GUIDELINE FOR MINI PROJECT

EAT 449 (ENVIRONMENTAL PROCESS CONTROL & INSTRUMENTATION)

1. Project Content

Title : Design of ................... (Each group will be given different processes, refer to Project
Title below)

Project 1: Temperature Controller in Constant Stirred Tank Reactor (CSTR)

Project 2: Concentration Controller in Constant Stirred Mixing Tank
Project 3: Concentration Controller in Fed Batch Reactor for Ethanol Production
Project 4: Concentration Controller in Continuous Bioreactor
Project 5: Dissolved Oxygen Concentration Controller in Activated Sludge Process

Chapter 1: Introduction (Literature Review on the specified process)

Chapter 2: Process Control diagram and Instrumentation
Chapter 3: Process Description and Modeling
Chapter 4: Process Control Design (using Matlab and Simulink)
 Solution of Process Control Modeling by Laplace Transform
 Control constant (K) adjustment
 Process Stability
 Root Locus plot
 Response of Control system by Simulink
Chapter 5: Summary and Conclusion

2. Group Distribution
Group 1: Project No. 1
Group 2: Project No. 2
Group 3: Project No. 3
Group 4: Project No. 4
Group 5: Project No. 5

3. Consultation Schedule

Proper schedule (day, time, place) will discuss (depend on student availability)

4. Mini Project Marking Scheme and Submission Schedule

1. Final Report (Total 100 %)
 Introduction (15 %)
 Process Control diagram and Instrumentation (15 %)
 Process Description and Modeling (15 %)
First Submission in softcopy (Week 10: 18 November 2016)
 Process Control Design using Matlab and Simulink (50 %)
o Solution of Process Control Modeling by Laplace Transform
o Control constant (K) adjustment
Second Submission in softcopy (Week 12: 2 December 20016)
o Process Stability
o Root Locus plot
o Response of Control system by Simulink
 Summary and conclusions (5 %)
Final Report Submission (Week 14: 16 December 20016)
 Sample of Report

UNIVERSITI MALAYSIA PERLIS

PUSAT PENGAJIAN KEJURUTERAAN ALAM SEKITAR
School of Environmental Engineering

EAT 449/3
ENVIRONMENTAL PROCESS CONTROL AND
INSTRUMENTATION

MINI PROJECT

Design of Concentration Controller in Constant Stirred Mixing

Tank

RK07-ENVIRONMENTAL ENGINEERING

2016/17 SEMESTER 1

Lecturer: PM Dr. Fahmi

Group Member: Group 5
No Name Matric Number

1. Tan Siew Yan 131132682

2. Teo Shwu Wan 131132722

3. Tsai Sen Mee 131132755

4. Yong Wei Lun 131132876

 CHAPTER 1

INTRODUCTION

The term of process in process control which is to create new end products from
changing or regenerating raw materials. Small changes in a process may bring a great impact
on the end result (www.PAControl.com, 2006). Process control involves in most of the
industries development such as chemical industry, food and beverage industry,
pharmaceutical industry, oil and gas industry, water industry and power industry.

However, process control is the methods that used to control different variables for any
process when producing a wide range of product. Measurement variables are important in
controlling a process. There are generally variables which are concentration, temperature,
level and flow rate. Besides, in controlling the production process for the benefits of reducing
variability of product, increasing efficiency of process and reducing the energy usage (Riggs
& Karim, 2006).

In industrial process engineering, mixing is process that reduces non-homogeneous

condition to achieve a desired process result. The non-homogeneous conditions involve
concentration, phase and temperature of the process. The process results may show the
reaction rate, end mass or heat transfer and properties of end product. The mixing process
depends on the phase of material being mixed which are liquid, semi-solid or solid.

Industrial mixing is an important process as can maintain the quality of the mixture in
producing an end product (The importance of industrial mixing, 2016). If the industrial
mixing does not perform well may lack of consistency of the end product. In continuous
mixer, the ingredients are continuously charged into the mixer and mixture is continuously
discharge at the discharge nozzle.

Nowadays, there are a lot of processed ready-to-eat products. Therefore, in food industry,
mixing of ingredients is needed in most food processing operations. The food mixing
applications are determined by the phases being mixed such as liquid-liquid, solid-liquid, or
solid-solid and the physical characteristic (viscosity and density) of the end product (Ross &
Company).
 CHAPTER 2

PROCESS CONTROL DIAGRAM AND INSTRUMENTATION

2.1 Process Control Diagram

Figure 1 shows the overall process of soft drink production. The main components in making
soft drink are water, sugar, flavors and carbon dioxide (CO2).

