ACKNOWLEDGE

Dear: All professors of the Department of Oil and Gas Process Engineering,
Our instructor – MSc. Nguyen Kim Trung,
To complete this project, our team realized that effective teamwork is impossible
without the guidance and instruction of our professors, who enabled us to establish a
solid theoretical foundation and apply it in the practical internship.
This project of Unit operation and process is an irreplaceable summary course in the
syllabus of Chemical engineering. The course is a huge support to students, providing a
chance to integrate theoretical knowledge into calculating and solving technological
process and design equipment. The project poses as an initial threshold for students to
apply the accumulations of understanding from various subjects into a practical issue
from an engineering approach.
Therefore, foremost of all, a special gratitude we would like to give to Dr. Bui Ngoc
Pha, Head of the Department of Processes and Equipments, and other professors of this
department for providing us with very valuable knowledge and documents about
processes and equipment in chemical technology. They also suggested and made changes
to the project so that we can easily complete the topic during the summer semester.
Secondly, we would also like to extend our sincere appreciation to Dr. Pham Hoang
Huy Phuoc Loi, our instructor for this project, for guiding us to complete this topic well.
His efforts not only indirectly imparted us with invaluable knowledge but also directly
impacted and motivated us to propose ideas throughout the project completion process.
Finally, we extend a special appreciation to our fellow team members who gathered
samples and other essential reference materials to successfully accomplish this
assignment.

HCM City, December, 2023

STUDENTS

i
 ABSTRACT
After a semester, the Project of Unit Operation and Process in Chemical Engineering
has been immensely beneficial to students in the calculation and design of chemical
equipments and system process, along with the fabrication, inspection, and testing
methods. This project is also a great opportunity to systematize knowledge about the
processes and equipment of chemical technology Despite the limited timeframe of just a
short-summer semester, students have broadened their perspectives and assimilated a
considerable amount of new experiences through each member's knowledge. By doing
so, they can accumulate necessary knowledge such as reading comprehension, research
skills, mathematical proficiency, and scientific writing style. These skills are highly
beneficial for them in their future employment after graduation.
Nowaday, the rapid development of technologies and the necessity for cleaner, safer
productions create a demand for purification processes. The traditional mass-transfer
method of distillation is more and more required in the industry and has ever since
become standardized technologies. Alongside with other esoteric divisions of chemical
engineering, petroleum processes is relatively old but possesses huge potential for further
application. One of the seven primary feedstocks of the industry is synthesis gas, can be
treated to produce methanol, which is a universal precursor and a common solvent. To
sustain the ever-growing need, an increment of methanol production and purification is
presented as a challenge, obscuring the reaching of humanity to a further future.
Due to the limited time and knowledge, this project may have some imperfections. We
earnestly seek feedback and recommendations from the esteemed Drs and classmates to
learn from our experiences and enhance our work. Our team is deeply grateful for their
support.

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 TABLE OF CONTENT
(viết ở đây)

iii
 LIST OF FIGURE
(viết ở đây)

iv
 LIST OF TABLE
(viết ở đây)

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CHAPTER 1
INTRODUCTION

1.1. Overview

(viết ở đây)

1.2. Background

Ethanol, commonly known as ethyl alcohol, holds a significant role in medicine and
various aspects of life, supported by scientific articles. Its applications extend beyond
being a solvent. Ethanol is utilized as an active ingredient in many pharmaceutical
preparations, including oral solutions, topical medications, and disinfectants. Research
studies have provided evidence of its effectiveness as an antiseptic. A study published in
the Journal of Hospital Infection demonstrated that alcohol-based hand sanitizers
significantly reduced bacterial contamination on hands compared to soap and water[1].
Moreover, ethanol has been investigated for its potential therapeutic benefits. Scientific
research, A study published in the Journal of Hospital Infection demonstrated that 60-
degree alcohol effectively eliminated a wide range of pathogens, including methicillin-
resistant Staphylococcus aureus (MRSA) and vancomycin-resistant Enterococcus (VRE),
thus aiding in infection control[2]. Additionally, the use of an ethanol yield during
fermentation is important for the efficient production of fuel alcohol, as well as wine and
other alcoholic beverages[3]. These scientific findings highlight the multifaceted role of
ethanol and its potential contributions to enhancing health and well-being in various
aspects of life.
Hence, it is of great significance to guarantee the accurate combination of ethanol at
the suitable concentration, not only in specific applications but also in a wide range of
industrial processes, by controlling the ratio between the two liquid. Scientific literature
provides insights into the context and importance of controlling the ratio between two
streams. For instance, in chemical manufacturing, maintaining precise proportions
between reactants is essential for achieving desired product quality and process
efficiency. A study of Antonio Visioli[4] emphasizes the significance of ratio control in
achieving optimal yield and minimizing unwanted by-products in chemical reactions. The
ability to accurately control the ratio between two streams enables operators to fine-tune

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processes, optimize resource utilization, and ensure consistent and high-quality

outcomes. These scientific insights highlight the importance of ratio control in various
industries and its positive impact on process performance and product quality. Thus, we
realize the importance of rate control in various industries and its positive impact on
process efficiency and product quality.

1.3. Problem statement

Ratio control is essential in various applications such as chemical dosing, water

