CH4404 Process Technology 1 Page 1 of 6 Repeat 2019

UNIVERSITY of LIMERICK
OLLSCOIL LUIMNIGH

School of Natural Sciences

Department of Chemical Sciences

End of Semester Assessment

Module Code: CH4404

Module Title: Process Technology 1

Lecturer(s): Dr. Saeed Shirazian

Dr. Peter Davern

Semester: Repeat 2019

Duration of Exam: 2.5 hours

Grading Scheme: 70% Examination

30% Labs+Quiz

Instructions to Candidates:
_____________________________________________________________________

1. There are three questions in this paper. Answer full questions.

2. Please use a separate answer booklet for Peter Davern’s parts (1c and 2c, marked PD).
3. Any non-programmable calculator may be used provided it has been cleaned of any information
that would subvert the purpose of the examination.
4. Calculations must be shown in sufficient detail to illustrate your understanding of the procedure.
5. An equation sheet is attached for your use in answering the questions.
6. Please write clearly and readably.
CH4404 Process Technology 1 Page 2 of 6 Repeat 2019

Question 1.
Q1. (a) It is desired to implement a feedback control loop on a jacketed stirred tank flow reactor
(shown diagrammatically below) for a liquid phase chemical reaction.

Reactant in

Steam in

Condensate
out

Product out

Jacketed stirred tank reactor

The control objective is to maintain a constant concentration of product in the reactor effluent stream
(Product out stream). The manipulated variable is reactor temperature which can be tuned by the
steam flow rate. The major input disturbance is fluctuation in the reactant concentration in the
reactor feed stream.

(i) Draw a simple diagram to show the physical representation of how a Feedback control loop
could be achieved (label clearly all items on your diagram) (6 marks)

(i) Draw a conventional block diagram to represent this process control system. Show clearly in
your diagram the input and output variables from each operational block and define each
variable. Explain the nature of each of the transfer functions for all of the operational blocks
in your diagram.
(10 marks)

Q1. (b) Describe briefly different variables in designing process control systems.
(3 marks)

Q1. (c) [Peter Davern’s section: please answer in a separate answer booklet]

In the context of the classification of human errors, clearly explain the difference between active
failures and latent failures.
(2 marks)
CH4404 Process Technology 1 Page 3 of 6 Repeat 2019
Describe the various actions that may be taken to overcome active failures.
(4 marks)

Clearly explain how a simple asphyxiant works. Provide two examples of a simple asphyxiant.
(2 marks)

_____________________________________________________________________

Question 2.
Q2. (a) Name and describe 5 different types of controllers in terms of the relation between the error
and the controller output.
(5 marks)
Q2. (b) An open loop response experiment is to be performed on a controller. The following error
signal profile is to be used:

0
E (%) 0 1 2 3 4 5 6 7

-1

-2

-3
Time (sec)

Plot qualitatively the shape of the corresponding controller output signal versus time for:
(i) Integral control mode only
(ii) Derivative control mode only

Show clearly the variation in controller output during each 1 second time interval from time = 0 to
time = 6 seconds. Indicate which sections (if any) of the plots are linear (L) and which are non-linear
(N). You may assume that error signal is defined as set-point value minus measured value, and that
the initial controller output is 50%.
(10 marks)
CH4404 Process Technology 1 Page 4 of 6 Repeat 2019

Q2(c) [Peter Davern’s section: please answer in a separate answer booklet]

Clearly define the following terms:

• harm
• risk
(2 x 1 mark)

Describe the two different types of respiratory tract irritant. In your answer provide one example of
each type.
(2 x 1 mark)

Schedule 1 of the 2018 Code of Practice for the Safety, Health and Welfare at Work (Chemical Agent)
Regulations 2001 lists the following entries for the chemical dimethylformamide:

• Carc.1A
• Sk

Clearly explain what each of these terms means.

(2 x 1 mark)

Explain the meaning of the two CLP hazard classification pictograms illustrated below.

Symbol A Symbol B
(2 marks)
CH4404 Process Technology 1 Page 5 of 6 Repeat 2019

Question 3.
It is desired to model the dynamic response behaviour of the batch reactor shown below:

Heater
tank

Lagging
jacket

Heating element

The reactor contents are heated electrically by a cylindrical metal heating element which is
immersed in the water. When power is switched on, the heater element heats up and supplies heat
to the surrounding water. Since the tank is well insulated thermally by a lagging jacket, it can be
assumed that negligible heat is lost through the outside wall of the tank. The heating element is
circular in cross-section.

(i) Starting from first principles, derive a differential equation which models the dynamic response
of the water temperature, TW, to changes in the heating element temperature, TE
(10 marks)

(ii) Using the equation from (i) derive an algebraic expression which relates TW to time for a step
change in TE.
(10 marks)
Define clearly all of the parameters used in your derivations for (i) and (ii).
CH4404 Process Technology 1 Page 6 of 6 Repeat 2019

Process Technology 1 CH4404 Equation Sheet

Time Function Laplace Transform

f(t) F(s)
a a/s
at a/s2
df(t)/dt sF(s) - f(0)
e-at 1/(s+a)
1
b-a
(
e − at − e − bt ) 1
(s + a )(s + b )
1
a 2
(at − 1 + e − at ) 1
s (s + a )
2

(where a and b are constants associated with the input signal)

 4 t  t D (32 + (6t D / )) 4t D

Kp =  + D TI = TD =
Kt D  3 4  (13 + (8t D / )) (11 + (2t D / ))

Kp = 0.6K TI = Tc/2 TD = Tc/8

R = 0.08206 dm3.atm.mol-1.K-1
= 8.314 J.mol-1.K-1