FACULTY OF ENGINEERING

Department of Chemical Engineering

P.O.Box 1906
Bellville
7535
TEL: (021) 959 6083
FAX: (021) 959 6323

Course NATIONAL DIPLOMA: CHEMICAL ENGINEERING

Subject Process Control III Code PRCO 30

Date 19 November 2008 Time 9h00 - 12h00

Marks 120

Assessor Mr. U. Narsingh

Moderators (INT) Mr. T. Madzimbamutho

(EXT) Mr. S. Rathilal

Requirements

1) Calculator

Instructions to Candidates

1) This paper consists of 4 questions. Answer all questions.

2) Laplace Transform tables will be supplied.
Question 1: [34] Instrumentation

1.1) List 5 needs/incentives for controlling a process. [5]

1.2) Define and describe the following terms in the context of process control:
1.2.1) Transducer
1.2.2) Range
1.2.3) Zero Drift
1.2.4) Sensitivity
1.2.5) Resolution
1.2.6) Accuracy
1.2.7) Precision [14]

1.3) An orifice plate can be used to measure the flow of a fluid in a pipe. Explain in
detail the operation of an orifice plate as used for process control purposes.
Your answer should include a discussion of strain gauges, wheatstone
bridge, and differential pressure measurement. [10]

1.4) Explain how the following instruments can be used to indicate the level of a
fluid in a tank:
1.4.1) U-Tube Level indicator
1.4.2) Sonic or Ultrasonic Level indicator [5]

Question 2: [30] Laplace Transforms

2.1) Define the Laplace Transform of a function and then use this definition to
determine the Transform of the second derivative of a function. [5]

2.2) A reactor, which displays second-order dynamics, was modelled. The

following differential equation describing the change in the temperature of the
reactor was obtained:

d2 T
2
+ 4T = e t T(0) = T(0) = 0
dt
Use Laplace Transforms to find the solution to the above model equation. [8]
2.3) Consider the Continuously Stirred Tank Reactor (CSTR) system shown in the
figure below:

V1

C A1

V2
V C A2
CA CB2

An elementary, liquid phase reaction, A → B, occurs in the reactor and

proceeds at rate

– r = kCA

where r = moles of A/(volume)(time)

k = rate constant
CA(t) = concentration of A in reactor, moles/volume

The following information is also available for the system:

V = 1 l
V1 = 1 l/hr

V = 1 l/hr
2

k = 0.1 l/(mol)(hr)

Assuming only component A enters the reactor, constant density, constant

reactor volume, and constant volumetric flowrates answer the following
questions:

2.3.1) Model the system and then use Cramer’s Rule to derive an expression
which shows how the concentration of component A changes with time. [10]

2.3.2) If the inlet concentration of component A varies as CA1(t) = sin t,

determine the concentration-time profile of Component A in the outlet
stream, i.e. CA2(t). [7]
Question 3: [20] Modelling

Consider the following reactor system in which the following elementary, liquid phase,
endothermic reaction
A⎯
⎯→
k
B
takes place. The heat required for the reaction is supplied by steam condensing in the
jacket.


V1

ρ1
C A1

Steam in Steam out

TS1 TR TS2


V2

ρ2
C A2
CB2

Determine the model equations defining the above system assuming the following:
▪ Only pure component A enters the reactor.
▪ The rate constant for the reaction is k
▪ The reactor wall has insignificant heat capacity

Note: in deriving the model equations, you need to state all simplifying assumptions.
Question 4: [40] Transfer Functions

4.1) Write down the procedure for determining the transfer function. [2]

4.2) Give 2 advantages of expressing model equations in deviation variable form. [2]

4.3) Consider the continuously stirred tank reactor system shown in the figure
below:

V V2
1

C A1 C A2
ρ1 2

V
CA V3
CA
CB
ρ

Reaction occurring in the reactor is A → B, and it proceeds at rate –r = k CA2

where r = moles of A/(volume)(time)

k = rate constant
CA(t) = concentration of A in reactor, moles/volume

Assuming constant density, constant reactor volume, V, and constant

flowrates, answer the following questions:

4.3.1) Develop a mathematical model for the process. [5]

4.3.2) Determine the transfer function relating the concentration of component A

in the reactor (CA) to the feed stream concentrations (CA1 and CA2) [15]

4.3.3) Using the data below:

V = 10 000 l

V1 = 5 000 l/hr


V = 20 000 l/hr
2

V3 = 15 000 l/hr

k = 2 l/(mol)(hr)
4.3.3.1) CA = 0.125 mol/l [6]

Determine the process time constant and static gains.

4.3.3.2)

Determine the response of the reactor concentration to a simultaneous

unit step increase in the inlet concentration, CA1 and a ramp increase in
[10]
inlet concentration, CA2 (slope of ramp = 1)
Note: the Laplace Transform of this ramp input is given by 1/s2.