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Chapter 2

2.1

a) Overall mass balance:

d (ρV )
= w1 + w2 − w3 (1)
dt

Energy balance:

d ρV (T3 − Tref ) 

C = w1C (T1 − Tref ) + w2C (T2 − Tref )
dt (2)
− w3C (T3 − Tref )
Because ρ = constant and V = V = constant, Eq. 1 becomes:

w3 = w1 + w2 (3)

b) From Eq. 2, substituting Eq. 3

d (T3 − Tref ) dT
ρCV = ρCV 3= w1C (T1 − Tref ) + w2C (T2 − Tref )
dt dt (4)
− ( w1 + w2 ) C (T3 − Tref )

Constants C and Tref can be cancelled:

dT3
ρV = w1T1 + w2T2 − ( w1 + w2 )T3 (5)
dt

The simplified model now consists only of Eq. 5.

Solution Manual for Process Dynamics and Control, 4th edition

Copyright © 2016 by Dale E. Seborg, Thomas F. Edgar, Duncan A. Mellichamp,
and Francis J. Doyle III

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Degrees of freedom for the simplified model:

Parameters : ρ, V

Variables : w1, w2, T1, T2, T3

NE = 1
NV = 5

Thus, NF = 5 – 1 = 4

Because w1, w2, T1 and T2 are determined by upstream units, we assume

they are known functions of time:

w1 = w1(t)
w2 = w2 (t)
T1 = T1(t)
T2 = T2(t)

Thus, NF is reduced to 0.

2.2

Energy balance:

d ρV (T − Tref ) 
Cp = wC p (Ti − Tref ) − wC p (T − Tref ) − UAs (T − Ta ) + Q
dt

Simplifying

dT
ρVC p = wC p Ti − wC p T − UAs (T − Ta ) + Q
dt
dT
ρVC p = wC p (Ti − T ) − UAs (T − Ta ) + Q
dt

b) T increases if Ti increases and vice versa.

T decreases if w increases and vice versa if (Ti – T) < 0. In other words, if

Q > UAs(T-Ta), the contents are heated, and T >Ti.

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2.3

a) Mass Balances:

dh1
ρA1 = w1 − w2 − w3 (1)
dt

dh2
ρA2 = w2 (2)
dt

Flow relations:

Let P1 be the pressure at the bottom of tank 1.

Let P2 be the pressure at the bottom of tank 2.

Let Pa be the ambient pressure.

P1 − P2 ρg
Then w2 = = (h1 − h2 ) (3)
R2 g c R2

P1 − Pa ρg
w3 = = h1 (4)
R3 g c R3

b) Seven parameters: ρ, A1, A2, g, gc, R2, R3

Five variables : h1, h2, w1, w2, w3

Four equations

Thus NF = 5 – 4 = 1

1 input = w1 (specified function of time)

4 outputs = h1, h2, w2, w3

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2.4

Assume constant liquid density, ρ . The mass balance for the tank is

d (ρAh + m g )
= ρ(qi − q )
dt

Because ρ, A, and mg are constant, this equation becomes

dh
A = qi − q (1)
dt

The square-root relationship for flow through the control valve is

1/ 2
 ρgh 
q = C v  Pg + − Pa  (2)
 gc 

From the ideal gas law,

(m g / M ) RT
Pg = (3)
A( H − h)

where T is the absolute temperature of the gas.

Equation 1 gives the unsteady-state model upon substitution of q from Eq. 2 and
of Pg from Eq. 3:

1/ 2
dh  (mg / M ) RT ρ gh 
A = qi − Cv  + − Pa  (4)
dt  A( H − h) gc 

Because the model contains Pa, operation of the system is not independent of Pa.
For an open system Pg = Pa and Eq. 2 shows that the system is independent of Pa.

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2.5

a) For linear valve flow characteristics,

Pd − P1 P − P2 P2 − Pf
wa = , wb = 1 , wc = (1)
Ra Rb Rc
Mass balances for the surge tanks

dm1 dm2
= wa − wb , = wb − wc (2)
dt dt

where m1 and m2 are the masses of gas in surge tanks 1 and 2,

respectively.

If the ideal gas law holds, then

m1 m2
P1V1 = RT1 , P2V2 = RT2 (3)
M M

where M is the molecular weight of the gas

T1 and T2 are the temperatures in the surge tanks.

