Beyond the classroom: An expanded view of

flow control
The interaction between flow control and pressure control can create new process methods for
industrial applications.

AUTHOR / Jeff Jennings*

Nov 10th, 2020

Figure 1. Interaction between pressure control and flow control delivers process control solutions to
innovative research and industrial applications.

In school, engineers are taught that flow control and pressure control are related but distinct
concepts — controlling flow focuses on volume while controlling pressure focuses on force. In
real-world applications, however, it is often the interaction between the two that gives innovators
an opportunity to create powerful new process methods.

Such opportunities have become even more exciting in recent years. Developments in flow
chemistry and continuous manufacturing have put a novel twist on longstanding traditions of
steady-state flow control for dosing and inline blending. Expanding the traditional model further
extends flow control into level control, temperature control, pH control and even coating weight
control.

Interaction between pressure and flow control

As innovators push the envelope to adapt processes, it can be helpful to review how flow control
and pressure control systems converge to create new process methods.
The flow chart in Figure 1 provides an overview of the interactions where pressure control
assists with flow control, and flow control is then used in either a direct application or to assist in
the control of other variables.

As illustrated, pressure and flow often work together to enable a specified outcome. In one
configuration, flow may be controlled with a constant supply pressure and a variable resistance
such as a control valve or solenoid valve. In another configuration, flow control can be achieved
by varying the supply pressure to a fixed resistance.

Constant supply pressure with variable resistance

A large manufacturing plant that processes fluids through several steps provides a classic
example of flow control in which a fluid with constant supply pressure is sent to a proportional-
integral-derivative (PID) control loop with a flowmeter and a control valve. In this situation,
engineers could use a globe-style flow control valve acting upon a relatively constant fluid
pressure supplied by a pump or header. The flow control valve adjusts in response to a flowmeter
and PID controller, providing variable resistance to achieve a desired flow set point (see Figure
2).

Figure 2. Flow control schematic with a fluid supplied at constant pressure to a control valve providing
variable resistance.
Variable supply pressure with constant resistance

A paint spraying system provides an example of using variable pressure and constant resistance
(see Figure 3). A pump is needed to keep fluid paint circulating, and the spray nozzle needs
various pressures applied to reach the proper flow. A back pressure regulator (BPR) is often used
to control pressure in the recirculating loop with the pump. The resistance of the spray nozzle is
considered a fixed resistance, which can be approximated by flow coefficient or an orifice
equivalent. Considering that virtually all industrial fluid processes are turbulent (even viscous
paint spraying), the flow rate can be approximated as the square root of the applied pressure. The
BPR provides the variable pressure to control the flow.

igure 3. A back pressure regulator provides variable pressure control in a recirculating loop with a spray
nozzle, resulting in controlled flow at the nozzle outlet.
Direct flow control applications and modern flow chemistry

The aforementioned steady-state process control strategies have been used in the chemical
industry for decades in processes such as dosing and bottle filling.

During the past 20 years, however, innovative developments have resulted in new ways of taking
advantage of the interaction between flow and pressure control. Pharmaceutical, fine chemical
and agrochemical industries have accelerated the conversion from batch-style reaction kettles to
inline blending and continuous reaction flow chemistry using precise pressure and flow control
techniques. These developments have been fueled by the availability of extremely reliable and
precise Coriolis flowmeters and the desire for simplified and more flexible processes.

In continuous flow reactor processes, precise flow control of reactants ensures proper ratio
control for a consistent reaction resulting in a quality final product. Reactor systems are uniquely
designed for equilibrium management, residence time and reaction speed. Designs typically
meter reactants through precision liquid Coriolis mass flowmeters (MFM) and gas mass flow
controllers (MFC), which are MFMs with an integrated solenoid valve. Fluids are metered into a
reactor where the conversion takes place inline and continuously.

