Process Simulation

using Simulink

Cheng-Liang Chen
PSE
LABORATORY
Department of Chemical Engineering
National TAIWAN University
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Process Simulation
Simulation of A Gas Process
Consider the gas tank shown below. A fan blows air into a tank, and from the
tank the air flows out through a valve. Suppose the air flow delivered by the fan is
given by
fi(t) = 0.16mi(t)
where fi(t) is gas flow in scf/min, (scf is cubic feet at standard conditions of 60oF
and 1 atm); mi(t) is signal to fan, %. The flow through the valve is expressed by
p
fo(t) = 0.00506mo(t) p(t)[p(t) − p1(t)]

where fo(t) is gas flow, scf/min; mo(t) is signal to valve, %; p(t) is pressure in
tank, psia; p1(t) is downstream pressure from valve, psia.
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The volume of the tank is 20 ft3, and it can be assumed that the process occurs
isothermally at 60oF. The initial steady-state conditions are

f¯i = f¯o = 8 scfm; p̄ = 40 psia; p̄1 = 14.7 psia; m̄i = m̄o = 50 %

An unsteady-state mole balance around the control volume, defined as the fan,
tank, and outlet valve, is

dn(t) V dp(t)
= = ρ̄fi(t) − ρ̄fo(t)
dt RT dt

ρ̄ = 0.00263 lbmoles/scf is molar density of gas at standard conditions; R = 10.73

psia-ft3/lbmoles-oR is ideal gas law constant; T = 520oR is gas temperature.
Please construct a Simulink model to simulate this process, and shows the
response of the pressure to a step change of 5% in the signal to the inlet fan
(starts from time =5 min.)
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Process Simulation
Simulation of A Gas Process
V dp(t)
= ρ̄fi(t) − ρ̄fo(t)
RT dt
fi(t) = 0.16mi(t) (ρ̄ = 0.00263 lbmole/scf, V = 20 ft3)
p
fo(t) = 0.00506mo(t) p(t)[p(t) − p1(t)]
mi(0) = m̄i = 50%, mo(0) = m̄o = 50%, p1(0) = p̄1 = 14.7psia
⇒ fo(0) = fi(0) = 0.16mi(0) = (0.16)(50) = 8.0 scf/min
p
fo(0) = 0.00506mo(0) p(0)[p(0) − p1(0)]
⇒ p(0) = 39.8 psia
dp(t) ρ̄RT
⇒ = [fi(t) − fo(t)]
dt V
(0.00263)(10.73)(520)
= [fi(t) − fo(t)]
20
= 0.734[fi(t) − fo(t)] (now: mi = 55% at t = 5)
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dp(t)
fi(t) = 0.16mi(t), = 0.734[fi(t) − fo(t)]
pdt
fo(t) = 0.00506mo(t) p(t)[p(t) − p1(t)] fo(0) = 39.8 mi : 50 → 55%
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subplot(2,1,1)
plot(dt,p,’m’,’linewidth’,2)
ylabel(’\bf p(t)’,’Fontsize’,14);
title(’\bf Gas pressure response to step fan change’,’Fontsize’,14)
subplot(2,1,2)
plot(dt,mi,’b’,’linewidth’,2)
ylabel(’\bf m_i(t)’,’Fontsize’,14);
xlabel(’\bf t (min)’,’Fontsize’,14);
set(gca,’linewidth’,3);
% set(gca,’Fontsize’,14);
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Process Simulation
Simulation of A Stirred Tank Heater

The stirred tank is used to heat a process stream so that its premixed components
achieve a uniform composition. Temperature control is important in this process
because a high temperature tends to decompose the product while a low
temperature results in incomplete mixing. The tank is heated by steam condensing
inside a coil. A proportional-integral-derivative (PID) controller is used to control
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the temperature in the tank by manipulating the steam valve position.