Substituting for m1 and m2 from Eq. 3 into Eq. 2, and noticing that V1, T1,
V2, and T2 are constant,

V1M dP1 V2 M dP2

= wa − wb and = wb − wc (4)
RT1 dt RT2 dt

The dynamic model consists of Eqs. 1 and 4.

b) For adiabatic operation, Eq. 3 is replaced by

γ γ
V  V 
P1  1  = P2  2  = C , a constant (5)
 m1   m2 
1/ γ 1/ γ
 P1V1 γ   P2V2 γ 
or m1 =  
 and m2 =  
 (6)
 C   C 

Substituting Eq. 6 into Eq. 2 gives,

1/ γ
1  V1 γ  dP1
  P1
(1− γ ) / γ
= wa − wb
γ  C  dt
 

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1/ γ
1  V2 γ  dP2
  P2
(1− γ ) / γ
= wb − wc
γ  C  dt
 

as the new dynamic model. If the ideal gas law were not valid, one would
use an appropriate equation of state instead of Eq. 3.

2.6

a) Assumptions:

1. Each compartment is perfectly mixed.

2. ρ and C are constant.
3. No heat losses to ambient.

Compartment 1:
Overall balance (No accumulation of mass):

0 = ρq − ρq1 thus q1 = q (1)

Energy balance (No change in volume):

dT1
V1ρC = ρqC (Ti − T1 ) − UA(T1 − T2 ) (2)
dt

Compartment 2:

Overall balance:

0 = ρq1 − ρq2 thus q2 = q1= q (3)

Energy balance:

dT2
V2ρC = ρqC (T1 − T2 ) + UA(T1 − T2 ) − U c Ac (T2 − Tc ) (4)
dt

b) Eight parameters: ρ, V1, V2, C, U, A, Uc, Ac

Five variables: Ti, T1, T2, q, Tc
Two equations: (2) and (4)

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Thus NF = 5 – 2 = 3

2 outputs = T1, T2
3 inputs = Ti, Tc, q (specify as functions of t)

c) Three new variables: ci, c1, c2 (concentration of species A).

Two new equations: Component material balances on each compartment.
c1 and c2 are new outputs. ci must be a known function of time.

2.7

As in Section 2.4.2, there are two equations for this system:

dV 1
= ( wi − w)
dt ρ
dT wi Q
= (Ti − T ) +
dt V ρ ρVC

Results:

(a) Since w is determined by hydrostatic forces, we can substitute for this

variable in terms of the tank volume as in Section 2.4.5 case 3.

dV 1  V 
=  wi − Cv 
dt ρ  A 
dT wi Q
= (Ti − T ) +
dt ρV ρVC

This leaves us with the following:

5 variables: V , T , wi , Ti , Q
4 parameters: C , ρ , Cv , A
2 equations

The degrees of freedom are 5 − 2 =3 . To make sure the system is specified, we

have:

2 output variables: T , V

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2 manipulated variables: Q, wi
1 disturbance variable: Ti

(b) In this part, two controllers have been added to the system. Each controller
provides an additional equation. Also, the flow out of the tank is now a
manipulated variable being adjusted by the controller. So, we have

4 parameters: C , ρ , Tsp , Vsp

6 variables: V , T , wi , Ti , Q, w
4 equations

The degrees of freedom are 6 − 4 =2 . To specify the two degrees of freedom, we

set the variables as follows:

2 output variables: T , V
2 manipulated variables (determined by controller equations): Q, w
2 disturbance variables: Ti , wi

2.8

Additional assumptions:

(i) Density of the liquid, ρ, and density of the coolant, ρJ, are constant.
(ii) Specific heat of the liquid, C, and of the coolant, CJ, are constant.

Because V is constant, the mass balance for the tank is:

dV
ρ = q F − q = 0 ; thus q = qF
dt

Energy balance for tank:

dT
ρVC = q F ρC (TF − T ) − Kq J A(T − TJ )
0.8
(1)
dt

Energy balance for the jacket:

dTJ
ρ J VJ C J = q J ρ J C J (Ti − TJ ) + Kq J A(T − TJ )
0.8
(2)
dt

where A is the heat transfer area (in ft2) between the process liquid and the
coolant.

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Eqs.1 and 2 comprise the dynamic model for the system.

2.9

Assume that the feed contains only A and B, and no C. Component balances for
A, B, C over the reactor give.

dc A
V = qi c Ai − qc A − Vk1e − E1 / RT c A (1)
dt

dcB
V = qi cBi − qcB + V (k1e − E1 / RT c A − k2e − E2 / RT cB ) (2)
dt

dcC
V −qcC + Vk2e − E2 / RT cB
= (3)
dt

An overall mass balance over the jacket indicates that qc = qci because the volume
of coolant in jacket and the density of coolant are constant.

