Process

- The conversion of feed materials to products using chemical and physical operations. In
practice, the term process tends to be used for both the processing equipment. (Seborg,
2004)
- The types of processes: Continuous, Batch, Semi-batch

Continuous - continuous stirred tank reactor, thermal cracking furnace, multi component
distillation column

Batch/Semi Batch - batch digester in a pump mill, plasma etcher in a semiconductor processing,
batch or semi batch reactor

Types of Process Variables

● Controlled (Measured) Variable

- The process variables that are controlled. The desired value of a controllable
value is referred to as its set point.

● Manipulated Variable
- The process variables that can be adjusted in order to keep the controllable
variables at or near their set points. Typically, the manipulated variables are flow
rates.

● Disturbance Variable
- Process variables that affect the controlled variables but cannot be manipulated.
Disturbances generally are related to changes in the operating environment of
the process.

Shell and Tube Heat Exchanger

A process fluid on the shell side is cooled by cooling water on the tube side. Typically,
the exit temperature of the process fluid is controlled by manipulating the cooling water flow
rate. Variations in the inlet temperatures and the process fluid flow rate affects the heat
exchanger operation. Consequently, these variables and disturbance variables.
 ● Controlled Variable
- Exit temperature
● Manipulated Variable
- Cooling water flow rate
● Disturbance Variable
- Inlet temperature
- Process fluid flow rate

A Blending Process - CSTR Blending System

The control objective is to blend the two inlet streams to produce an outlet stream that
has the desired composition. Stream 1 is a mixture of two chemical species, A and B. We
assume that its mass flow rate w 1 is constant, but the mass fraction of A, x 1, varies the time.
Stream 2 consists of pure A and thus x 2 = 1 the mass flow rate of Stream 2, w 2, can be
manipulated using a control valve. The mass fraction of A in the exit stream is donated by x and
the desired value (set point) by x sp.

Controlled variable x
Manipulated Variable w2
Disturbance Variable x1
Design Question: If the nominal value of x 1 is x́ 1, what nominal flow rate ẃ 2 is required to
produce the desired outlet concentration x sp?

Overall Balance; Steady-state

ẃ 1+ ẃ2= ẃ
ẃ 1+ ẃ2 + ẃ=0

Complete A Balance; Steady-state

ẃ 1 x́ 1 + ẃ2 x́ 2−wx=0
´
x sp −x́1
ẃ 2=ẃ 1 ( 1−x sp )
Process Dynamics

● The term refers to unsteady-state (transient) process behavior.

● Transient operation occurs during important situations such as startups and shutdowns,
unusual process disturbances, and planned transitions from one product to grade to
another. (Seborg, 2004)

A Blending Process - CSTR Blending System

Process Control

● The primary objective is to maintain a process at the desired operating conditions safely
and efficiently, while satisfying environmental and product quality requirements. (Seborg,
2004)
● This refers to the methods that are used to control processes variables when
manufacturing a product.

Process Variables

● A condition of the process fluid (a liquid or gas) that can change the manufacturing
process in some way.
- Pressure
- Flow
- Level
- Temperature
- Density*
- pH*
- Mass*
- Conductivity*

Manufacturers control the production process for three reasons:

- Reduce variability
- Increase efficiency
- Ensure safety
Reduce Variability
● Process control can reduce variability in the end-product, which ensures a consistently
high-quality product.
● Reducing variability can also save money by reducing for product padding to meet
required product specifications.

Increase Efficiency
● Some processes need to be maintained at a specific point to maximize efficiency.
● Manufacturers save money by minimizing the resources required to produce the end-
product.

Ensure Safety
● A run-away process, such as an out-of-control nuclear or chemical reaction, may result if
manufacturers do not maintain precise control of all process variables. The
consequences of a run-away process can be catastrophic.
● Precise process control may also be required to ensure safety.
Process Control Terms

Setpoint
- A value for a process variable that is desired to be maintained.

Error
- The difference between the measured variable and the setpoint can be either positive or
negative.
- The objective of any control scheme is to minimize or eliminate error.

Magnitude
- The deviation between the values of the setpoint and the process variables.

Duration
- The length of time that an error condition has existed.
Rate of Change
- The length of time that an error condition has existed.

Offset
- A sustained deviation of the process variable from the setpoint.

Load Disturbance
- An undesired change in one of the factors that can affect the process variable.
Control Algorithm
- The mathematical expression of a control function.
- This can be used to calculate requirements of much more complex control loops.

Manual Control
- Control operations that involve human action to make an adjustment.
Automatic Control
- Control operations in which no human intervention is required
- Automatic valve actuator

Closed Control Loops

- Loop that exists where a process variable is measured, compared to setpoint, and action
is taken to correct any deviation from setpoint.

Open Control Loops

- Loop that exists where the process variable is not compared, and action is not taken not
in response to feedback on the condition of the process variables that is instead taken
without regard to process variable conditions.

Process Control Loop

Elements of the Design of a Control System

Hierarchy of Process Control Activities

1. Measurement and Actuation

Measurement devices (e.g sensors and transmitters) and actuation equipment
(e.g control valves)
2. Safety and Environmental/Equipment Protection
Process safety relies on the principle of multiple protection layers
Safety equipment operates independently of the regular instrumentation used for
regulatory control
Environment regulations

Philippine Clean Air Act

Continuous Emission Management System (CEMS)

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