treatment, chlorination, mixing vessels, and waste incinerators. For instance, in
combustion systems, controlling the air-to-fuel ratio is crucial for achieving high
efficiency, while blending processes require maintaining a specific ratio of different
flows to ensure a consistent product composition[4]. Trong bối cảnh sản xuất công
nghiệp hiện đại, việc duy trì tỉ lệ hỗn hợp chính xác là quan trọng để đảm bảo chất lượng
sản phẩm, tính đồng đều và hiệu suất. Điều này trở nên quan trọng đặc biệt trong các
ngành như dược phẩm, hóa chất, thực phẩm, cũng như sản xuất vật liệu, nơi sự chệch
lệch nhỏ về thành phần có thể dẫn đến sự thay đổi đáng kể trong sản phẩm cuối cùng.
Để kiểm soát tỉ lệ hỗn hợp đat chính xác cao, việc điều khiển lưu lượng là một yếu tố
cực kỳ quan trọng. Điều khiển lưu lượng không chỉ liên quan đến việc duy trì một tỷ lệ cố
định của từng thành phần mà còn đảm bảo sự ổn định trong các bước sản xuất và quá
trình truyền tải. Sự chính xác trong điều khiển lưu lượng đồng thời đảm bảo tính đồng
đều của sản phẩm và ngăn chặn các biến động không mong muốn, từ đó cải thiện hiệu
suất sản xuất và giảm lãng phí. Các hệ thống điều khiển lưu lượng hiện đại thường sử
dụng cảm biến lưu lượng và hệ thống điều khiển tiên tiến để tự động điều chỉnh lưu
lượng theo yêu cầu, giúp tối ưu hóa quy trình sản xuất và đảm bảo sự đồng đều và ổn
định của sản phẩm cuối cùng.
Đối với ngành công nghiệp sản xuất, việc kiểm soát tỉ lệ hỗn hợp, thực tế được đặc
trưng bởi việc triển khai các công nghệ tiên tiến, hệ thống tự động hóa và các cách thức
giám sát nghiêm ngặt. Các công ty đầu tư mạnh mẽ vào trang thiết bị hiện đại và theo dõi
thời gian thực để giảm thiểu biến động, nâng cao năng suất và giảm lãng phí. Sự chính
xác được cung cấp bởi kiểm soát tỉ lệ hỗn hợp không chỉ cải thiện chất lượng sản phẩm
mà còn đóng góp vào hiệu quả tài nguyên, tính kinh tế và tối ưu hóa quy trình trong các
môi trường công nghiệp.

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1.4. Objective

The overarching objective of this project is to acquire comprehensive knowledge and

expertise in building flow rate flower modeling by understanding its essential and
fundamental steps. The project aims to gain mastery in mixing methods, especially with
regard to achieving the desired concentration of the output product. Furthermore, the
project helps develop an understanding of controller design and how control systems
operate. By delving into these areas, the project aims to equip individuals with the
necessary skills and knowledge to operate an efficient and safe control process.

1.5. Scope of the study

The scope of research on control systems in this context includes building modeling
equations, adjusting parameters on real devices and building controllers.
Building the modeling equation requires evaluating and determining factors such as
raw material ratio, composition, and flow rate of the two streams during the mixing
process.
Then, the device parameters need to be adjusted to ensure the desired output product.
This may involve fine-tuning the DC pump, flow sensor and other equipment parameters
to achieve balance and precise control of flow rates and ratios.
Build a control system to automatically adjust the mixing process and maintain the
desired ratio and flow rate. This can be achieved by using a PI control method and
implementing a control system through software such as MATLAB to optimize the
performance and responsiveness of the mixing process.

1.6. Outline of thesis

(viết ở đây)

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CHAPTER 2
LITERATURE REVIEW

2.1. Overview

Ratio controlled system is one of the common types of control systems used in
automation. The main objective of ratio control is to maintain a specific ratio between
two variables, such as concentration, pressure, or flow rate, in a system. This control
system operates based on the principle of feedback/feedforward, where the control
output/input is adjusted ratio to the deviation between the actual value of the variable and
the desired setpoint.
The ratio control method is widely applied in many fields, including industrial, process
control, and automation systems. It is often used in processes where maintaining ratios
between variables is important, such as during mixing, controlling pressure in a system,
or regulating fluid flow.
The ratio control system typically consists of key components such as a sensor to
measure the actual value of the variable, a controller to calculate and generate the control
signal, and an actuator to adjust the system's operation. The parameters of the ratio
control system need to be adjusted and fine-tuned to ensure optimal performance and
meet the system's requirements.
Technological advancements have brought significant improvements to ratio control,
with the utilization of intelligent control algorithms and advanced tuning methods. This
has enabled the application of ratio control in more complex systems, achieving higher
performance and accuracy.
In summary, ratio control is an important control system for maintaining a ratio
between variables in automated systems. In this chapter, we want to introduce some
research related to our project. Some of these studies are the foundation for building
knowledge about modeling, control systems, controlled methods as well as positive
results that these articles can achieve which are the reasons for us making this project.

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2.2. Review of past design

2.2.1. Research #1: Effect of operating conditions on hydrothermal liquefaction of

kitchen waste with ethanol-water as a co-solvent for bio-oil production (2023)[5]
In this study, Mi Yan et al. argue that the influence of operating temperatures within
the range of 240 to 280°C and various solvents (ethanol, water, and ethanol-water co-
solvent) on the hydrothermal liquefaction (HTL) of kitchen waste (KW) for bio-oil
production. Notably, HTL exhibits the capability to directly convert KW into bio-oil
without the prerequisite of pre-drying. The researchers conducted a comprehensive
characterization of the bio-oil, focusing on its composition, boiling point, and viscosity.
The findings indicate that elevated reaction temperatures and increased ethanol
concentrations in the co-solvent positively impact both the yield and quality of the bio-
oil, suggesting enhanced liquefaction efficiency under these conditions. When compared
to HTL in water alone, utilizing an ethanol-water co-solvent leads to a higher energy
yield. Additionally, the incorporation of ethanol in the co-solvent contributes to an
elevated concentration of ester compounds in the bio-oil, accompanied by a reduction in
viscosity.
In contrast to HTL conducted in water, the addition of ethanol in the co-solvent
notably enhances the yield and quality of bio-oil, characterized by a higher proportion of
esters and reduced viscosity. Under identical reaction temperature and time conditions
(260°C in 30 min), the bio-oil yield from HTL in different solvents follows the order of
water-ethanol co-solvent > pure ethanol > pure water, indicating the existence of a
synergistic effect between water and ethanol during HTL.
2.2.2. Research #2: Pseudo-gel ternary systems of xanthan gum in water-ethanol
solutions for industrial applications (2023)[6]
Hydrocolloids with xanthan gum are widely applied, especially considering the food
and cosmetics industries. The solubility and capacity for intermolecular association in
aqueous solutions of xanthan gum can be influenced by various factors, with alcohols, in
particular, playing a significant role in promoting conformational structural changes that
result in a gelation process. Howis et al. focused on examining the impact of pseudo-gel
ternary systems involving xanthan gum in water-ethanol solutions as thickening agents.
Formulations with varying mass proportions of xanthan gum and solvent ratios were