Energy balance for the reactor:

d (Vc A M A S A + VcB M B S B + VcC M C SC ) T 

= ( qi c Ai M A S A + qi cBi M B S B ) (Ti − T )
dt
−UA(T − Tc ) + (−∆H1 )Vk1e− E1 / RT c A + (−∆H 2 )Vk2e− E2 / RT cB (4)

where MA, MB, MC are molecular weights of A, B, and C, respectively

SA, SB, SC are specific heats of A, B, and C.
U is the overall heat transfer coefficient
A is the surface area of heat transfer

Energy balance for the jacket:

dTc
ρ j S jV=
j ρ j S j qci (Tci − Tc ) + UA(T − Tc ) (5)
dt
where:
ρj, Sj are density and specific heat of the coolant.
Vj is the volume of coolant in the jacket.

Eqs. 1 - 5 represent the dynamic model for the system.

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2.10

The plots should look as shown below:

Notice that the functions are only good for t = 0 to t = 18, at which point the tank
is completely drained. The concentration function blows up because the volume
function is negative.

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2.11

a)

Note that the only conservation equation required to find h is an overall

mass balance:

dm d (ρAh) dh
= =
ρA =+w1 w2 − w (1)
dt dt dt

ρg
Valve equation: w = C v′ h = Cv h (2)
gc
ρg
where C v = C v′ (3)
gc

Substituting the valve equation into the mass balance,

dh 1
= ( w1 + w2 − C v h ) (4)
dt ρA

Steady-state model:

0 = w1 + w2 − C v h (5)

w1 + w2 2.0 + 1.2 3.2 kg/s

b) =
Cv = = = 2.13 1/2
h 2.25 1.5 m

c) Feedforward control

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Rearrange Eq. 5 to get the feedforward (FF) controller relation,

w2 = C v hR − w1 where hR = 2.25 m

w2 = (2.13)(1.5) − w1 = 3.2 − w1 (6)

Note that Eq. 6, for a value of w1 = 2.0, gives

w2 = 3.2 –1.2 = 2.0 kg/s which is the desired value.

If the actual FF controller follows the relation, w2 = 3.2 − 1.1w1 (flow

transmitter 10% higher), w2 will change as soon as the FF controller is
turned on,

w2 = 3.2 –1.1 (2.0) = 3.2 – 2.2 = 1.0 kg/s

(instead of the correct value, 1.2 kg/s)

Then C v h = 2.13 h = 2.0 + 1.0

3
or h= = 1.408 and h = 1.983 m (instead of 2.25 m)
2.13

2.25 − 1.983
Error in desired level = × 100% =
11.9%
2.25

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The sensitivity does not look too bad in the sense that a 10% error in flow
measurement gives ~12% error in desired level. Before making this
conclusion, however, one should check how well the operating FF
controller works for a change in w1 (e.g., ∆w1 = 0.4 kg/s).

2.12

a) Model of tank (normal operation):

dh
ρA = w1 + w2 − w3 (Below the leak point)
dt
π (2) 2
A= = π= 3.14 m 2
4

dh
(800)(3.14) = 120 + 100 − 200 = 20
dt

dh 20
= = 0.007962 m/min
dt (800)(3.14)

Time to reach leak point (h = 1 m) = 125.6 min.

b) Model of tank with leak and w1 , w2 , w3 constant:

dh
ρA =20 − d q4 =20 − ρ(0.025) h − 1 = 20 − 20 h − 1 , h ≥ 1
dt

To check for overflow, one can simply find the level hm at which dh/dt =
0. That is the maximum value of level when no overflow occurs.

0 = 20 − 20 hm − 1 or hm = 2 m

Thus, overflow does not occur for a leak occurring because hm < 2.25 m.

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2.13

Model of process

Overall material balance:

dh
ρAT = w1 + w2 − w3 = w1 + w2 − C v h (1)
dt

Component:

d (hx3 )
ρAT = w1 x1 + w2 x 2 − w3 x3
dt

dx3 dh
ρAT h + ρAT x3 = w1 x1 + w2 x 2 − w3 x3
dt dt

Substituting for dh/dt (Eq. 1)

dx3
ρAT h + x3 ( w1 + w2 − w3 ) = w1 x1 + w2 x 2 − w3 x3
dt

dx3
ρAT h = w1 ( x1 − x3 ) + w2 ( x 2 − x3 ) (2)
dt

or
dx3
=
1
[w1 ( x1 − x3 ) + w2 ( x2 − x3 )] (3)
dt ρAT h

a) At initial steady state ,

w3 = w1 + w2 = 120 + 100 = 220 Kg/min

220
Cv = = 166.3
1.75

b) If x1 is suddenly changed from 0.5 to 0.6 without changing flowrates, then

level remains constant and Eq.3 can be solved analytically or numerically
to find the time to achieve 99% of the x3 response. From the material
balance, the final value of x3 = 0.555. Then,

dx3 1
= [120(0.6 − x3 ) + 100(0.5 − x3 )]
dt (800)(1.75)π

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