Figure 2.1: Soft Drink Production Diagram

Quality of water is important in the process of making soft drink. The water is pre-
treated to ensure its quality. Impurities such as suspended particles,organic matter and
bacteria are removed through coagulation, filtration and chlorination. The alkalinity must be
adjusted with an addition of lime to reach the desired pH level during clarification process.
Sterilization is vital to destroy bacteria and organic compounds that influence the taste and
color of water.

On another side of the process, dissolved sugar and flavor concentrates are pumped
into dosing station. Dissolved sugar and flavor are mixed into mixture before further mixing
with water. The dosage of the ingredients are mixed carefully in batch system, to avoid
agitation preventing from aeration.

At pre mix tank, water and syrup is combined in predetermined proportions. The
mixture is then become a “flat” soda drink. Next, the carbonation process occur by adding
CO2 into the finished product. Temperature in this process is well maintained since the
solubility of CO2 is affected by temperature.

After that, the finished product is transferred into filling machine. Soft drinks are
filled into bottles or cans in high fow rates. Then the bottles are sealed immediately and ship
to distributors in crates or large pallets.
2.2 Instrumentation

Figure 2.2: Diagram of mixing tank

Figure 2.3: Modeling of a constant stirred mixing tank

  C – the concentration of the component in the mixed stream (g mol/l)
 C1 – the concentration of the component in stream 1 (g mol/l)
 C2 – the concentration of the component in stream 2 (g mol/l)
 F1 – the mass flow rate of stream 1 (kg/min)
 F2 – the mass flow of stream 2 (kg/min)
 t – time (min)
 V – the volume of the mixer (l)
 Ρ – the constant density of the feed and product stream (kg/l)
 τv – the time constant for the flow controller on stream 1 (s)
 – retention time (min)

There are 2 inputs at the mixing tank, the water and the syrup. Flow transmitter and
flow controller are applied at the input of the syrup. As for the output, the concentration of
the mixture is then detected by analyzer transmitter.

Water flow into mixing tank at flow rate of F2. Meanwhile, the flow rate of syrup F1 is
being controlled. Flow transmitter detects the flow rate of the syrup and flow controller
control the valve adjusting the flow rate F1.

Stirrer inside the mixing tank is to mix the water and syrup. Mixture will then transmit
out at the bottom of the tank where the concentration of mixture is measured. The mixture
will be transmitted for carbonation with CO2 before filling in bottles.

The above process is continuous as the syrup and water is continuously flowing into
the mixing tank and the mixture is continuously flow out. All the system is being controlled
by a control panel shown in Figure 2 above. The concentration of the outflow is being
monitored.

2.3 Block diagram

Figure: Block diagram of a general feedback control loop.

 *e is the error from setpoint, c is the controller output and u is the MV.

Block diagram above represent a commonly feedback control system which as a logic
flow diagrams to demonstrate flow of information and the effect of on process element on
another. However, block diagram does not represent the physical layout of a process. Each
block diagram consists of a controller, an actuator, a process and as sensor, in that order,
along with feedback of the measured value of the controlled variable to the controller.
Furthermore, each process is affected by disturbances.

The sensor reading is compared with the setpoint to produce the error (e) from setpoint
and the controller chooses the control action (c) based upon this difference. The actuator
system is making changes in the level of the MV (u) based on the changes in control action.
The “process” in the control loop can determine the relationship between the inputs and the
controlled variables. The symbol⊕ represents a summation function. The negative sign on
the measurement of the CV will affect the result between the setpoint and the measured value
of the CV, which is the error form setpoint.

In this case, the set point is to control the concentration of the soda water in a continuous
reactor. The valve at the syrup transporter acts as the actuator while the sensor of this system is the
chemical composition analyzers. Disturbance is the concentration in stream 1, C1. Manipulated
variable is the flowrate of stream 1 and controlled variable is the product concentration measured at
the exit of the reactor.
 CHAPTER 3

PROCESS DESCRIPTION AND MODELING

3.1 Actuator Model

The actuator system based on a control valve consists of the 1/P converter, the instrument air
system and the control valve. When a change in the analog signal to the 1/P converter is
made, the instrument air pressure to the valve changes. Hence the flow rate is affected
through the control valve. The dynamic response of the valve actuator to changes in the
instrument air pressure applied to the valve is usually considerably slower than either the
response of the 1/P instrument air system or the flow through the valve. The dynamic
behaviour of the control valve can be represented as a linear first-order process. And it is
represent in the following equation:

1
= ( , − )

3.2 Process Model

Assume that the mixer volume is perfectly mixed and assuming that there are no chemical
reactions occurring, a lumped parameter based on a component mole balance can be used.

