PROCESS CONTROL IN

CHEMICAL ENGINEERING
BY USING MATLAB

Presented by
LAKSHMIPRIYA J,
ASSISTANT PROFESSOR,
DEPT. OF CHEMICAL ENGINEERING,
ESEC.
 OVERVIEW ABOUT THIS WORKSHOP

 Introduction to Process control

 Basic concepts in process control

 Introduction to MATLAB

 Introduction to Simulink in MATLAB

 Examples
 INTRODUCTION TO PROCESS CONTROL

 Chemical industry – we have numbers of unit

operations.

 For example – Reactors, Distillation Columns,

Pumps and Compressors.

 Now we construct a chemical plant, we need to

assemble few these unit operations.
 OBJECTIVES OF CHEMICAL PLANT

 The chemical plant receives raw material and convert

into desired product using available sources, in a most
economic way.

Raw materials Product

Chemical Plant
 REQUIREMENTS

 We need to achieve this objectives, we need some

external requirements. These are:
 Safety

 Product Specifications – both Quality and Quantity

 Environmental Requirements

 Operational Constants
To achieve this
 Economics requirements,
we need
control system
 NEED FOR CONTROL SYSTEM

 Suppress the influence of external disturbances.

 Ensuring the stability of the chemical process.

 Optimizing the performance of a chemical process.

 T YPES OF PROCESSES USING PROCESS
CONTROL

 Discrete – manufacturing, Motion and Packaging applications.

For example, Robotic assembly in automotive production.

 Batch – Some applications require specific quantities of raw

material in a specific way and specific time to produce the end

product. For example, Production of adhesives, glues, food,

medicine and beverages. This process generally used to

produces relatively low quantity of product pre year.

CONT..

 Continuous – All raw materials are mixed together

and product coming out of the process. Some
important chemical processes are the production of
fuels, chemicals and plastics. This process are used
to produce very large quantities of product per year.
 CLASSIFICATIONS OF VARIABLES IN PC

 Input Variables
 Manipulated Variables – Values can be adjusted by
operator or control mechanisms.

 Disturbances – Values can’t be changed

 Output variables
 Measured output

 Unmeasured output
 T YPES OF INPUT SIGNALS

 Step

 Ramp

 Impulse

 Sinusoidal
 CONTROL PROCESS

Disturbances
Process
Control
Variable
Loop
(PV)
Process

Adjustment Measurement

Controller
Controlled
Output
(CO)
Set Point (SP)
 IMPORTANT TERMS

 Set Point (SP) – Desired or target value of an process

variable.

 Process Variable (PV) – Process parameter will be

monitored in the process.

 Disturbances – internal and external disturbances that

affects the process.
 BLOCK DIAGRAM OF CONTROL SYSTEM

 Control system divided into two types:

 Feedback Control System

 Feed forward Control System

 FEEDBACK CONTROL SYSTEM

 This system will react only after detecting the error

signal from the process. In this system, no action
control action will be taken until the error affects the
process variable.
 FEED FORWARD CONTROL SYSTEM

 This system, the disturbances will be directly

measured and corrective action takes place.

 In this system, the process variable doesn’t change.

Disturbances

Input su Output
m Controller Process
 COMPARATOR

 Compares the controlled output and set point.

 Based on this comparison the control system divided

into two types:

 Negative Feedback control system e = R-B

 Positive Feedback control system e = R+B

 HOW DID YOU UNDERSTAND THE
RESPONSE OF CONTROL SYSTEM

Laplace transform of output variable

 G(S) =
Laplace transform of Input variable
 T YPES OF CONTROLLER

 Pneumatically operated controllers are widely used in chemical

process control in industrial applications.

 Here the compressed air is used to open and close the control
valve.

 Types of controllers:
 Proportional Controller

 Proportional Derivative Controller

 Proportional Integral Controller

 Proportional Integral and Derivative Controller

 ON/OFF Controller
 TIME DELAY / TRANSPORTATION LAG

 The measured process variable (PV) first begins to

respond.
 TUNING OF CONTROLLERS

Why Controller Tuning is Important

 The control system acts as the nervous system for the
plant. It provides sensing, analysis and control of the
physical process.

 When a control system is at properly tuned, the

process variability is reduced, efficiency is maximized,
energy costs are minimized, and production rates can
be increased.
 CONTROLLER TUNING

 Controller tuning refers to the selection of tuning parameters

to ensure the best response of the controller.

 Choose tuning that is too slow, and the response will be

sluggish.

 The controller will not handle upsets, and it will take too long

to reach set point.

 TUNING METHODS

 Cohoon – Coon Method – Open loop system

 Ziegler – Nichols Method – Closed loop system

Open loop system – Closed loop system

No action to error – Controller takes
signals. Only the set action to error. The
point will vary by the set point will be
operator. constant.
MATLAB
 INTRODUCTION TO MATLAB

 MATLAB is a commercial “Matrix Laboratory” package with

operates as an interactive programming environment.

 It is well adopted to numerical experiments.

 High – Performance language for technical computing.

 USES

 Algorithm development

 Data Acquisition

 Modeling and Simulation

 Data Analysis, Exploration and Visualization

 Scientific and Engineering Graphics

 Application Development including graphical user interface

building
MATLAB WINDOW
TOOLS
 SIMULINK

 SIMULINK is an extension to MATLAB which uses a icon driven

interface for the construction of block diagrams representation
of a PROCESS.

 Steps involved in Simulink solution:

 Creating the block diagram

 Specify the block parameters

 Setting up the solver

 Running the simulation

SIMULINK
SIMULINK LIBRARY BROWSER
 RESPONSE OF TIME
DELAY FOR DIFFERENT
ORDER PROCESS FOR
DIFFERENT TYPES
INPUTS
STEP INPUT – FIRST ORDER PROCESS
RAMP INPUT – FIRST ORDER PROCESS
SINE INPUT – FIRST ORDER PROCESS
STEP INPUT – SECOND ORDER PROCESS
RAMP INPUT – SECOND ORDER PROCESS
SINE INPUT – SECOND ORDER PROCESS
TUNING OF PID
CONTROLLER
OPEN LOOP DIAGRAM (COHOON – COON
METHOD)
CLOSED LOOP SYSTEM (ZIEGLER
NICHOLS METHOD)
PV

Ko
 P – Controller K p = Ko / 2

 PI – Controller K p = K o / 2.2

t I = P V / 1 .2

KI = 1 / tI
 PID – Controller

K p = K o / 1 .7

tI = PV / 2

KI = 1 / tI

t D = PV / 8

KD = 1 / t D