (ICCEBS'2012) Penang, Malaysia

-3.e+007

-3.e+007
420.0 440.0 460.0

460.0
460.0
plot1 -

5.35

0.75
STREAMS("6").Zn("EB") kmol/kmol
5.6

0.5 0.6 0.7 0.8 0.9 1.0

0.5 0.55 0.6 0.65 0.7

STREAMS("6").F kmol/s
BLOCKS("R1").level m

BLOCKS("R1").Q W

STREAMS("6").T K
BLOCKS("R1").T K
S6.F

STREAMS("6").F kmol/s
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5.5
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440.0

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440.0
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Time Hours
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Fig. 8 Effect of TC disturbamce on different variables(+10% Sp)

400.0

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0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0
Time Hours
TABLE V
Fig. 6Response of different variables with default controller RESPONSE TIMES FOR +/-10% STEP DISRURBANCE IN TC SET POINT
values Parameter Response times(in hours)
+10% disturbance -10% disturbance
5.55

45.0 50.0 55.0 60.0 65.0 70.0 75.0 80.0 85.0

6.0

in TC SP in TC SP
Reactor Temperature 2 5
5.35 5.4 5.45 5.5

Reactor level 2 4
5.75
Controller Output %
Process Variable m

Duty 1.5 2.5

Set Point m

OP
5.5

4.4 Regulatory Performance

5.25

SP In order to investigate the regulatory performance of level

and temperature controllers at time t=6 hours, +10%step input
change in both feed temperatures (from 298K to 330K) was
5.0

PV
5.3

introduced. Response of the process, level and temperature

controllers have been given in TABL-V.
5.25

0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0
Time Hours TABLE VI
RESPONSE TIMES FOR +10%/-10% STEP DISTURBANCE IN FEED TEMPERATURE
Fig. 7 Level controller response with default controller values Parameter Response times(in hours)
+10% disturbance -10% disturbance
TABLE IV in TC SP in TC SP
CSTR RESULTS Reactor Temperature 56
Parameter Response times(in hours) Reactor level 33
Duty 2 4

Reactor Temperature 5
Reactor level 5 Temperature controller and Level controller tuned parameters
Duty 2.5
are shown in Table-VI and VII.
TABLE VII
4.3 Servo Performance On Temperature Controller TEMPERATURE CONTROLLER TUNED PARAMETERS
4.3.a+10% disturbance in TC set point KC TI KUPU
Z-N Settings 11.4 3.5 22 4.2
After the controllers reached steady state TC has been T-l Settings 7.8 10.56
subjected to +10% set point disturbance(with default
controller parameters) by changing SP in TC faceplate from TABLE VIII
430K to 470K at time t=6 hours. Effect of set point LEVEL CONTROLLER TUNED PARAMETERS
disturbance on various parameters has been observed. For this KC TI KU PU
disturbance TC attempts to compensate for changes through Z-N Settings 1200 1E+06 2494 0.18
T-l Settings 14701E+06
manipulation of coolant temperature (controller
OP).Disturbance in TC set point has been found toeffect the
reactor liquid level which can be observed from the LC plot.
Level controller compensates the TC set point disturbance by 4.5 Process responses with tuned control parameters
increasing liquid level in the reactor. And TC set point Response of the system with Z-N and T-L control settings
disturbance also effects the Ethylbenzene purity and total flow for +10%/-10% disturbances in TC set point are given in
rate in the product stream. TABLE-IX and Table-X.