ℎ = −
ℎ ℎ
ℎ

Assuming a constant volume, V in the mixer and applying the component mass balance
equation in terms of concentration yields:

= ( ) + ( ) − [( ) + ( )]

Since the mass flow rate are specified, it is necessary to convert from volumetric flow rates to
mass flow rates assuming that the density is not affected by the concentration. The previous
equation to mass flow rates yields

= + −( + )
3.3 Sensor Model

The sensor for the system is measured by sampling systems. The sampling system is
responsible for collecting a representative sample of a process stream and delivering it to the
analyser for analysis. Obviously, the reliability of the sampling system directly affects the
reliability if the overall deadtime for an analysis system. The transport delay associated with
the sampling system contributes directly to the overall deadtime for an on-line composition
measurement.

= ( − )
 CHAPTER 4

PROCESS CONTROL DESIGN

Figure 3.1 Modeling of a constant stirred mixing tank

 C – the concentration of the component in the mixed stream (0.75 g mol/L)

 C1 – the concentration of the component in stream 1 (0.5 g mol/L)
 C2 – the concentration of the component in stream 2 (1.0 g mol/L)
 F1 – the mass flow rate of stream 1 (500 kg/min)
 F2 – the mass flow of stream 2 (500 kg/min)
 t – time (min)
 V – the volume of the mixer (1000 L)
 Ρ – the constant density of the feed and product stream (1 kg/L)
 τv – the time constant for the flow controller on stream 1 (2 s)
 – retention time (6 min)
The model equations that represent the dynamic behaviour of this continuous reactor are
shown as below:

Actuator : = ( , − )

Process : = + −( + )

Sensor : = ( − )

Actuator:

Laplace transform:

1
= ( , − )

1 1
( ) − (0) = , ( )− ( )

1 1
( )+ ( )= , ( )

1 1
( ) + = , ( )

1
, ( )
( )=
1
+

Transfer function:

1
( )= =
, 1
+
 1
( )=
+1

Substituting time constant, = 2s:

1
( )=
2 +1

Process:

Laplace transform:

= + −( + )

Ĉ = C – C0 Ĉ1 = C1 – C0 Ĉ2 = C2 – C0

Ĉ
ρV = Ĉ + Ĉ −( + )Ĉ

[ ( )− ]= (s) + ( )−( + ) ( )

( )+( + ) ( )= ( )+ ( )

( )[ + + )= ( )+ ( )

( )+ ( )
( )=
+ +

Transfer function:

( )
( )= =
( ) [ + + ]

Substituting:

Mass flow rate of stream 1, F1 = 500 kg/min

Mass flow rate of stream 2, F2 = 500kg/min

Density of feed and product stream, = 1 kg/L

Volume of mixer, V = 1000L

 0.5
( )=
+ 1

Sensor:

Laplace transform:

1
= ( − )

1 1
( ) − (0) = ( )− ( )

1 1
( )+ ( )= ( )

1 1
( ) + = ( )

Transfer function:

( )
(s) = ( )
=

(s) =

Substituting retention time, = 6 min

(s) =

Characteristics equation:

. . . +1=0
 1
( )=
2 +1
0.5
( )=
+1
1
( )=
6 +1
( )= (P controller)

Process stability:

By substituting all the models into formula:

. . . +1=0

.
( ) ( )+1=0

0.5
+1=0
12 + 20 + 9 + 1

0.5 + 12 + 20 +9 +1= 0

12 + 20 + 9 + (1 + 0.5 )=0

Then, applying Routh Array Criterion,

12 + 20 + 9 + (1 + 0.5 )=0

12 9
⎡ ⎤
⎢ 20 ⎥
⎢ 1 + 0.5
⎥
⎢ (20)(9) − (12)(1 + 0.5 ) ⎥
⎢ 0 ⎥
⎢ 20 ⎥
⎢ ⎥
⎢(8.4 − 0.3 )(1 + 0.5 ) − (20)(0) 0 ⎥
⎣ (8.4 − 0.3 ) ⎦
Table below shows various values are chosen to obtain different set of roots of the
characteristic equation as shown below by using MATLAB.

