01 Control de Procesos 21-22 PDF

CONTROL DE PROCESOS
CHEMICAL PROCESS CONTROL
Degree in Chemical Engineering

University of Alicante
Juan Javaloyes
2021/2022
Textbooks
Chemical process control : an introduction to theory and practice
STEPHANOPOULOS, George. (1984)
Process modeling, simulation, and control for chemical engineers
LUYBEN, William L. (1990)
Process Dynamics, Modelling and Control
OGUNNAIKE, Babatunde A. and RAY, Harmon W. (1995)
Process Control: Modeling, Design and Simulation
BEQUETTE, Wayne B. (2003)
Process Dynamics and Control
SEBORG, Dale E. et al. (2003)
Chemical process control [34528] Academic year 2021/22 2
Course Contents – Block diagram
Motivation
Mathematical Tools
Dynamic modeling of
chemical processes Ordinary Differential
Equations
Transfer Functions Input‐Output model
Linearization of nonlinear systems
Deviation variables
Dynamic Behavior of First‐, Second‐ and
Laplace Transforms
Higher‐Order Systems
Solution of ODEs using
Stability Analysis of Design of Feedback Laplace Transforms
Feedback Systems Controllers
Instrumentation and
Frequency Response
Control valves
Design of Feedback Controllers by
Advanced Process Control
Frequency Response
Introduction
Learning objectives
Given a process, we should be able to do the following:
 Determine possible control objectives, input variables (manipulated and
disturbances) and output variables (measured and unmeasured)
 Classify the process as continuous or batch
 Asses the importance of process control from safety, environmental, and
economic points of view
 Understand the basic idea of feedback and feedforward control
 Know the basic steps involved during the design of a control system
 Draw a simplified control diagram
Chemical process control [34528] Chapter 1: Introduction Academic year 2021/22 5

A Chemical plant is …
[source:
https://www.kaspe
rsky.com/blog/hack
ing‐chemical‐
plant/9603/]
Chemical plant requirements
Safety Environmental regulations Economics
Production specifications Operational constraints
A control system must …
Suppress the influence of external disturbances
Ensure the stability of a chemical process
Optimize the performance of a chemical process

Stirred Tank Heater
Fi ,Ti Process objectives
‐ To keep the effluent temperature at a desired value Ts
‐ To keep the volume of liquid in the tank at a desired value Vs
External factors
h
T ‐ Changes in the feed flowrate Fin
F ,T ‐ Changes in the feed temperature Tin
Q ‐ …

Stirred Tank Heater
External factors
h
Q ‐ …
Fi ,Ti
TC
T
Q F ,T
Stirred Tank Heater
External factors
h
Q ‐ …
Fi ,Ti Fi ,Ti
LC
TC h
T T
Q F ,T Q F ,T
Feedback control systems
Stirred Tank Heater
External factors
h
Q ‐ …
Fi ,Ti Fi ,Ti Fi ,Ti
LC
TC h TC
T T T
Q F ,T Q F ,T Q F ,T
Feedback control systems Feedforward control system
Stable (or self‐regulating) process Unstable process
y (t )
t0 Time t0 Time
heat
cAi , Fi ,Ti time
P3
Fc ,Tc
P2
Fc ,Tc A ¾¾ B P1
i cA, F ,T
T1 T2 T3 T éëC ùû
CSTR
y (t )
t0 Time t0 Time
heat
cAi , Fi ,Ti time
P3
Fc ,Tc
P2
i cA, F ,T
T1 T2 T3 T éëC ùû
CSTR
y (t )
t0 Time t0 Time
heat
cAi , Fi ,Ti time
P3
Fc ,Tc Q2r
Q2c
P2
i cA, F ,T
T1 T2 T2'T3 T éëC ùû
CSTR
Optimize the performance of a chemical process
tR
max ò é revenue from the sales of B - cost of steam ù dt
0 ë û
1 2 + cost of pruchasing A
A ¾¾  B ¾¾ C
stm Optimal steam flowrate profile
Qmax
Q
DH > 0 Controller
tR
Time