The feed has a density ρ of 68.0 lb/ft3, a heat capacity cp of 0.80 Btu/lb-oF. The
volume V of liquid in the reactor is maintained at 120 ft3. The coil consists of 205
ft of 4-in. schedule 40 steel pipe, weighting 10.8 lb/ft with a heat capacity of 0.12
Btu/lb-oF and an outside parameter of 4.500 in. The overall heat transfer
coefficient U , based on the outside area of the coil, has been estimated as 2.1
Btu/min-ft2-oF. The steam available is saturated at a pressure of 30 psia; it can
be assumed that its latent heat of condensation λ is constant at 966 Btu/lb. It
can also be assumed that the inlet temperature Ti is constant.
An energy balance on the liquid in the tank, assume negligible heat losses, perfect
mixing, and constant volume and physical properties, results in the equation

dT (t)
V ρcv = f (t)ρcpTi(t) + U A[Ts(t) − T (t)] − f (t)ρcpT (t)
dt
An energy balance on the coil, assuming that the coil metal is at the same
temperature as the condensing steam, results in (CM : heat capacitance of coil
metal, Btu/oF; w(t): steam rate, lb/min)

dTs(t)
CM = w(t)λ − U A[Ts(t) − T (t)]
dt

The initial steady-state conditions are T (0) = 150oF and Ts(0) = 230oF. Also the
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initial design conditions are f (0) = 15 ft3/min, Ti(0) = 100oF, and w(0) = 42.2
lb/min.
Construct a Simulink diagram for the simulation of the heater. shows the
responses of the temperatures to a step changes in process flow.
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Process Simulation
Simulation of A Stirred Tank Heater
dT (t) 1 UA
dt = V f (t)[T i (t) − T (t)] + V ρcv [Ts (t) − T (t)], T (0) = 150oF
dTs (t) 1
dt = CM {λw(t) − U A[Ts (t) − T (t)]} Ts(0) = 230oF
o 3
Ti(0) = 100 F, f (0) = 15ft /min, w(0) = 42.2lb/min
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Process Simulation
Simulation of A Stirred Tank Heater

Response of heater outlet temperature and steam chest temperature

to a step change in process flow
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Process Simulation
Simulation of A Stirred Tank Heater
Subsystem Block for The Stirred Tank Heater
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Transfer Function Simulation

Temperature Control of A Stirred Tank Heater (p.201)
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Transfer Function Simulation

Temperature Control of A Stirred Tank Heater (p.201)
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Process Simulation
Simulation of A Batch Bioreactor
Many important specialty chemical products are produced in bioreactors by
processes such as fermentation. Most of these processes are carried out in batch
mode by filling a tank with a substrate solution and inoculating it with a small
amount of biomass. The biomass, feeding on the substrate, reproduces to produce
the desired product, until the substrate is consumed. This example is presented
here to show some of the special characteristics of biochemical processes.
A dynamic model of the growth of the biomass concentration x(t) and of the
consumption of the substrate concentration, s(t), is given on a per unit volume
bsis as follows:
dx(t)
dt = µ(t)x(t)
ds(t) 1
dt = − y(t) µ(t)x(t)
where y is the yield in biomass per unit mass of substrate and µ(t) is the biomass
growth rate function (h−1). This growth rate function is analogous to the kinetic
models used to model chemical reactors. It is designed to match experimental
data. Here we will use the Monod model with adaptability wich has the following
form:  
dµ(t) s(t)
= α µm − µ(t)
dt k + s(t)
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where α is the adaptability parameter, and k and µm are the parameters of the
model. Please use Simulink to simulate the model with the following data:
α = 15h−1, k = 0.5g/liter, s(0) = 2.5g/liter, µ(0) = µm = 1.2h−1, and
x(0) = 0.001g/liter.
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Process Simulation
Simulation of A Batch Bioreactor
dx(t) ds(t) 1
dt = µ(t)x(t) dt = − y µ(t)x(t)
h i
dµ(t)
dt
s(t)
= α µm k+s(t) − µ(t) α = 15 h−1, µ(0) = µm = 1.2
k = 0.5 g/liter, s(0) = 2.5 g/liter, x(0) = 0.001 g/liter
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Process Simulation
Simulation of A Pressure Tank
A stray bullet fired by a careless robber punctures the compressed air tank at a gas
station. The mass balance of air in the tank is

