School of Chemical Engineering

The University of New South Wales

CEIC3006
Process Dynamics and Control

Term 2 2022
Lecture 1
Lecturer: Prof. Jie Bao
 CEIC 3006 Process Dynamics and Control
Staff  Mr Jun Wen Tang
 Prof. Jie Bao  Tutor, marker
 Lecturer in charge
 Email: j.bao@unsw.edu.au

 Mr Shuangyu Han
 Mr Adam Larkin  Marker
 Tutor, marker
 Email: adam.larkin@unsw.edu.au

CEIC3006 Term 2, 2022 2

 Introduction to Process Control

 What’s on today

 What is process dynamics and control

 The objectives of process control (why do we study process control)

 Basic control principles (feedback, feedforward control)

 Course outline

CEIC3006 Term 2, 2022 3

 Example: control of an exothermic reactor
Reactant feed in

Reactor temperature

Reaction rate

Exothermic Heat generated

Reactor
T

The reactor temperature

must be maintained
Cooling at a desired value!
water out Product
Cooling
𝐴𝐴 → 𝐵𝐵 Water
Using a cooling jacket:
Cooling water removes heat
from the reactor.

CEIC3006 Term 2, 2022 4

 Example: control of an exothermic reactor
Method 1:
1. Work out the heat generation rate of
the reaction (for given temperature
Reactant feed in
and reactant feeding rate and purity,
etc.)

Exothermic 2. Calculate the flowrate of the cooling

Reactor water such that the rate of heat
T removal equals the rate of heat
generation, based on
 heat transfer coefficient
Cooling  heat transfer area
water out  temperature of the cooling water
Product
Cooling
Water
Set and forget!

CEIC3006 Term 2, 2022 5

 Control of an exothermic reactor
Reactant feed in Unknown variations

Disturbances
 Temperature variations in
cooling water
Exothermic  Variations in concentrations
Reactor of reactants
T
Model uncertainties

Operation based on
Cooling optimized steady-state The process needs to
water out Product condition (set and forget) be operated
won’t work!
Cooling
The process is UNSTABLE!
(controlled) with the
Water
cooling water
𝐴𝐴 → 𝐵𝐵
flowrate adjusted
in real time!
(dynamically).
CEIC3006 Term 2, 2022 6
 Control of an exothermic reactor

Feed in
Method 2: Feedback
TT Control
Temperature
Transducer
What’s
What’stotobebecontrolled:
controlled
The
The temperatureofofthe
temperature thereactor
reactor

FC
Flow Disturbance:
Disturbance:
Exothermic Controller Temperature increase
Reactor in cooling water
Temperature variations in
cooling water
Control structure:
Measurestructure:
Control the temperature of
Cooling
water out Actuator  Measure the temperature of
Product
the reactor
Cooling
water  Manipulate the flowrate of
Problem:
the cooling water
The corrective action taken by
the feedback controller is
delayed.

CEIC3006 Term 2, 2022 7

 Process Control Systems
A process control system includes:
Devices that convert pressure, temperature etc. to
signals the controller can use ⇒ sensors (transducers)

Devices that are used to manipulate the process, such

as control valves, pumps heating elements, etc. ⇒
actuators

A controller: decision maker. It gathers the

information from the transducers and qualitatively or
quantitatively decides the action of the actuators in real
time to attenuate the effects of disturbances.

CEIC3006 Term 2, 2022 8

 Industrial Process Control
Process A plantwide process
 Multiple process units
 Interconnected/interact
ed through mass and
energy flows

Perturbations/ Control
Disturbances objectives

 Variations in raw  Safety

materials  Product quality
 Climate  Productivity
…
 Minimizing
Operation Environmental Impacts
Time varying  More $$$
Control
On-line, dynamically
CEIC3006 Term 2, 2022 9
 Process Control systems
Controllers: Stand-alone Controllers
Slide-out Inner
Bezel Housing
chassis chassis