Classification of the variables in a chemical process
Manipulated
Input Fc (F ) Measured
Disturbances Ti , Fi ,Tc
i
Variable Unmeasured
(cAi )
Measured
Output T , F ,Tc ,V
Unmeasured
cAi , Fi ,Ti (cA )
Fc ,Tc
Fc ,Tc A ¾¾ B cA, F ,T

i

Classification of the variables in a chemical process
external disturbances
measured (d) unmeasured (d´)
manipulated variables … …
measured outputs
(m) (y)
PROCESS SYSTEM
…
…
…
unmeasured outputs (z)

Design Elements of a Control System
Q1 ‐ What are the operational objectives that a control system is called upon to
achieve?  Define control objectives
Q2 ‐ What variables should we measure in order to monitor the operational
performance of a plant?  Select measurements
Primary measurements: when the control objectives can be monitored directly
Secondary measurements: when the control objectives can not be measured directly
unmeasured output = f  secondary measurements 
Q3 ‐ What are the manipulated variables to be used to control a chemical
process?  Select manipulated variables

Q4 ‐ What is the best control configuration for a given chemical process control
situation?  Select the control configuration
“ A control configuration is the information structure that is used to connect the available
measurements to the available manipulated variables”
Fi ,Ti Fi ,Ti
The same information
LC (measurement of liquid
LC level) flows to different
h
T T manipulated variables
Q F ,T Q F ,T
Fi ,Ti Fi ,Ti
The same manipulated
variable but different
TC TC measurements
T T
Q F ,T Q F ,T

Q5 ‐ How is the information, taken from the measurements, used to adjust the
values of the manipulated variable?  Design the controller
Control law
Proportional (P)
C  t   K c  t   C s
Proportional‐Integral (PI)
Kc
C  t   K c  t      t dt  C
t
I 0 s
Proportional‐Integral‐Derivative control (PID)
Kc d  t 
C  t   K c  t     t dt  K c D
t
I 
0 dt
 Cs

Hardware elements of a control system
1. The chemical process
It represents the material equipment with the physical and/or chemical operations
that take place there
2. The measuring instruments or sensors
Instruments used to measure the disturbances and the controlled output variables.
Are the main sources of information about the process. Thus, they are critical for a
good control
3. Transducers
Transducers convert the magnitude of a process variable (e. g., flowrate, pressure,
temperature, level or concentration) into a signal that can be sent directly to the
controller (electric voltage or current, or pneumatic signal)
4. Transmission lines
Used to carry the measurement signal from the sensor to the controller. In the past,
transmission lines were pneumatic (air or liquids), but nowadays, transmission lines
carry electric signals.

Hardware elements of a control system
5. The controller
Is the hardware element that receives the information from the measuring devices
and decides whet action should be taken.
6. The final control element (actuator)
Is the device that enables a process variable to be manipulated.
The control valve is the most frequently used final control element (others final
elements are variable‐speed pumps/compressors, relay switches)
7. Recording elements

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CONTROL DE PROCESOS

CHEMICAL PROCESS CONTROL

Degree in Chemical Engineering

Chemical process control [34528] Chapter 1: Introduction Academic year 2021/22 5

Chemical process control [34528] Chapter 1: Introduction Academic year 2021/22 7

Chemical process control [34528] Chapter 1: Introduction Academic year 2021/22 8

Fi ,Ti Fi ,Ti Fi ,Ti

Chemical process control [34528] Chapter 1: Introduction Academic year 2021/22 15

Fc ,Tc A ¾¾ B cA, F ,T

Chemical process control [34528] Chapter 1: Introduction Academic year 2021/22 16

Chemical process control [34528] Chapter 1: Introduction Academic year 2021/22 17

Chemical process control [34528] Chapter 1: Introduction Academic year 2021/22 18

Chemical process control [34528] Chapter 1: Introduction Academic year 2021/22 19

Chemical process control [34528] Chapter 1: Introduction Academic year 2021/22 20

Chemical process control [34528] Chapter 1: Introduction Academic year 2021/22 21

Chemical process control [34528] Chapter 1: Introduction Academic year 2021/22 22

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