dρ(t) p
V = wi(t) − Ao 2ρ(t)[p(t) − po]
dt

where
M
ρ(t) = p(t)
RT
wi(t) kg/s, is the inlet flow from the air compressor, V = 1.5 m3, is the volume of
the tank, Ao = 0.785 cm2, is the area of the bullet hole, M = 29 kg/kmole, is the
molecular weight of air, R = 8.314 kPa-m3/kmole-K, is the ideal gas law
constant, and temperature T is assumed constant at 70oC, po = 500 kPa gauge.
Use Simulink to simulate the process and plot the response of the pressure in the
tank.
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Process Simulation
Simulation of A Pressure Tank
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Process Simulation
Simulation of A Mixing Tank
Computer-room Exercise
Consider the mixing process shown below. Assume
that the density of the input and output streams
are very similar and that the flow rates f1 and
f2 are constant. It is desired to understand
how each inlet concentration affects the outlet
concentration. Develop the mathematical model.
Use Simulink to simulate the mixing process
and plot the response of the outlet concentration to a step change of 5
gallon/minute (gpm) in flow f1. At the initial steady-state conditions the flow
from the tank is 100 gpm, and its concentration is 0.025 moles/cm3. The tank
volume is 200 gallons, and the feed compositions are 0.010 and 0.05 moles/cm3.
Assume a tight level controller keeps the volume in the tank constant.
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Process Simulation
Simulation of A Nonisothermal Chemical Reaction
Computer-room Exercise
Consider a stirred-tank reactor with reaction A → B
as shown below. To remove the heat of reaction the
reactor is surrounded by a jacket through which a
cooling liquid flows. Let us assume that the heat
loss to the surroundings are negligible, and that
the thermodynamic properties, densities, and heat
capacities of the reactants and products are both
equal and constant. The heat of reaction is constant and is given by ∆Hr in
Btu/lbmole of A reacted. Let us also assume that the level of liquid in the reactor
tank is constant; that is, the rate of mass into the tank is equal to the rate of
mass out of the tank. Finally, the rate of reaction is given by

lbmoles of A reacted
rA(t) = koe−E/RT (t)c2A(t)
ft3-min
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where the frequency factor ko and energy of activation E are constants. The
following Table gives the steady-state values of the variables and other process
specifications. It is desired to find out how the outlet concentrations of A and B,
and the outlet temperature respond to changes in the inlet concentration of A,
cAi(t); the inlet temperature of the reactant Ti(t); the inlet temperature of
cooling liquid Tci(t); and the flows f (t) and fc(t).

Process information
V = 13.26 ft3 ko = 8.33 × 108 ft3/(lbmole-min)
E= 27, 820 Btu/lbmole R= 1.987 Btu/(lbmole-oR)
ρ= 55 lbm/ft3 Cp = 0.88 Btu/(lbm-oF)
∆Hr = −12, 000 Btu/lbmole U= 75 Btu/(h-ft2-oF)
A= 36 ft2 Cpc = 1.0 Btu/(lbm-oF)
Vc = 1.56 ft3
Steady-state values
CAi(t) = 0.5975 lbmole/ft3 Ti(t) = 635oR
Tc = 602.7oR f= 1.3364 ft3/min
cA(t) = 0.2068 lbmole/ft3 T (t) = 678.9oR
Tci(t) = 540oR fc(t) = 0.8771 ft3/min
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Assume the reactor is initially at the design conditions. Use Simulink to simulate
the process and plot the response of the reactor temperature to a step change of
0.25 ft3/min in process flow, and of 0.1 ft3/min in coolant flow.

dcA(t)
f (t)cAi(t) − f (t)cA(t) − V rA(t) = V
dt
rA(t) = koe−E/RT (t)c2A(t)
dT (t)
f (t)ρCpTi(t) − U A[T (t) − Tc(t)] − f (t)ρCpT (t) − V rA(∆Hr ) = V ρCv
dt
dTc(t)
fc(t)ρcCpcTci(t) + U A[T (t) − Tc(t)] − fc(t)ρcCpcTc(t) = VcρcCvc
dt