Control
Control
Panel
Panel

Panel
Panel
latch
latch Side panel Industrial computer
Reliability is crucial!
keypad

control stations
Stand high temperature,
Humidity, dusty environment
Strong magnetic field, …

CEIC3006 Term 2, 2022 10

 Example: Aluminimum Smelting Cells

Aluminium smelting process:

Cryolite: NaF and AlF3

Process control instrument must be able to work

in harsh industrial environments:
 Temperature: >960C
 Very strong magnetic field caused by 400kA current
 Very dusty
CEIC3006 Term 2, 2022 11
 Corrosive gases
 Process Control Systems
 Distributed Control Systems (DCS)

• Functional distribution
• Geographical distribution

CEIC3006 Term 2, 2022 12

 An example of a membrane plant

Controller server
Membrane
plant
Controller modules

Process Control System in Pilot Hall

User interface CEIC3006 Term 2, 2022 13
 Process Control Systems
 Distributed Control System – the operator room (user interface)

CEIC3006 Term 2, 2022 14

 Introduction to Process Control

 What is process control about? (recap)

Concerned with operating a process such that

important process characteristics is maintained
at desired targets, despite the effects of external
perturbations (disturbances). e.g. Refinery – the
compositions of
certain species in the
products should be of
the desired values.
CEIC3006 Term 2, 2022 15
 Importance of Process Control

1. Process control improves the safety and

reliability of a process.
 A control system ensures safe operation
 Alarms, interlocks, safety constraint control, start-up and
shutdown. e.g., pressure control, temperature control in a
reactor

 Stabilize unstable processes

 Prevent certain important variables from running away
e.g. Temperature control of polymerization reactor
(exothermic reaction)
CEIC3006 Term 2, 2022 16
 Importance of Process Control

2. Proper process control improves the product quality

e.g., a refinery process

Reflux flow controls

distillate composition
(purity)

Without proper control

With proper control
Target purity

Product Purity
Product Purity

Target purity

Minimum purity requirement

Time Time

 Reduced variability  Improved economic benefit

CEIC3006 Term 2, 2022
17
 Importance of Process Control
3. Maximizing productivity
 Process control often involves controlling
against constraints.
 The closer that you are able to operate to
these constraints, the more profit you can
make.
4. More environmentally friendly operation
 Reduce energy consumption
 Reduce pollution

Bottom Line: Process control has a major impact on

the profitability of a chemical company.
CEIC3006 Term 2, 2022 18
 Importance of Process Control
A control system is an indispensable part of every
modern chemical plant.

 Process design
 Process operation
 Interdisciplinary area of
• Chemical engineering
• Instrumentation (electrical/mechanical engineering)
• Control theory (mathematics)
• Information technology (computer science)

• A Shell study shows that its plant margin can be

increased by 10 to 20% by adopting better process
control.
“Can you afford not to improve your
control system?” CEIC3006 Term 2, 2022 19
 Why Do We Study Process Control?
• It is a compulsory subject in Chemical Engineering curriculum (you have no choice!)

More importantly,
• Advanced computer control systems are widely used in process industries

Process control is a well-paid

technical profession for chemical
engineers.

• Professional process control companies: e.g., Honeywell, ABB, Foxboro,

Yokogawa, etc.
CEIC3006 Term 2, 2022 20
 Why We Study Process Control?
For those of you who are not going to be process control
engineers

 A chemical plant with an automatic control system

will behave very differently. You need to
understand the process behaviours with the
presence of a control system for process
operation and trouble shooting.

 Process control concepts (process operability)

should be considered in process design.
− Integrated process design and control is the key to
efficiency and plant economy
− A poorly designed process can be very difficult to control
CEIC3006 Term 2, 2022 21
 Why We Study Process Control?
For those of you who are not going to be process control
engineers

 You need to understand the potential benefit and

limitation of process control
 You need to able to communicate with process control
engineer.

 Chemical Engineers should be equipped with the basic

knowledge of the principles of process control regardless of Not
their career paths: recommended
process operation engineers/process design engineers/
process control engineers.