In the example in Figure 4, a liquid is supplied at constant pressure through a liquid Coriolis
MFM paired with a control valve to control flow. In parallel, a gas at constant supply pressure is
metered through a gas MFC to control flow. They are mixed together at the reactor inlet and flow
continuously through the reactor. Temperature is controlled to optimize the reaction, and an
optional BPR may be used to increase reaction rate or control phases of certain byproducts. This
design may be used in processes such as hydrogenation.
Figure 4. Continuous flow chemistry process control system meters a liquid and a gas into a flow
chemistry reactor.

A similar design would work for inline product blending where ingredients are metered and
blended in a modern steady-state continuous manufacturing process to reach a desired ingredient
ratio.

Controlling flow to control other variables

Expanding the pressure and flow control interactions even further, flow control can be used to
affect other variables such as pH, level, temperature or coating weight.

The case for cascade control

Cascade control uses two feedback loops, with a primary outer control loop sending a set point
signal to the secondary inner control loop. Together, they control the final process variable.
Cascade control works well when the inner loop responds quickly to set point changes and is
controlling a primary outer loop that is slow to respond to changes (level, temperature, pH, etc).

Cascade control loops are commonly designed so that the secondary inner loop controls flow,
and the primary outer loop adjusts the flow set point to achieve desired final process variable.
The advantage to this arrangement is that the inner loop will respond quickly to process upsets
and send a signal to the outer loop, avoiding large excursions in the final process variable.

pH cascade control application

In one case study, a water treatment facility was designing a pH control system where CO2
would be sparged into a body of water to control the pH of the water. (See Figure 5.) The
application involved the need to control mass flow over a wide flow range to cater to various
volumes of water, while at the same time, reducing time lag between CO2 injection and pH
changes of the water.
Figure 5. pH cascade control system using flow control of CO2.

or this situation, an Alicat MFC with a 200:1 turndown ratio was used in a cascade design to
control pH. (See Figure 6.) The integrated solenoid valve response to feedback from an internal
PID in the MFC achieved flow control of the CO2 gas. The set point for the pH was established
in a programmable logic controller (PLC). A pH meter in the water signaled to the PLC, which
adjusted the setpoint of the MFC to arrive at the prescribed pH. 

The wide range of flow control in the MFC allowed the system design to work for various water
tank sizes, and the communication capabilities of the MFC facilitated easy pairing to the PLC.

Temperature cascade control

Cooling control loops are ubiquitous in chemical processes and manufacturing plants to control
temperature in various systems. From brewing or fermentation chambers to chemical
manufacturing plants and even data center cooling, temperature control is an important process
variable. Precise cooling liquid flow control can help maintain accurate process temperatures
even within a strict operating window.

In a typical cooling or chiller loop, cooling fluids are delivered to the process at a flow rate
capable of maintaining the target temperature. In some designs, cooling fluid pressure may be
controlled in a recirculating loop using a BPR to control flow, as in the spray nozzle example in
Figure 3. The variable pressure through a constant orifice delivers the appropriate flow, which
cascades to controlling the final temperature of the process. The process temperature sends a
signal to the pressure control loop, which varies to adjust flow to keep the temperature in control.
Figure 7. Dome-loaded direct-sealing diaphragm valve with an electronic controller for PID back pressure
control cascading to temperature control.

Expanding the view

While many of these examples are familiar to experienced process engineers, continued
improvements in flow control valves, pressure control regulators, meters and automation systems
are creating groundbreaking opportunities. By reexamining the way flow and pressure interact, it
is often possible to imagine new and innovative ways of using available control components to
meet challenging application requirements and develop improved systems for world-class
manufacturing. 

 Jeff Jennings, PE, is founder and president of Equilibar, an engineering company that specializes
in precision fluid control for challenging applications around the world. Jennings has more than
30 years of engineering experience including 16 years with The DuPont Company. He holds
several international patents and continues active research in the field of fluid controls. He may
be reached at jeff.jennings@equilibar.com.