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utilized to create model moldings. Thermal stability assessments for both moldings and
pseudo-gel systems were conducted using DSC-TG. The internal structure of the
moldings underwent evaluation through absorption and porosity tests using solvents of
differing polarity, and SEM imaging was employed for visualizing the internal structure.
Modifications in the xanthan gum content and the solvents' ratio within the
formulation have a direct impact on the porosity of the internal structure, subsequently
influencing the fragility of the samples. A reduction in xanthan gum content leads to an
increase in the porosity of the molding. The components within the formulation
contribute to the polar nature of the samples. The introduction of ethanol into the
formulation amplifies the porosity of the structure due to solvent diffusion during the
drying process. Furthermore, ethanol diminishes the persistence of interactions between
xanthan gum and solvent molecules, thereby reducing the drying temperature and energy
input during the process. Overall, formulations incorporating ternary systems of xanthan
gum in water–ethanol solutions demonstrate satisfactory thermal stability.
2.2.3. Research #3: Improving microbial quality of wheat flour using ethanol-water
mixture as a tempering solution (2023)[7]
Wheat flour is susceptible to high microbial loads due to contamination of the wheat
surface from various sources, leading to potential outbreaks of foodborne diseases
associated with wheat and wheat-based products. In this study, Ari Akin et al. introduce a
novel approach aimed at reducing microbial contamination during the tempering stage of
wheat. The research evaluates the impact of water with varying ethanol concentrations
(10–90% v/v) on the microbial load of wheat. While 70% ethanol is commonly used as
an antimicrobial agent, the study reveals a substantial reduction in aerobic plate count
(APC) and yeast-mold count (YMC) in wheat, reaching 5.02 ± 0.20 log CFU/g and 5.96
± 0.22 after tempering with 50% ethanol and above, respectively.
The results demonstrate that a 50% ethanol solution as a tempering agent is sufficient
to lower the microbial load to undetectable levels for wheat with low microbial counts
and provides an approximately 3.0 log CFU/g decrease for wheat with high microbial
loads. The higher diffusion coefficient of water allows for faster penetration into the
wheat kernel than ethanol, resulting in an increased ethanol concentration on the wheat
kernel surface. In terms of flour functionality, tempering wheat with 50% ethanol leads to

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a prolonged dough development time, reduced water absorption, enhanced stability, and
decreased softening compared to the control dough.
2.2.4. Research #4: Design and tuning of a ratio controller (2005)[4]
In this research, Antonio Visioli introduces a design and tuning procedure for a ratio
control architecture, offering a practical solution for industrial applications. The proposed
methodology allows for the automatic selection of control parameters based on a simple
process model, making it easy to implement in real-world settings. Simulation and
experimental results demonstrate the effectiveness of the methodology across a wide
range of processes.
The research proposes a new ratio control structure and presents an automatic tuning
procedure, eliminating the need for manual tuning efforts. The methodology is
straightforward to implement, as it does not require additional measurements beyond
standard ratio controllers. It utilizes classical PI controllers, making it easily
understandable for operators who can leverage their existing knowledge. The results
demonstrate the effectiveness of the proposed approach for a wide range of processes.
Therefore, the overall methodology is suitable for implementation in distributed control
systems (DCS) and single-station controllers, catering to the industrial context.
2.2.5. Paper #5: A remedy design of PI controller for liquid level control[8]

Figure 2.1: Block diagram of PI contronller

Rahmawati et al. proposes a solution to improve the performance of the PI controller

using the St. Clair method. Because of maintaining proper liquid levels in tanks is crucial.
The control of liquid levels in tanks involves adjusting the flow rate of the liquid to
achieve the desired set point. Although PI (Proportional-Integral) control tunned based on

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the Ziegler-Nichols method is commonly used, it often exhibits undesired oscillations.

The results demonstrate that by implementing the PI control with the St. Clair method,
the level control system achieves a stable response with no oscillation change (0%
oscillation), a rise time of 1.71 seconds, and a settling time of 4.9 seconds. This indicates
that the proposed combination of PI control and the St. Clair method effectively stabilizes
the system against changes in the manipulated value (MV) and ensures reliable level
control.
2.2.6. Paper #6: Design of PI Controller using Characteristic Ratio Assignment
Method for Coupled Tank SISO Process (2011)[9]
This study focuses on the design of a PI controller for a coupled tank system, which is
considered as a Single Input Single Output (SISO) process. The design methodology
employed in this study is the Characteristic Ratio Assignment (CRA) method. CRA is a
direct control approach for manipulating the transient response of linear time-invariant
control systems. By introducing a set of parameters (αi), known as characteristic ratios
(i=1,2,...,n), and a generalized time constant, the transient response of an nth order system
can be effectively controlled, as well as improved specifications and performance for the
control system.
The coupled tank system, chosen as the SISO process in this study, serves as a
challenging plant to assess the performance of the PI controller. The simulation results of
the CRA-PI controller have been obtained using MATLAB. Both the simulation results
and real-time experimental results demonstrate that the CRA-based controller can be
conveniently designed by selecting only one characteristic ratio parameter. This
advantage simplifies the design process and enhances the practical implementation of the
controller.
2.2.7. Paper #7: Flow Control of Fluid in Pipelines Using PID Controller[10]
In this study, a PID controller is used to regulate the flow rate of heavy oil in pipelines
by controlling the vibration of a motor pump. To achieve this, a torsional actuator is
introduced to the motor pump to manipulate the motor's vibration, thereby controlling the
flow rates in the pipelines. Vargas-Jarillo et al. want to establish stability conditions for
tuning the PID and utilize Lyapunov stability analysis to derive sufficient conditions for
setting the proportional, integral, and derivative gains at their minimum values.

