IME 8310 – INSTRUMENTATION AND CONTROL

A downdraft fixed-bed gasifier, illustrated in Figure 1, is designed to produce synthesis gas

(syngas) from waste biomass. The biomass is fed to the reactor through a worm drive mechanism,
driven by an electrical motor.

Figure 1 - Gasifier Illustration.

The biomass feed rate is a function of the controller signal, according to the following transfer
function:
0.2(𝑘𝑔/ℎ)/%𝐶𝑂
𝐺𝐹 (𝑆) =
(0.01min)𝑠 + 1
The controlled variable is the 𝐻2 concentration (in volume %) in the syngas, while the biomass
feed rate is the manipulated variable. The concentration transmitter has a range of 5 − 90%𝐻2 and
can be modeled with a pure gain transfer function. A step change of ∆𝑚 = +5%𝐶𝑂 is made to the
controller output signal, causing a smooth response exhibiting a total change of −1.48%𝐻2 in the
syngas composition. Moreover, a delay of 𝑡0 = 3𝑚𝑖𝑛 is observed, followed by a lead-lag response
with a lead time of 0.5𝑚𝑖𝑛 and a lag time of 4𝑚𝑖𝑛. Recall that a lead-lag-plus-dead-time transfer
function response structure is as follows:
𝜏𝑙𝑒𝑎𝑑 𝑠 + 1
𝐺(𝑠) = (𝑘𝑒 −𝑡0𝑠 )
𝜏𝑙𝑎𝑔 𝑠 + 1

The main disturbance to this loop is the steam flow. After a change of +0.2𝑘𝑔/𝑠 in the steam
flow, the response of the 𝐻2 concentration is as follows:
 • At 𝑡 = 1𝑚𝑖𝑛, the 𝐻2 concentration change was 0.566%.
• At 𝑡 = 2𝑚𝑖𝑛, the 𝐻2 concentration change was 1.264%.
• Finally, the concentration change is 2%𝐻2 (steady-state).

1) Draw a block diagram of the closed-loop, containing all transfer functions (including the
main disturbance) and units for all signals

2) Suggest which control modes should be used

3) What is the correct controller action?

4) Provide the controller’s tuning parameters for QDR response

5) If a P-only controller is used, tuned for QDR response, calculate the change in the 𝐻2
concentration after a change of 0.15𝑘𝑔/𝑠 in the steam flow

6) If the gain of the controller you obtained in item 5) is changed to be 1.5 times higher, will
the response after disturbance changes be stable or unstable, monotonic or oscillatory?

Solution:

1) The transmitter gain is:

100%𝑇𝑂 100%𝑇𝑂
𝑘𝑇 = = ≅ 1.18%𝑇𝑂/%𝐻2
𝑠𝑝𝑎𝑛 (90 − 5)%𝐻2
The process transfer function relating the controller output, 𝑚(𝑡), and the transmitter
output, 𝑐(𝑡), in open-loop must have a lead-lag-plus-dead-time structure. Its gain, by
definition, will be the ratio between the change in the transmitter signal and the change in
the controller signal, i.e.:
 ∆𝑐 ∆𝐶𝐻2 ∙ 𝑘𝑇 (−1.48%𝐻2 )(1.18%𝑇𝑂/%𝐻2 )
𝑘= = = = −0.35%𝑇𝑂/%𝐶𝑂
∆𝑚 ∆𝑚 5%𝐶𝑂
Then, the process transfer function is:

0.5𝑠 + 1
𝐺1 (𝑠) = (−0.35𝑒 −3𝑠 )
4𝑠 + 1
The transfer function relating the open-loop interaction between the steam flow (the main
disturbance) and the controlled variable can be modeled as a first-order-plus-dead-time
(FOPDT) function, i.e.:
𝑘2 𝑒 −𝑡02 𝑠
𝐺2 (𝑠) =
𝜏2 𝑠 + 1
Its gain, by definition, will be:
∆𝑐 ∆𝐶𝐻2 ∙ 𝑘𝑇 (2%𝐻2 )(1.18%𝑇𝑂/%𝐻2 )
𝑘2 = = = = 11.77%𝑇𝑂/(𝑘𝑔/𝑠)
∆𝑤𝑠 ∆𝑤𝑠 0.2𝑘𝑔/𝑠
To find the time constant, we must check the change in the controlled variable at 𝑡 = 1𝑚𝑖𝑛
and 𝑡 = 2𝑚𝑖𝑛. At, 𝑡 = 1𝑚𝑖𝑛, ∆𝐶𝐻2 = 0.566%𝐻2 , which corresponds to the
0.566%𝐻2
100% = 28.3% of the total steady-state change. Thus, 𝑡1 = 1𝑚𝑖𝑛. On the other
2%𝐻2
1.264%𝐻2
hand, at 𝑡 = 2𝑚𝑖𝑛, ∆𝐶𝐻2 = 1.264%𝐻2 , which corresponds to the 100% =
2%𝐻2

63.2% of the total steady-state change. Thus, 𝑡2 = 2𝑚𝑖𝑛. Then:

3 3
𝜏2 = (𝑡2 − 𝑡1 ) = (2𝑚𝑖𝑛 − 1𝑚𝑖𝑛) = 1.5𝑚𝑖𝑛
2 2
𝑡02 = 𝑡2 − 𝜏2 = 2𝑚𝑖𝑛 − 1.5𝑚𝑖𝑛 = 0.5𝑚𝑖𝑛
Now, 𝐺2 (𝑠) can be written as:
11.77𝑒 −0.5𝑠
𝐺2 (𝑠) =
1.5𝑠 + 1
The block diagram will be as follows:
2) It is desirable to operate without offset. Thus, the integral mode must be included within
the controller. Moreover, since the response is not noisy or fast, the derivative mode should
also be included to provide trend anticipation power. A PID controller should be chosen.
3) Since the process gain is negative, so will the controller gain be. Thus, it must be a direct-
action controller.
4) To obtain the tuning parameters for QDR response, we must find previously the ultimate
gain, 𝑘𝑐𝑢 , and the corresponding period, 𝑇𝑢 , as if the controller were Proportional (although
it is not). The loop’s characteristic equation will be:
1 + 𝐺1 (𝑠)𝐺𝑐 (𝑠) = 0
0.5𝑠 + 1
1 + 𝑘𝑐 (−0.35𝑒 −3𝑠 ) =0
4𝑠 + 1
Then:
4𝑠 + 1 + 𝑘𝑐 (−0.35𝑒 −3𝑠 )(0.5𝑠 + 1) = 0
Using Padé’s first order approximation:
1 − 1.5𝑠
4𝑠 + 1 + 𝑘𝑐 (−0.35 ) (0.5𝑠 + 1) = 0
1 + 1.5𝑠
Then:
(4𝑠 + 1)(1.5𝑠 + 1) + 0.35𝑘𝑐 (1.5𝑠 − 1)(0.5𝑠 + 1) = 0
The above equation can be re-written as:
(6 + 0.2625𝑘𝑐 )𝑠 2 + (5.5 + 0.35𝑘𝑐 )𝑠 + 1 − 0.35𝑘𝑐 = 0
To obtain marginal stability, we substitute 𝑠 = 𝜔𝑢 𝑖 and 𝑘𝑐 = 𝑘𝑐𝑢 . Then:
 −(6 + 0.2625𝑘𝑐𝑢 )𝜔𝑢2 + (5.5 + 0.35𝑘𝑐𝑢 )𝜔𝑢 𝑖 + 1 − 0.35𝑘𝑐𝑢 = 0
Splitting the above equation into its real and imaginary parts, respectively, yields:
ℝ: − (6 + 0.2625𝑘𝑐𝑢 )𝜔𝑢2 + 1 − 0.35𝑘𝑐𝑢 = 0 (1)
𝕀: (5.5 + 0.35𝑘𝑐𝑢 )𝜔𝑢 = 0 (2)
Considering that 𝜔𝑢 ≠ 0, Eq. (2) yields:
𝑘𝑐𝑢 = −15.71%𝐶𝑂/%𝑇𝑂
Replacing the above result into Eq. (1):