118
 International Conference on Chemical, Environmental and Biological Sciences (ICCEBS'2012) Penang, Malaysia

Disturbance in level controller set point (servo problem) has

TABLE IX
RESPONSE TIMES FOR +/-10% STEP DISRURBANCE IN TC SET POINT WITH Z-N
been observed to show no loop interaction.
SETTINGS It can be concluded that the process control structure has
Parameter Response times( minutes) one-way interaction only.
+10% disturbance -10% disturbance T-L controller tuning parameters have been observed to
in TC SP in TC SP
provide good ramp disturbance rejection settings when
Reactor Temperature 1624
Reactor level -- compared to Z-N controller tuning parameters.
Duty 1218 In the case of disturbance in temperature controller set point
(Servo problem), Z-N settings provided better response when
compared to T-L settings.
TABLE -X The regulatory performance of the process subjected to step
RESPONSE TIMES FOR +/-10% STEP DISRURBANCE IN TC SET POINT WITH disturbance has been found to be almost similar with both Z-N
T-L SETTINGS
and T-L settings.
Parameter Response times( minutes)
+10% disturbance -10% disturbance
For –ve step disturbance in temperature controller set point
in TC SP in TC SP (servo problem), the process performance is oscillatory, while
Reactor Temperature 12 such oscillatory behavior was absent in the case of +ve step
Reactor level 10 - disturbance.
Duty 10 15

VI. REFERENCES
305

305
STREAMS("6").Zn("EB") kmol/km
-8.e+007-6.e+007-4.e+007-2.e+007
435.0 440.0

5.29

1.0

1.0
STREAMS("6").F kmol/s
BLOCKS("R1").level m

[1] William L. Luyben, ”Chemical reactor design and control”, John

BLOCKS("R1").Q W

STREAMS("1").T K

STREAMS("2").T K
BLOCKS("R1").T K

R1.Q Wiley&sons, 2007.

[2] Amia K Jana, “Process simulation and control using Aspen dynamics”,
0.8

0.8

285.0

285.0

2ndedition,2008,PHI Learning private ltd.

5.285

S6.F
[3] J. Ingham,I. J. Dunn,E.Heinzle, J. E.Přenosil, “ Chemical Engineering
430.0

0.6

0.6

level
R1.T
EB molfraction
Dynamics, ( An Introduction toModeling and Computer Simulation)”,2nd
S1.T S2.T Edition, Wiley-VCH. 2000
425.0

265.0
5.28

0.4

0.4

0.0 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0
[4] Karl J. Astrom, Tore Hagglund, “PID controllers design theory and
Time Hours tuning”, 2nd edition, Instrument Society of America, 1995
[5] Cheres, “Parameter estimation of an unstable system with a PID
Fig. 9 Response of different variable with tuned Z-N controller
controller in a closed loop configuration”, J. Franklin Inst., Automatica,
settings for step disturbance in TC Set point 37, 2005
[6] MassimilianoVeronesiand Antonio Visioli,“Performance assessment
and retuning of PID controllers for integral processes”, IEE
-2.5e+007

34
STREAMS("6").Zn("EB") kmol/kmol

proceedings on the CTA, pp. 148, 2009

420.0425.0430.0435.0440.0445.0450.0455.0

280.0290.0300.0310.0320.0330.0340.0
0.4 0.5 0.6 0.7 0.8 0.9 1.0
0.8
5.283

320.0
STREAMS("6").F kmol/s

R1.T
BLOCKS("R1").level m

BLOCKS("R1").Q W

STREAMS("1").T K

STREAMS("2").T K
BLOCKS("R1").T K

R1.Q

S6.F
5.282

300.0
-4.5e+007

S2.T level
0.6

EB molfraction
5.281

280.0

S1.T
-6.5e+007
5.28

0.4

2.0 2.5 3.0 3.5 4.0

Time Hours

Fig.10. Response of different variables with tuned T-L controller

parameters

VCONCLUSIONS
Controllability of an irreversible exothermic reaction is
difficult when compared to that of an endothermic reaction.
The performance of the process was found to be poor when
default controller parameters were used.
Tuning the controller parameters has been found to improve
the process performance with respect to both Z-N and T-L
tests.
Disturbance in temperature controller set point (servo
problem) has been observed to influence the reactor liquid
level, causing loop interaction.

119