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The effectiveness of PID controllers in minimizing motor vibration and controlling

flow rates in pipelines is verified through numerical simulations and analysis. The key
contributions of this research lie in validating the stability of the PID controller, an aspect
that has not been emphasized in previous studies focusing on flow rate control.
Additionally, the novel concept of employing a torsional actuator on the motor-pump
arrangement is introduced, offering a new approach to address flow rate control
challenges.
2.2.8. Paper#8: Design flow rate controll experimental model Chau Gia Tien (2021)
In this research, Gia Tien revolves around the study and implementation of automation
techniques to achieve stable liquid flow control in systems with varying structures,
ranging from simple to complex, based on the specific requirements and production
scale. The research primarily focuses on utilizing Ziegler & Nichols' method, which
involves experimental calculations of fundamental control parameters for PID
(Proportional-Integral-Derivative) controllers, in order to stabilize and regulate fluid
flow. The project aims to explore and apply different control strategies, develop suitable
controllers, conduct comparative analyses, and evaluate various control algorithms to
determine the most appropriate approach for achieving fluid flow stabilization.
2.2.9. Paper #9: The Ratio Controller for Regulation of Turnout Flow Rate(2015)
[11]
The task of setting and adjusting flow rates using turnout gates is a common practice
in canal operations and irrigation systems. This research paper proposes a method that
utilizes downstream flow measurement, where a relatively stable canal serves as the flow
source, and a sluice gate controls the turnout. The flow rate through the sluice gate is
approximately proportional to the gate opening, allowing for a simple ratio calculation to
estimate the required change in gate position to achieve a desired flow rate.
This method can be used to estimate the next manual adjustment of the gate or can be
integrated into an automated ratio controller. The stability of the control method is
analyzed, and example applications are modeled to compare its performance with that of
a typical proportional controller. The method demonstrates comparable performance to
the proportional controller without the need for empirical tuning. The only tuning
parameter required by the method is the selection of a control cycle time.

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The control cycle time is chosen based on the settling time required for the canal reach
between the turnout gate and the measurement device to reach equilibrium after a flow
change. The paper proposes a design parameter for estimating a stable control cycle time,
providing guidance for selecting an appropriate value.

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CHAPTER 3
CONTROLLED SCHEME

3.1. Introduction of control process

3.1.1. Process
A process is a set of one or more interacting activities aimed at a first goal, which is
composed of many interrelated tasks that take input or a disturbance and transform it into
an output. For technological processes, activities are understood as marine, chemical,
biological... phenomena that promote the transformation, operation or storage of starting
materials into desired output products. For chemical processes, the general goal is to
produce large quantities of materials and transform them into useful substances. It is a
chemical engineer’s job to utilize different tools such as process flow diagram (PFD),
piping and instrumentation diagram (P&ID), and different types of simulation, to put out
a detailed description of the process.
Variable processes and operating states can display information about quantities and
numbers in input and output. Quantities and numbers that are called by convention are
process variables. Common technological process variables are temperature, pressure,
flow, metering, concentration, pH, humidity, etc.

Figure 3.2: Block diagram of closed-loop control systems

The system in Figure 3.2 is called feedback control since information about the state of
the system is “fed back” to a controller, which in turn, uses it to make necessary changes.
For closed-loop systems, data are constantly collected, and changes are made
automatically, whereas, for open-loop systems, the signal is disconnected from the
controller, requiring manual adjustment for the controlled variable. In specific cases, an
open-loop system is considered a manual mode compared to the automatic one (closed-
loop) in some processes (Figure 3.3).

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Figure 3.3: Open-loop control system

Many processes are interferences that try to account for process changes but cannot be
read. This process is understood as the temperature, concentration... input to the process
is always changing; uncontrolled flow process; weather changes; thermal complexity;...
Measurement noises are disturbing interference factors errors in mission control
operations
The advance of this technology has gradually transformed chemical processes, making
them more efficient, more eco-friendly, and at the same time more complicated to
operate. To cope with these changes, building automatic control systems is the most
direct answer since they can bring the following benefits:
- Increased profit
- More efficient operation
- Safety enhancement
- Product quality assurance
3.1.2. Nomenclature of control process system
3.1.2.1. Process variables
- Input variables: are variables that are processed to reflect the external light actions of
the process, which are the causes of changes in the process. The inputs of symbolic
chemical technology are understood as changes in flow, changes in the composition of
the stored substance or heat supply,...1
- Output variables: are variables that can have an impact outside the process,
specifically the result or system of the process. Variations of symbology are understood
as: perfect temperature, performance, quality in equipment; or product concentration,
product flow, exhaust gas content, wastewater,...2

1
Chapter I, page 11, Cơ sở điều khiển (
2
Chapter I, page 11, Cơ sở điều khiển (

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Figure 3.4: Process variables

- Controlled Variables: are variables directly related to the goals and requirements of
the process that need to be achieved. Variables need to be specifically controlled for
stable operation, overall system or quality product3. For example, the energy, materials or
applications in the system need to be maintained within the limits of efforts to ensure
stable and safe operation of the system; The final module process temperature needs to be
achieved and maintained at the required value; The flow or product concentration needs
to be adjusted in an effort to ensure the product reaches the desired yield and quality.
- Manipulated Variables: also known as control actions, are variations of the process
that we can directly intervene or influence, from which we can achieve the variables that
need to be controlled according to desired request 4. The most common control effects are
process input and output flow rates, input efficiency; temperature quality storage; heat
supply, etc.
- Disturbance variables: are input variables that have an impact on the process that
cannot be determined or can be but cannot be determined within the scope of the process
of interest5. Many variables include process and noise disturbances.
3.1.2.2. Components in process control
- Sensor: performs the function of automatically sensing the quantity that needs to be
checked in the technical process (such as flow, temperature, level, etc.) and converting it
into a measurement signal.
- Controller: control is a strategy and directional impact on a control object - to ensure
it operates according to desired requirements6. Controller is a device that performs
control functions and is the core component of a control system. A Controller can be
performed manually or automatically. It receives the measured value of the process,

3
Chapter I, page 12, Cơ sở điều khiển (
4
Chapter I, page 12-13, Cơ sở điều khiển (
5
Chapter I, page 13, Cơ sở điều khiển (
6
Chapter I, page 17, Cơ sở điều khiển (