Table 1 Stability of the 12S3 + 20S2 + 9S + (1 + 0.5Kc) = 0 with different Kc value

Equation K R1 R2 R3 Stability

12 + 20 +9 +1=0 0 -1 -0.5 -0.1667 Stable

12 + 20 + 9 + 16 30 - 0.0116 + 0.0116 – Unstable

=0 1.6898 0.8882i 0.8882i

12 + 20 + 9 + 15.25 28.5 - 0.0029 + 0.0029 – Unstable

=0 1.6725 0.8717i 0.8717i

12 + 20 + 9 + 14.75 27.5 - -0.0030 + -0.0030 – Stable

=0 1.6607 0.8603i 0.8603i

12 + 20 + 9 + 13.5 25 -1.63 -0.0183 + -0.0183 – Stable

=0 0.8306i 0.8306i

According to the table above by substituting the values into the characteristic equation,
when the Kc value exceed 28.5, the equation become unstable. Meanwhile, when Kc values
are less than 28.5, the real part of R2 and R3 appear to be at negative side of the real-
imaginary graph. Hence we can deduce Kc value at 27.5, any value larger than 27.5 will
cause the system to be unstable.

Root locus:

By using MATLAB, the root locus of the system was found. And Figures below show the
command codes and the result.
 Figure 1 Root array for 12S3 + 20S2 + 9s + (1 + 0.5Kc) = 0 with Kc = 0

Figure 2 Root locus for 12S3 + 20S2 + 9s + (1 + 0.5Kc) = 0 with Kc = 0

Stimulation by using Simulink

 Figure: Block diagram of pre-mix tank in soda water manufacturing.

To further ensure the stability of the system, the modelling is tested by using Simulink.
Different value of Kc is substitute into the controller in order to test the stability of the
system.

When K = 30,

When K=30, the dynamic behaviour of the graph is sustained oscillations which is unstable.
When K=28,

When K=28, the dynamic behaviour of the graph is sustained oscillations which is unstable.

When K=27.5,

When K=27.5, the dynamic behaviour of the graph is damped sinusoidal which is stable.
When K=25,

When K=25, the dynamic behaviour of the graph is damped sinusoidal which is stable.

When K=15,

When K=15, the dynamic behaviour of the graph is damped sinusoidal which is stable.
When K=10,

When K=10, the dynamic behaviour of the graph is damped sinusoidal which is stable.

When K=5,

When K=5, the dynamic behaviour of the graph is damped sinusoidal which is stable.
When K=1,

When K=1, the graph is a linear model which is stable.

When K=0.5,

When K=0.5, the graph is a linear model which is stable.

The dynamic behaviour shows a damped sinusoidal behaviour at K =27.5, hence the system
is stable at the range of 0 to 27.5.

CHAPTER 5

SUMMARY AND CONCLUSION

In this project, we are able to design a concentration controller in constant stirred

mixing tank. As proposed, the mixing tank is designed for manufacturing of soda water,
where mixing process happen before the carbonation of the soda water. Syrup and water are
mixed together in specific flow rate in order to obtain desire concentration.

Throughout this process, the process modeling and block diagram of the process are
constructed. A conventional P controller is proposed to obtain desire concentration. Besides
that, we included valve as our actuator, continuous reactor as process and sampling system as
sensor in this project.

Then the characteristic equation of the system which is 12 + 20 + 9 +

(1 + 0.5 ) = 0 was yielded. And from the roots stability, we found out that the Kc value
has a range of less than 28. Any Kc value larger than 28 will causes the system to be unstable;
in other hand Kc value less than 28 happen to be stable. This result is further confirmed by
plotting root locus using MATLAB. Furthermore, the equation underwent stimulation of
Simulink to check its stability. From Simulink, we can conclude that the equation maintain at
stable state when K value is range between 0 to 27.5.

In further studies, it is recommended that the uses of PI and PID controller should be
included. By doing this, the best controller among them can be determined which perform
better in a constant stirred mixing tank.
REFERENCES

1. Niranjam, K. (1995). An appraisal of the characteristics of food mixing. Food Process

Design and Evaluation, 47-67.
2. Riggs, J. B., & Karim, M. N. (2006). Chemical and Bio-Process Control Third
Edition. Pearson Education International.
3. Ross, C., & Company, S. (n.d.). Mixing Equipment and Application in the Food
Industry.
4. The importance of industrial mixing. (2016, November 17). Retrieved from Ginhong
Mixer: http://www.ginhong.com/articles/the-importance-of-industrial-mixing/
5. www.PAControl.com. (2006). Instrumentation & Control: Process Control
Fundamentals.