CEIC3006 Term 2, 2022 22

 Course outline
 Purpose
To learn essential knowledge of process dynamics and analysis, and control
systems design concepts

Because good control needs understanding of dynamics of controlled process,

this subject will cover two major areas:

(1) Analysis of process dynamics

(2) Control system design
• Continuous time system design
• Digital control system design

CEIC3006 Term 2, 2022 23

Overall Process Plant Design – a Page from CEIC3005

Conceptual design
CEIC3004 CEIC3005 CEIC3006
Process simulation Safety engineering

Block Flow Diagram Electrical

(BFD) design

Underground
Plant networks
Process Flow Diagram (PFD)
layout

Mass & Energy Balance (MEB)

Piping
calculation
Equipment sizing
Equipment
Materials of Equipment Piping design
specification &
construction drawing
design
Civil
design
Piping &
Instrumentation Piping
Diagram (P&ID) materials
Instrumentation &
Control design

Multi-discipline required for Process Plant Design!

 Course outline
 Focus
 Analysis of process dynamics
• Process modeling
• Dynamic behaviours of a range of processes
 Control system analysis and design
• Feedback control system
• Dynamic behaviour and stability of closed-loop control systems
• Controller design for transient responses (PID and IMC)
• Introduction to advanced control techniques (e.g., cascade control)
• Digital control systems (sampling, filtering, discrete time models, discrete time control
design)
• Plantwide control considerations
CEIC3006 Term 2, 2022 25
 Studying Materials
 Text book
D. E Seborg, T. F. Edgar, D. A. Mellichamp, Process Dynamics and Control, John Wiley &
Sons, 2004 ISBN 0-471-86389-0

(2nd or 4th edition can also be used)

Reference books:

1. Riggs, J. B., Chemical Process Control, Ferret Publishing,

1999. ISBN 0-9669601-0-6.

2. Ogunnaike, B. A. and Harmon Ray, W., Process Dynamics,

Modelling and Control, Oxford University Press, 1994.
3. Luyben, W. L. Process Modeling, Simulation and Control for
Chemical Engineers (2nd Edition) McGraw Hill International
(ISBN 0-07-100793-8).

CEIC3006 Term 2, 2022 27

 Studying Materials
 Software
Matlab with Control Toolbox and Simulink

 Available on computers in School Computer Labs

 MyAccess |AAA

 https://www.myaccess.unsw.edu.au/

 Matlab online: https://matlab.mathworks.com/ Matlab

 Lecture recordings on Microsoft Teams

 Microsoft Teams – Discussion forum

 Workshop/tutorial questions

 Assignment questions

 Moodle

CEIC3006 Term 2, 2022 28

 Attendance at lectures and workshop/tutorial sessions

 Class discussion and student participation are highly encouraged. Please feel
free to ask questions (asking me directly or using MS Teams chat)

 This subject is not difficult but is different to other

chemical engineering subjects you have learned.

 Please make sure that you attend all the lectures.

 Previous experience shows that absence of one or two lectures could

create significant difficulties in understanding subsequent lectures.

CEIC3006 Term 2, 2022 29

 Assessments
Assignments (2) 30%
Quizzes (2) 30%
Examination (1) 40%
 Assignments
Due dates: Week 3 and Week 8
Assignments should be attempted independently. Copied submissions will attract zero marks.

 Quizzes
Quiz 1 (15 %) Week 5;
Quiz 2 (15 %) Week 8.
Quizzes and final exams will be online.
The quizzes will be open for 8 hrs. Once started, you have one hour to complete the quiz.
Only one attempt is allowed. CEIC3006 Term 2, 2022 30
 Contact me!

Prof. Jie Bao

 MS Teams

Channel: Discussion forum

 E-mail: J.Bao@unsw.edu.au
Please send e-mail to me with the following subject: Re: CEIC3006

CEIC3006 Term 2, 2022 31

 Introduction

 What is a process (again!) ?

 How do we control it?