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implements the control rules and issues the corresponding control signal to the actuator to
intervene back in the process7.
The controller receives input values and makes control actions based on pre-installed
control rules or algorithms.
- Measurement equipment: often called by the name of the quantity it measures, in
process control commonly encountered measuring equipment: temperature measuring
equipment, flow measuring equipment, measuring equipment. liquid level meter, pressure
meter, pH meter, humidity meter, etc8.
HÌNH
- Final control element: is the part that directly intervenes in the control object. The
actuator is responsible for receiving the output signal from the controller and performing
intervention on the control variable to adjust the value of the control plate corresponding
to the controller's signal. Normally, actuators include two basic components: actuator and
control element9.
3.1.2.3. Terminology in process control
- Regulatory control: is to maintain a stable output quantity of a control object
following the main value by introducing control effects into the object 10. Regulatory
control is an important functional class of the control system. process control, in which
process output quantities such as temperature, pressure, flow, level, concentration... need
to remain stable at the desired control or set value.
- Control loop: is a cycle that performs control. Any process control loop in industry
performs three tasks: measuring, calculating and providing intervention to the process11.
- Setpoint: is the output value of the process that we want to achieve, set value is the
value that we want the variable to be controlled to achieve 12. The set value is also called
the dominant value. The set value can be set by the operator or calculated from an
optimization algorithm in a computer and then fed into the controller.

7
Chapter I, page 27, Cơ sở điều khiển (
8
Chapter I, page 25, Cơ sở điều khiển (
9
Chapter I, page 28, Cơ sở điều khiển (
10
Chapter I, page 17, Cơ sở điều khiển (
11
Chapter I, page 18, Cơ sở điều khiển (
12
Chapter I, page 19, Cơ sở điều khiển (

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- Error (e): is the difference between the set value and the control output value of the
process13. Control error is a function of time, control error at any time can be calculated
according to the formula:
e = Ysp - Y(t)
In which Ysp, Y(t) are the set point and the instantaneous value of the variable to be
controlled, respectively.
- Control algorithm: is an algorithm that represents the relationship between the output
value and the input value of the controller during the control process14:
U = f(e).
3.1.3. PID control system

PID controller is a controller that provides control actions based on component actions
including component P, component 1 and component D. page 136-137, Chapter 6, sách
thầy

- P component is a component that has the dynamic proportional to the magnitude of the
control error e(t)

- I component is the component whose impact is proportional to the control error integral
e(t)

- D component is the component whose impact is proportional to control error differential

e(t)

While the proportional component P responds to the magnitude of the control error at the
current time C, the integral component 1 responds to the duration of the error control up
to the present time, the differential component D reacts to the rate of change of the bias
block to predict its change trend in the future and provide control action against that
change.

The formula of PID:

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And the corresponding is:

The diagram:

Trong đó các thông số của bộ điều khiển:

kc kD
k c =k p :hệ số khuếch đạicủa bộ điềukhiển τ I = : thời gian tích phânτ D = :thời gian vi phân
kI kc

3.1.3.2. Phương pháp chỉnh định bộ điều khiển

During the control system design process, preliminary controller implementations
are based on understanding of the process, control objectives, and previous experience.
After a controller is set, the initial set parameters may have to be corrected to achieve the
control problem requirements. This direct on-site calibration is called by many different
names: online calibration, controller calibration.
Controller tuning is tested at the factory on a trial and error basis. Therefore, to
reduce time and effort, parameters from the control system design can be used as initial
settings. first, then add the main province accordingly.
In this section, we look at three important methods commonly used to calibrate
controllers
- Trial and Error method
The trial and error tuning method is based on guess-and-check. In this method, the
proportional action is the main control, while the integral and derivative actions refine it.

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The controller gain, Kc, is adjusted with the integral and derivative actions held at a
minimum, until a desired output is obtained.
Below are some common values of Kc, Ti, and Td used in controlling flow, levels,
pressure or temperature for trial and error calculations.
Flow: P or PI control can be used with low controller gain. Use PI control for more
accuracy with high integration activity. Derivative control is not considered due to the
rapid fluctuations in flow dynamics with lots of noise.
k c = 0.4-0.65
τ I = 6s

Level: P or PI control can be used, although PI control is more common due to

inaccuracies incurred due to offsets in P-only control. Derivative control is not
considered due to the rapid fluctuations in flow dynamics with lots of noise.
The following P only setting is such that the control valve is fully open when the
vessel is 75% full and fully closed when 25% full, being half open when 50% filled.
kc = 2

Bias b = 50%
Set point = 50%
For PI control:
k c = 2-20
τ I = 1-5 min

Pressure: Tuning here has a large range of possible values of Kc and Ti for use in
PI control, depending on if the pressure measurement is in liquid or gas phase.
Liquid: k c= 0.5-2, τ I = 6-15 s
Gas: k c = 2-10, τ I = 2-10 min
Temperature: Due to the relatively slow response of temperature sensors to
dynamic temperature changes, PID controllers are used.
k c = 2-10
τ I = 2-10 min
τ D = 0-5 min

- Ziegler-Nichols tuning method

The Ziegler-Nichols (ZN) rules are commonly employed to tune PID (Proportional-
Integral-Derivative) controllers, even when the dynamics of the plant are not precisely

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known. These rules can also be applied to plants with known dynamics. Ziegler and
Nichols introduced a set of guidelines for determining the values of the proportional gain
(k p), integral time (τ I ), and derivative time (τ D) based on the transient response
characteristics of a specific plant. By analyzing the plant's behavior during the transient
response, suitable values for these controller parameters can be determined using the ZN
rules.
Step Response Method: The first method of Ziegler and Nichols (ZN-I) is used to
adjust the controller parameters P, PI and PID based on the transient response curve of
the object, obtained from experiment. The experimental procedure is quite simple:
1. With the plant in open-loop, let the plant run at normal operating condition
with constant input u0 and steady state output y 0.
2. At the initial time t 0, apply a step change to the plant, from u0 to u∞ (in the
range of 10 to 20% of full scale).
3. Record the output response to get the reaction curve. In the figure, the m.s.t.
stands for the maximum slope tangent.
y∞ − yo
4. Compute: K= L=t 1−t 0, T= t 2−t 1.
u∞ −uo
K is the system gain. L and T are often called the apparent dead time and the
apparent time constant.