1 − 0.35𝑘𝑐𝑢 1 − 0.35(−15.71)
𝜔𝑢 = √ =√ = 1.86𝑟𝑎𝑑/𝑚𝑖𝑛
6 + 0.2625𝑘𝑐𝑢 6 + 0.2625(−15.71)

2𝜋
𝑇𝑢 = = 3.37𝑚𝑖𝑛
𝜔𝑢
Using Ziegler and Nichols’ formulas for a PID controller:
𝑘𝑐𝑢 𝐶𝑂 𝑇𝑢 𝑇𝑢
𝑘𝑐′ = = −9.24% , 𝜏𝐼′ = = 1.69𝑚𝑖𝑛, 𝜏𝐷′ = = 0.42𝑚𝑖𝑛
1.7 %𝑇𝑂 2 8
Finally:
𝜏𝐷′
𝑘𝑐 = 𝑘𝑐′ (1 + ′ ) = −11.54%𝐶𝑂/%𝑇𝑂
𝜏𝐼
𝜏𝐼 = 𝜏𝐼′ + 𝜏𝐷′ = 2.11𝑚𝑖𝑛
𝜏𝐷 = 𝜏𝐷′ 𝜏𝐼′ /(𝜏𝐼′ + 𝜏𝐷′ ) = 0.34𝑚𝑖𝑛
5) For a P-only controller:
𝑘𝑐𝑢
𝑘𝑐 = = −7.86%𝐶𝑂/%𝑇𝑂
2
The closed loop transfer function respect to the disturbance is:

𝐷
𝐺2 (𝑠)
𝐺𝐶𝐿𝑇𝐹 (𝑠) =
1 + 𝐺1 (𝑠)𝐺𝑐 (𝑠)
Moreover:
∆𝑐 𝐷 𝐷
𝑘2
= 𝑘𝐶𝐿𝑇𝐹 = 𝑙𝑖𝑚 𝐺𝐶𝐿𝑇𝐹 (𝑠) =
∆𝑤𝑠 𝑠 →0 1 + 𝑘𝑘𝑐

𝐷
11.77%𝑇𝑂/(𝑘𝑔/𝑠)
𝑘𝐶𝐿𝑇𝐹 = = 3.14%𝑇𝑂/(𝑘𝑔/𝑠)
1 + (−7.86%𝐶𝑂/%𝑇𝑂)(−0.35%𝑇𝑂/%𝐶𝑂)
After a change of ∆𝑤𝑠 = 0.15𝑘𝑔/𝑠, the steady-state change in signal 𝑐 will be:
𝐷
∆𝑐 = 𝑘𝐶𝐿𝑇𝐹 ∆𝑤𝑠 = (3.14%𝑇𝑂/(𝑘𝑔/𝑠))(0.15𝑘𝑔/𝑠) = 0.47%𝑇𝑂
6) Now, 𝑘𝑐 = 1.5(−7.86%𝐶𝑂/%𝑇𝑂) = −11.79%𝐶𝑂/%𝑇𝑂
The characteristic equation is:
0.5𝑠 + 1
1 + 𝑘𝑐 (−0.35𝑒 −3𝑠 ) =0
4𝑠 + 1
In item 4), a polynomial expression for the characteristic equation was found, which is:
(6 + 0.2625𝑘𝑐 )𝑠 2 + (5.5 + 0.35𝑘𝑐 )𝑠 + 1 − 0.35𝑘𝑐 = 0
Replacing the gain value into the above equation yields:
2.9𝑠 2 + 1.375𝑠 + 5.125 = 0
The roots of the above polynomial are:
𝑟1,2 = −0.2371 ± 1.3081𝑖
Since both roots are complex with a negative real part, the response will be oscillating and
stable.