CEIC3006 Term 2, 2022 32

 An example of Process
 Speed Control of Automobile

 Measured and controlled:

Speed ⇒ controlled variable (output variable)
 Manipulate or actuated:
Pressure on accelerator footpad (or brake) ⇒ manipulated variable (input variable)
 Outside factors:
 Friction, slope of the road ⇒ disturbances (input variable)

Friction,
slope, etc
Controller
Pressure on Speedometer

Desired
+ accelerator pad Speed
Speed

CEIC3006 Term 2, 2022 33

 Processes
 INPUTS
• Manipulated Variable : u
 Something that you can manipulate
– actuating signals
• Disturbance: d
 Something that comes as a result of some outside phenomenon and affects the output but
cannot be manipulated
 OUTPUT (Controlled Variable) : y
• An observable quantity that we can measure and want to regulate (i.e., control!)

d
u y
P
Information Flow Control block diagram
CEIC3006 Term 2, 2022 34
 Concept of processes in control theory
 In process flowsheets: Physical flow
Input quantities Output quantities
Process

System Physical
Transfer of
Boundary
fundamental Physical
quantities
Mass, Energy and Momentum

 In process control: Information flow

MVs and Disturbances CVs
Input variable Output variable
Process
Abstract
Operation

From the point of view of a controller

CEIC3006 Term 2, 2022 35
 Example
 Stirred tank heater

M System boundary IN:

Inlet mass flow
Tin, w
Energy in
by flow
by convection

OUT:
T, w Outlet mass flow
Energy out
Q by flow
by convection

What are the MV, CV and disturbances?

CEIC3006 Term 2, 2022 36

 Example
 What are the inputs and output variables? M

 Depends on Tin, w

 What needs to be controlled

 What can be manipulated Q
T, w

If T is to be controlled by manipulating the power of the

heater Q:
Disturbance
MV Tin CV
Process T
Q

CEIC3006 Term 2, 2022 37

 Control

What is the purpose of control?

 To regulate a process output despite the effect of disturbances

 Driving a car
 Controlling the compositions of a chemical reactor

 To stabilize unstable processes

 Riding a bike
 Flight control
 Temperature control of exothermic reactors (e.g., a polymerization process)

CEIC3006 Term 2, 2022 38

 Control Systems
 A controlled process is a system which is comprised of two interacting systems:
e.g. Most controlled systems are feedback-controlled systems

Disturbances Outputs
Process
Action Observation
intervene Controller monitor
The controller is designed to provide regulation of process outputs in the presence of
disturbances

CEIC3006 Term 2, 2022 39

 Control Strategies

What strategies we can use in process

control?

 Feedback

 Feedforward

CEIC3006 Term 2, 2022 40

 Feedback control of speed
1. Measure the actual speed

2. Find the difference:

Error = Desired_Speed – Actual_Speed

3. Decide how much force should be applied to the accelerator:

if Error>0 then push the accelerator footpad harder
if Error<0 then release the accelerator footpad a bit
Friction,
slope, etc
+ Controller Speedometer
Desired Error Accelerator
Speed
-
Setpoint

 The controlled variable is measured.

 The controller acts according to measurement of the controlled variable.
41
CEIC3006 Term 2, 2022
 Feedforward control of speed
1. Watch the slope of the road

2. If it is uphill, push the accelerator footpad harder

if it is downhill, release the accelerator footpad a bit or even use the brake

 The controlled variable is not measured.

 The disturbance is measured, and the controller acts according to the disturbance.

CEIC3006 Term 2, 2022 42

 Control Strategies
 Control of temperature Assumptions:
(1) Inlet flowrate=outlet flowrate
M
(2) Constant liquid density
Tin, w

Control objective: T=TR (called the setpoint)

T, w
Q
1. How much heat must be supplied? MV?
Steady state energy balance: Q = w C (T − Tin ) Disturbance?
A model
CV?