Type of control Kp τI τD

T
P
L

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0.9 ×T L
PI
L 0.3

1.2× T
PID 2×L 0.5 × L
L

Ziegler-Nichols controller settings

Self-Oscillation Method: Ziegler-Nichols offers a second method (ZN-II) based on
parameters obtained from experiments when bringing the system to a critical oscillation
state. The procedure for making adjustments is as follows:
1. Set the system in manual control mode, adjust so that the system operates
stably at the working point.
2. Switch the system to automatic control mode with a proportional controller P,
with a coefficient k psmall enough.
3. Gradually increase the coefficient until the system reaches a critical oscillation
state that the oil has a harmonic oscillation. The value of the parameters is
then called the critical gain coefficient K th and the oscillation period is called
the critical oscillation period T th.
Depending on the choice of P, PI or PID controller, their parameters are calculated
based on the formula in the table below: Determine parameters for PID controller types
as follows:

Type of control Kp τI τD

P 0.5 × K th 0 0

T th
PI 0. 4 5 × K th 0
1.2

PID 0. 6 × K th 0.5 ×T th 0. 125 ×T th

- Cohen-Coon tuning method

The C-C method requires the use of an open-loop step response (process reaction
curve). Such method can be summarized in the following steps:
1.After the process reaches steady state at the normal level of operation, switch the
controller to manual mode.

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2. With the controller in manual, introduce a small step change in the controller
output that goes to the valve and record the transient.
3. Draw a straight-line tangent to the curve at the point of inflection.
4. Using available equations to calculate controller parameters.

Step test for tuning

Type of control Parameter setting

Proportional (P)

Proportional – Integral (PI)

Proportional – Derivation (PD)

Proportional – Integral – Derivation (PID)

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Cohen – Coon controller settings

3.2. Control scheme and classification of controlled scheme

In process control, determining process seas is extremely important and necessary, but
what is even more important and necessary is to determine a control scheme or control
strategy. To be classified as a functional control system, these criteria must be fulfilled:
- Ability to maintain desired values of the variables even if disturbances occur.
- Ability to alternate variables values according to users’ settings
Because of real processes are multi-step processes, with many input variables and
many output variables, the choice of measured information of which input and output
variables is expressed in the control strategy. Most control strategies are based on a
combination or extension of two basic control principles, namely feedback control (error
control) and disturbance control.
3.2.1. Feedback controller
The feedback control strategy is based on the principle of continuously measuring the
controlled value and feedback information to the controller, the controller compares it
with the set value, recalculates the value of the required control variable. influence the
process to achieve the desired set value of the controlled sea15.
HÌNH CẤU TRÚC ĐK PHẢN HỒI
Feedback controller is a control strategy that plays a fundamental role and is
commonly applied in process control. The essence of the feedback control strategy is the
control method based on feedback from the controlled sea, also known as error control:
the difference between the controlled variable value and the set value.
Feedback control strategies offer several advantages. They can compensate for
disturbances and uncertainties in the system, ensuring robust operation. They also

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provide the ability to adapt to changing conditions and maintain desired performance
levels. Moreover, feedback control enables system optimization by continuously
adjusting the control signal based on real-time measurements.
Feedback control has the disadvantage of having a slow impact, because when a
deviation is detected, the process of correcting that deviation begins. Especially for
processes with slow kinetics, the impact of disturbances on the output of the process
takes a long time, leading to a slower process of detecting deviations and correcting
deviations. Although there are some disadvantages as mentioned above, the advantages
of feedback control are still outstanding. Therefore, among the independent control
strategies, the feedback control strategy still plays the most important role and is used in
most automatic control systems. The main advantages include: feedback control for high
precision control quality. This is explained because the control effect U is formed based
on the control deviation, so as long as there is a deviation, the controller will still exert an
impact on the control variable to make the deviation smaller, creating out the correct
response. Another advantage of feedback control is its ability to eliminate the effects of
unknown or unmeasured variables.
3.2.2. Feed-forward controller
The feed-forward controlled strategy is a strategy in which the controller receives
signals of measured disturbances and transmits them to the controller in order to
promptly prevent the impact and influence of disturbance variables on the process. that
can achieve the purpose of the process. The nature of the feed-forward control strategy is
a control method based on noise variable information, so it is also called a noise
compensation control strategy16.
HÌNH CẤU TRÚC ĐK PHẢN HỒI
In the feed-back control strategy, the feed-back information used is the measured
signal of the variable to be controlled, while in the feed-forward control strategy, the
information used is the measured signal of the disturbance variable.
Feed-forward control is widely applied in process control with the important
advantage of fast action due to the ability to eliminate the influence of disturbances
before they can adversely affect the process. submit. However, direct transmission
control also has disadvantages: the control quality is not highly accurate. This can be
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understood because when controlling a direct transmission, it is necessary to know

clearly information about the process and the effects of noise. However, not all noise can
be measured, so it cannot eliminate unmeasured or unknown noise, so control bias always
exists.
In conclusion, feed-forward control strategies offer an effective approach to anticipate
and compensate for disturbances in control systems. By proactively addressing
disturbances, feed-forward control enhances system performance and stability. Addition,
when combined with feedback control techniques, it can provide robust and reliable
control in various applications.
3.2.3. Feedback combined feed-forward controller
The combination of feedback control and feed-forward control is a powerful strategy
used in control systems to achieve enhanced performance, accuracy, and disturbance
rejection. By leveraging the strengths of both control techniques, this approach addresses
both known disturbances and uncertainties in the system, resulting in improved control
capabilities17.
The feedback control component in this strategy continuously measures the system's
output and compares it to the desired setpoint. It generates a control signal based on the
error between the measured output and the setpoint. Feedback control provides stability,
error correction, and adaptation to changing operating conditions.
On the other hand, the feed-forward control component utilizes a model or knowledge
of the system to predict and counteract disturbances in advance. It estimates the effect of
disturbances and generates a control signal based on these predictions. Feed-forward
control enables proactive compensation for disturbances, reducing the reliance on
feedback control and improving disturbance rejection capabilities.
HÌNH CẤU TRÚC ĐK PHẢN HỒI
In summary, the strategy of combining feedback control and feed-forward control is a
powerful approach to achieve superior control performance. By integrating the strengths
of both techniques, it provides enhanced disturbance rejection capabilities and improved
tracking accuracy. Proper system modeling, accurate disturbance estimation, and careful
tuning are crucial for the successful implementation of this strategy in control systems.