For T=TR : Q = w C (TR − Tin )

If: (1)Assumptions are valid
(2)Inlet flow rate and inlet temperature are constant and equal to their nominal
values
Then T=TR An idealistic case!
CEIC3006 Term 2, 2022 43
 Control Strategies
 Suppose inlet temperature Tin changes with time. How can we ensure T remains at or near the set point TR?

1. Use a LAR GE tank and a HIGH CAPACITY heater (no control)

• Expensive: high capital costs and no flexibility
2. Measure T and adjust Q Feedback control
• Compare T with TR
• Adjust Q based on the error dynamically
3. Measure T and adjust w Feedback control
4. Measure Tin and adjust Q Feedforward control

5. Measure Tin and adjust w Feedforward control

6. Measure both Tin and T and adjust Q Feedforward+feedback control

7. Measure both Tin and T and adjust w Feedforward+feedback control
44
CEIC3006 Term 2, 2022
 Control Strategies

 Classification of control strategies

 Feedback control: (Methods 2 and 3)
• Controlled variable is measured and the measurement is used to adjust the
manipulated variable.
T is measured and
Q (method 2) or w (method 3) is adjusted
• Disturbance variable (Tin) is not measured
The error is calculated as

It is called negative feedback.

CEIC3006 Term 2, 2022 45

 Control Strategies
 Advantage and disadvantage of feedback control
 Advantages:
1. Corrective action - compensate for all disturbance
(disturbances in Tin, w, ambient temperature etc.)
2. Needs minimum knowledge of the process
 Does not need measurements of disturbance
 Adjust the control action by trial and error
 Does not need an accurate model
 Disadvantage:
1. Compensate for disturbance only after the controlled variable has deviated from
the set point. “Perfect” control is impossible.

CEIC3006 Term 2, 2022 46

 Control Strategies
 Feedforward control: (Methods 4 and 5)
 Disturbance (Tin) is measured and manipulated variable (Q or w) is adjusted
Controlled variable is not measured
 Advantages of feedforward control
• Capable of providing perfect control (theoretically, if the model is perfect and accurate
measurements of disturbances available)
 Disadvantage
• Needs a perfect model (we never have perfect models!)
• Cannot deal with unmeasured disturbances (e.g. changes of ambient temperature)
• Not economical to measure all the disturbances
 Feedback control used in combination of feedforward control (Methods 6 and 7)

CEIC3006 Term 2, 2022 47

 Implementation of Feedback Control
Implementation of Method 2 (feedback control)
Measure: T(t)
Adjust: Q(t)

 Operation of temperature control

1. The tank exit temperature is measured with a thermocouple which generates
corresponding milli-voltage signal.
2. This time varying signal must be amplified to a voltage level signal V(t) and sent to the
controller
3. The controller performs three tasks:
 Calculates error e(t)=VR-V(t)
 Calculates heat duty Q(t) and sends its corresponding signal u(t) to the heater
4. In response to the input signal u(t), the heater converts signal u(t) to a current generates
Q(t)
CEIC3006 Term 2, 2022 48
 Control Block Diagrams
 Control block diagram
P&ID diagram (Schematic diagram Physical connection)
TT

Tin, w Thermocouple

Heater
Q T, w
TC

Control block diagram

W, Tin
Controller Heater
TR+ e u Q T(t)
C A P
-
controller actuator Stirred Tank
process
M
TM Information flow
sensor
49
CEIC3006 Term 2, 2022
 Control Block Diagrams: Feedback Control
d
+
r e u y
Controller Process
-
Generalized process

Classical Feedback Control System

 Control is meant to provide regulation of process outputs about a reference, r,

despite inherent disturbances
 The deviation of the plant output, e=(r-y), from its intended reference is used to
make appropriate adjustments in the plant input, u
 Controller could be an analog controller, a digital controller, a computer, or an
operator that performs the required manipulations
CEIC3006 Term 2, 2022 50
 Control Block Diagrams: Feedforward Control
 Measure Tin, adjust Q
TT
Tin, w
Thermocouple
Heater T, w
Q
TC
Schematic diagram

Tin
M

C A P
Q(t)
Control block diagram
CEIC3006 Term 2, 2022 51
  Qualitative Control Design
(A part of P&ID design)

CEIC3006 Term 2, 2022 52

 Hierarchies of Process Control
 Qualitative control design (P &ID diagrams)
 What to be controlled?
 What to be manipulated?
 What are the disturbances?
 Process control instrumentation
Specify:
 Sensors
 Actuators
 Alarms
 Quantitative control design
 Mathematical control algorithms to determine, in real time, the actual amount of
control action, based on measurements. CEIC3006 Term 2, 2022 53
 Sensors

 Transducers and Indicators

 Selection criteria:
 Measurement range (span)
 Performance and cost
 Reliability
 Materials of construction
 Prior use
 Potential for releasing process materials to the environment.
 Electrical classification
 Invasive or noninvasive

CEIC3006 Term 2, 2022 54

 Sensors

 Main categories:
 Temperature

 Differential pressure

 Liquid or gas flow rate

 Liquid level

 Chemical composition

CEIC3006 Term 2, 2022 55

 Sensors
 Symbols
T – Transducer I – Indicator C- Controller
R - Recorder

Sensors:
TT FT PT LT
Panel mounted

TT FT PT LT

Locally mounted
TI FI PI LI

Temperature Flow Pressure Level

CEIC3006 Term 2, 2022 56

 Final Control Elements (Actuators)
Actuators are the devices that can be used to manipulated process variables
 Control valves (pneumatic)
 Failure modes
• Fail closed or air to open (A-O)

• Fail open or air to close (A-C)

CEIC3006 Term 2, 2022 57

 Controllers

 Dotted or dashed lines are used to for instrument connecting

lines.

CEIC3006 Term 2, 2022 58

 Instrumentation Symbology

https://www.aiche.org/chenected/2010/09/interpreting-piping-and-instrumentation-
diagrams-symbology
 A Piping & Instrumentation Diagram
TT
0009
CV0006 FT0004

Hot Water

Plate Heat Exchanger TT

0008 FT0003
TT 90HE91 TT CV0005
0007 0010 Chilled Water
Retentate S3 S4
90HV21
90HV22
Manual
Divert Valve FT0005
TT S1 S2 (90FT61)
0011
CV9001
Back Pressure
Control Valve

PT
9041
PH APV0015
0002 Feed Tank 90HV31 Butterfly
90HV32 Stop Valve
90BT401 Manual
Divert Valve
TT
0013 FT0001

(90TT71)

LT
Membrane
0014 90MV301
(90LS81) DP
0012

Permeate

APV0016
FT0002 Butterfly
(90FT51) Stop Valve

90HV11
Manual
Drain Valve
Re-circ Pump
SC9021
PU9021 CEIC3006 Term 2, 2022 60
 Typical Control Systems
 Flow control methods
A. Throttling or flow control valve
B. By-pass control
C. Stop/start control
D. Variable Speed Drives (VSDs)

CEIC3006 Term 2, 2022 61

 Throttling
 Pump runs continuously.
 Valve in the pump discharge line is opened or closed to adjust the flow to the
required value.

CEIC3006 Term 2, 2022 62

 By-pass Control
 Pump runs continuously at the maximum process demand duty.
 A by-pass line is attached to the outlet.

CEIC3006 Term 2, 2022 63

 Variable Speed Drives (VSDs)
 Pump speed adjustments provide the most efficient means of controlling pump
flow.
 Less energy is imparted to the fluid and less energy needs to be throttled or
bypassed.

CEIC3006 Term 2, 2022 64

 Typical control systems
 Level control

LC

Simplest level control

• The control valve should be placed on the discharge line from the pump.
• Interlocks may be used to stop the pump when the tank is empty.