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3.2.4. Ratio controller

Ratio controller is a special form of feedforward and feedback control, in which the
controller receives signals from input variables (for feedforward) and signals from output
of controlled components (for feedback), maintains the ratio between those variables at
an appropriate value to control the operating process. according to desired requirements.
Basis for applying the ratio control strategy: In real technological processes, there are
many processes whose inputs involve two material flows: one can be controlled (can be
controlled). can be interfered with), while one line cannot be controlled (many can be
measured). The results or products of such processes are directly affected and influenced
by the ratio between those two amounts of matter18.

(a) (b)

Figure 3.5: P&ID of ratio control system

In configuration (a), the two-stream flow signal is measured by sensors FT-01.1 and
FT-01.2, respectively, and passed through the "Divide block" to calculate the actual rate
R at the present time. This rate is transmitted to the RC ratio controller (preset R), where
a comparison of R with R sp will be performed, to control the flow of the intervened
stream. Therefore, the case of configuration control (a) is also called bias control (bias e
= Rsp - R). Normally, if we do not represent the controller with the symbol RC separately
from the "split" but represent it combined into a single flow ratio controller, then we use
the symbol FFC (Flow Fraction Control) for flow rate ratio controllers, instead of using
the ratio controller symbol RC.
In configuration (b), the process flow signal from the FT-01.1 sensor is multiplied by
the RX set value, which is for setting setpoint for the controller RC to control the steam

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flow. Thus, in fact, configuration (b) of the control flow controller also performs bias
control. In addition, it is also possible to combine the "multiplier" with the FC flow
controller into a single flow controller, denoted FFC. This configuration is often applied
in practice, because choosing the parameters for the traffic controller is usually quite
simple. This is also the advantage of ratio control over pure noise compensation control.
In addition to the general disadvantages of the direct transmission control strategy, it is
also important to note that when setting the controller for this case, the setting value is
unknown and changes continuously over time.
3.2.5. Cascade controller
Cascade control is a control strategy that uses a nested multi-controller structure, in
which the control signal of the outer loop will be used as a set value for the inner loop
controller19.

Figure 3.6: P&ID of cascade control system

In case the single loop feedback control system is working well, the temperature T 2 is
equal to the set value T sp, at this time the amount of steam supplied to the process is
constant, corresponding to the valve opening remaining the same. Suppose that under the
influence of a certain factor, such as steam flow pressure, the amount of steam supplied
to the process changes while the valve opening remains constant, but this change in steam
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flow takes a period of time. It takes a long time to change the output temperature of the
process stream. As a result, by the time the temperature controller reacts to that
temperature change and issues a valve opening control signal, it may be too late if the
steam quantity has already returned to normal values. This problem makes the pure
feedback control strategy unable to meet the quality requirements, and can even cause
system instability.
To prevent this slow response, the control system is supplemented with a flow control
loop as shown in Figure 3.6 to early detect and minimize the effects of interference right
at the place where it arises. The output from the outer loop's TIC-102 temperature
controller is fed down as the set value to the inner loop's FIC-101 flow controller.

3.3. Evaluation of control system

3.3.1. Evaluation of feedback control system

- Construction of a feedback control system based on CFD simulations for the 64-
element Canadian SCWR (2023)[12]
Following the study, transient full-scale computational fluid dynamics (CFD)
simulations were used to obtain input and output data sets for a 64-element Canadian
supercritical water-cooled reactor (SCWR). Linear dynamic models of the reactor were
then obtained using system identification techniques and validated against CFD results.
Based on these models, a feedback control system with three PI/PID controllers was
constructed. The objective was to regulate the system back to the design point in the
presence of disturbances. The performance of the designed control system was evaluated,
demonstrating its ability to minimize deviations and return the reactor to the desired
operating condition.

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Figure 3.7: Flowchart of embedding controller of the feedback control system

Figure 3.7 illustrates the block diagram of the feedback control system implemented
for the fuel bundle. The controllers in this system become active after the input
disturbance has been sustained for 12 seconds. The deviations between the output results
of the transient CFD simulations and the desired values at each time step serve as the
input variables for the controllers. The outputs of the controllers, in turn, become the
inputs for the subsequent time step of the CFD simulations. This arrangement creates a
closed-loop system involving the controllers and the transient CFD simulations. Both the
transient CFD simulations and the control system operate with a time step size and
sampling time interval of 0.01 seconds. Notably, the feedback control system effectively
regulates the outputs to the desired design point within approximately 8 seconds.
3.3.2. Evaluation of feedback combined feed-forward control system
- Dissolved oxygen controller based on on-line measurements of ammonium
combining feed-forward and feedback (2002)[13]
Following the study, a straightforward approach to utilize real-time ammonium
measurements for controlling aeration in a pre-denitrification plant. The control is
achieved by adjusting the dissolved oxygen setpoint. Moreover, the controller parameters
are continuously updated based on ammonium concentrations in the effluent of the
secondary sedimentation unit. This integration of feedback and feed-forward control is
particularly beneficial for plant setups where the aerobic zone is continuously operated
and supplied.
The controller was implemented and tested in a full-scale wastewater treatment plant
for a duration of 35 days. The experiment involved two identical activated sludge lines,

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with the controller implemented in one line while the other line served as a reference for
comparison.
Utilizing online in-situ sensor measurements directly from the process offers a
significant advantage over effluent measurements as it eliminates or significantly reduces
the time delay for obtaining information. Preliminary results indicate that the proposed
control strategy leads to energy savings in the range of 5-15% for aeration, while
maintaining a similar effluent quality compared to the reference line. It is anticipated that
even higher energy savings can be achieved by optimizing the controller further.
- Oxygen excess ratio control for proton exchange membrane fuel cell using model
reference adaptive control (2019)[14]
The research is about improving the efficiency and economic performance of proton
exchange membrane fuel cells (PEMFCs) requires robust control of the oxygen residual
ratio (OER). However, controlling the OER is challenging due to modeling errors,
parameter uncertainties, and disturbances. To address these challenges, the paper
proposes a control system based on model reference adaptive control (MRAC),
specifically designed for air supply systems that face inherent difficulties.
The proposed control system implements MRAC and feedback controllers on a
nonlinear model of the fuel cell system to demonstrate the system's robustness under
various operating conditions. The results indicate that the presented MRAC strategy
outperforms the nominal feedback control method, resulting in reduced wear and control
effort on the compressor.