CEIC3006 Term 2, 2022 65

 Typical control systems

 Pressure control
 Direct venting (non-toxic gas)

 Condenser pressure control

• By controlling the coolant flow

CEIC3006 Term 2, 2022 66

 Typical control systems

 Temperature control (for Heat Exchangers)

Varying the flow of the cooling or heating medium

CEIC3006 Term 2, 2022 67

 Typical control systems

 Temperature control (for Heat Exchangers)

– If the temperature is critical and needs to be regulated precisely and
quickly, or,
– If the exchange is between two process streams whose flows are fixed
or not controllable,
by-pass control can be used:

Disadvantage:
The heat exchanger is oversized.

CEIC3006 Term 2, 2022 68

 Typical control systems

 Ratio control
Ratio control can be used where it is desired to maintain two flows at a
constant ratio. (e.g., stoichiometric ratio of the reactants)

F1

F2

CEIC3006 Term 2, 2022 69

 Guidelines for Qualitative Control Design
(at early design stages)

1. Identify and draw the control loops

that are obviously needed for steady
plant operation. Feed in
TT

2. Identify the key process variables that

need to be controlled.
3. Identify and include those additional
control loops required for safe Exothermic
Reactor
operation, not already covered in steps
1 and 2.
Cooling
4. Decide on the alarms and interlocks water out Product
needed; this would be done in Cooling
water
conjunction with step 3. make up

CEIC3006 Term 2, 2022 70

 Type of Control Variables

Variable types
1. Production rate
2. Inventory
3. Environmental
4. Product quality
5. Economic

CEIC3006 Term 2, 2022 71

 Type of Control Variables
 Production rate
 Determines the rate at which a process
operates.

 Typical measurement is flow (mass or

volumetric)

 Generally only one of production rate

variable in any given process.
 Usually the rate of feed.

 When operations are conducted in series, a

single production rate sets the steady-state
throughput of all operations. Production
rate is a key variable to all processes
because it affects all other controlled
variables
CEIC3006 Term 2, 2022 72
 Type of Control Variables
 Inventory variables
 Represent the accumulation of material or
energy at specific points in the process.
 Typical measurements:
a. Gas Pressure
b. Liquid Liquid level or pressure
c. Solid Weight
d. Energy Temperature or pressure
 In the steady state, the inventories must be
balanced
 Inventory controllers are responsible for
closing material and energy balances.

CEIC3006 Term 2, 2022 73

 Type of Control Variables
 Environmental variables
 Determines the conditions under which a process
functions.
 Typical measurements:
a. Temperature Temperature sensor
b. Pressure Pressure sensor
c. Composition Chemical analysis
 Particularly important in conducting chemical reactions as
they are sensitive to temperature, pressure, and
composition.
 Tend to affect process performance as well as product
quality.
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 Type of Control Variables
 Product quality
 Typical measurements
a. Physical Physical property
b. Chemical Chemical analysis
 Most important controlled variable because product value
depends on it.
 Most difficult to control because it is disturbed by almost
every other variable in the process.
 Difficult to measure in most cases,
• usually requires sampling and even off-line
determinations, whose delays degrade control.

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 Key Aspects of Control System Design

Process objectives
• Chemical reactor: maximizing the yield, selectivity, or throughput
subject to satisfying process constraints (e.g., safety and the
environmental constraints).

• Distillation column: maximizing throughput or minimizing energy

consumption, while satisfying product specifications and other
constraints.

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 Key Aspects of Control System Design
Control objectives
• Process objectives, process constraints, and economic data
Example:
• Liquid-level control:
 Tight level control: for a specified set point for a continuous
bioreactor. Constant residence time is important.

 Averaging control: liquid level is allowed to vary between specified

upper and lower limits. For process vessels that are used as
intermediate storage tanks for surge control.

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 Example: Distillation Column
 Primary process objective
 Separating a feed mixture into two (or more) product streams with specified compositions

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 Example: Distillation Column
 Production rate: D or B determined controlled by the feed flow rate (think the
steady-state!)
 Inventory of liquid: column base and condenser levels, hD , hB
 Environmental variable: temperature & pressure in the distillation column
 Product quality: concentrations of distillate and/or bottom product, xD and xB

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 Example: Distillation Column
 Manipulated variables:
 Feed flow rate F
 Product flow rates, D or B
 Reflux flow rate R
 Heat duties for the condenser and reboiler, qD and qB

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 Example: Evaporator Control System
 The evaporator shown below is used to concentrate a dilute solution of
a single, nonvolatile solute in a volatile solvent by evaporating solvent
using heat supplied by a steam coil.
 Manipulated variables: steam pressure, Ps, product flow rate, B, and vapor flow
rate of solvent, D
 Disturbance variables: feed composition, xF, and feed flow rate, F

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 Example: Evaporator Control System
 Propose control strategies for two situations:
 The product composition xB can be measured on-line
 xB cannot be measured on-line

 The compositions are expressed as mole fractions of solute,

and the flow rates are in molar units

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 Example: Evaporator Control System
 Case (a): Product composition xB is measured on-line

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 Example: Evaporator Control System
 Case (b): Product composition cannot be measured on-line
 The CVs are the same as in Case (a).
 Controlled variable xB cannot be measured:
 Standard feedback control is not possible.
 A feedforward control strategy can be developed based on a steady-
state component balance for the solute.

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 Example: Evaporator Control System

 Replacing 𝐵𝐵� and 𝐹𝐹� by the actual flow rates, B(t) and F(t), and replacing 𝑥𝑥̅𝐵𝐵
by the set-point value, 𝑥𝑥𝐵𝐵𝐵𝐵𝐵𝐵

a) B is adjusted based on the measured value of F, the set point 𝑥𝑥𝐵𝐵𝐵𝐵𝐵𝐵 , and the nominal
value of the feed composition, 𝑥𝑥̅𝐹𝐹 .
b) The MVs are the same as for Case (a): D, B, and Ps.
c) Bottom flow rate B has already been used in the feedforward control strategy
d) P-D pairing is still desirable for the reasons given for Case (a).
e) This leaves h to be controlled by adjusting the rate of evaporation via Ps.

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 Example: Evaporator Control System
 Case (b): Product composition cannot be measured on-line

 Disadvantages:
• Assume constant feed
composition
• Feedforward control
technique was based on a
steady-state analysis, it
may not perform well
during transient
conditions.

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 Other Examples of Qualitative Control Design

 Process-to-process Exchangers

Use of bypass

Use of auxiliary
exchanger

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 Other Examples of Qualitative Control Design

 Reactor/column heat integration

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 Other Examples of Qualitative Control Design
Control of Both Production Composition
D-V: For high reflux ratio (RR>4)

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 Quantitative Control Design

Let us zoom into the controller loops...

Quantitative control design

How we actually control the CVs?

We need to understand the process dynamics

(i.e., dynamic behaviour)
We need to develop process models

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 Control Philosophies
To have a good control, we need quantitative description of the process – a
mathematical model.
So that the controller can predict the behavior of the process and act
accordingly.

 Model-based approaches
 Develop mathematical models
 Design and optimize the controller based on the model
 Advantages of model based control
 Better control performance
 The model predicts the dynamical behavior of the process when the manipulated
variables changed

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 Process Control and Modeling

 In designing a controller, we must

Define control objectives
Develop a process model
Design controller based on model
Test through simulation
Implement to real process
Tune and monitor

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 Control System Development

 Objectives
 “What are we trying to control?”
 Process modeling
 “What do we need?”
• Mechanistic and/or empirical
 Controller design
 “How do we use the knowledge of process behavior to reach our process control objectives?”
• What variables should we measure?
• What variables should we control?
• What variables can be manipulated?
• What control algorithm should be used?

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 Control System Development
1. Define Objectives CEIC3005
Plant Design
2. Develop a process
model CEIC3000
Process Modelling
3. Design controller
based on model
4. Test by
Simulation
Steps 3-6 are covered
5. Implement and in this subject
Tune
6. Monitor
Performance

Often an iterative process, based on performance we may decide to retune,

redesign or remodel a given control system
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