Figure 3.8: Block diagram of a mode reference adaptive control system (MRAC)

Additionally, the paper suggests a combined controller that integrates feedback control
and feedforward control, based on a simplified three-level model and state observer. The
feedforward control, utilizing a map-based approach, enables quick monitoring of the

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desired oxygen residual ratio, while the variable feedback control law based on LQR state
regulation ensures the system's dynamic performance. Simulation results confirm the
effectiveness of the proposed controller design.
Nuclear reactors have gained considerable interest for potential use in spacecraft due
to their extended lifespan and high power-density characteristics. However, the dynamic
behavior and operational requirements of space nuclear reactors (SNRs) differ from
traditional reactors, necessitating a thorough investigation of their control strategies for
the design of suitable control systems. This study focuses on analyzing the dynamic
characteristics of SNRs in both the time and frequency domains.
3.3.3. Evaluation of cascade control system
Qian Ma, Peiwei Sun, Xinyu Wei, Shifa Wu (2023)[15]
Nuclear reactors have gained considerable interest for potential use in spacecraft due
to their extended lifespan and high power-density characteristics. However, the dynamic
behavior and operational requirements of space nuclear reactors (SNRs) differ from
traditional reactors, necessitating a thorough investigation of their control strategies for
the design of suitable control systems. This study focuses on analyzing the dynamic
characteristics of SNRs in both the time and frequency domains.
The cascade control method is employed to design control systems for SNRs,
encompassing electric power and coolant temperature control. The controller parameters
are tuned using frequency-domain analysis techniques. To assess control performance,
step and ramp disturbances are introduced to the electric power and coolant temperature
setpoints, and comprehensive comparisons are conducted. The findings indicate that the
cascade control systems outperform traditional proportional-integral-derivative (PID)
control methods. Furthermore, the wide-range power regulation exhibits smooth and
stable control performance.

Figure 3.9: Structure of coolant temperature cascade control system

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The coolant temperature cascade control system's structure is illustrated in Figure 3.9.
In this system, the coolant temperature control serves as the outer loop controller within
the cascade control structure. The deviation between the measured coolant outlet
temperature and the setpoint is utilized as the input for the outer loop proportional-
integral (PI) controller. The output of the outer loop PI controller is then employed as the
setpoint for reactor power. The reactor power control system functions as the inner loop
controller within the cascade control structure. The discrepancy between the measured
reactor power and the setpoint provided by the outer loop controller is considered as the
input for the inner loop proportional (P) controller. The output of the inner loop controller
is used as the driving voltage for the control drum motor. To determine the parameters of
the outer loop PI controller, the inner loop of the cascade control system is regarded as
the control object, allowing for the design of appropriate control parameters for the outer
loop controller.
In conclusion, the control strategy and cascade control system proposed in this study
offer viable solutions for thermionic nuclear reactors utilized in space applications. These
findings contribute to the development of appropriate control systems for SNRs, ensuring
their efficient and reliable operation.

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CHAPTER 4
COMPONENTS OF SYSTEM

4.1. Overall

Apart from the main hardware including cylinder tank and two pumps, there are many
more components belonging to this model. They are categorized by individual function,
such as:
- Controller - Other instruments
- Measuring instruments - Electrical cabinet
- Controlled instruments - Software

4.2. Materials

4.2.1. Ethanol
Ethanol (EtOH), also called alcohol, ethyl alcohol, and grain alcohol, is a clear,
volatile colorless organic liquid with a characteristic pleasant odor, and burning taste. It is
highly flammable. Because it can readily dissolve in water and other organic compounds
(rapidly absorbs water from the air), EtOH is a main ingredient in alcoholic beverages, a
wide range of cosmetic and personal grooming products, household cleaners and
polishes, pharmaceutical products, disinfectants, and insecticides, paints and paint
products (such as thinners), products made from particle board, lubricating oils,
household and industrial inks (including printed materials), and pet products[16].

Figure 4.10: Structure of Ethanol

In industry, EtOH is produced as a result of manufacturing basic chemicals and

industrial machinery and equipment. In nature, EtOH is produced from a wide range of
microbiological processes (by fungi and bacteria), and possibly from some plants. In

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daily life, EtOH can be produced in vehicle exhaust when it is used as a fuel additive or
substitute. EtOH can also be generated from evaporation of vehicle fuels[16].
4.2.2. Water
Water (H2O) is a compound that can be found everywhere on Earth. It is the basis of
all living organisms and most chemical reactions will ultimately produce water as a
byproduct. Humans cannot survive without water for more than three days, so it is
essential to stay hydrated and protect the planet’s clean water reservoirs.
Moreover, H2O can be utilized in many ways, from household applications to chemical
engineering.
4.2.3. Ethanol – Water binary
A colorless, non-viscous liquid with the properties of a homogenous mixture can be
formed by mixing EtOH and H 2O. The binary system could be the product through the
process of diluting high alcohol to mass produce alcoholic beverages or prepare
pharmaceutical products such as medical alcohol.
The physical properties of EtOH and H2O are illustrated in Table 4.1 and Table 4.2:
Table 4.1: Thermodynamic points of Methanol and Water[17].

Properties Unit Ethanol (90o) Water

Molecular weight (M) kg/kmol 46.07 18.02
Boiling point (TB) ⁰C 78 100
Melting point (TM) ⁰C -114 0

Table 4.2. Physical properties of Methanol and Water at various temperatures[17].

Condition
Unit Ethanol (90o) Water
Parameters Temperature
Density 30 ⁰C kg/m³ 809 997
Heat capacity (Cp) 30 ⁰C kJ/(kmol.K) 114.32 75.32
Viscocity 30 ⁰C cP 0.5043 0.8196

4.3. Controller

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A controller sets up data from measuring instruments and responds with necessary
actions so that a set-point can be reached. In this project, an Arduino UNO R3 board will
play the part of a processing and controlling device.
The Arduino UNO R3 is a micro-controller Arduino board that can read inputs and
turn them into outputs. A wide variety of controllers, pins, LEDs, ports, and
microprocessors are included in the board, allowing it to connect with many kinds of
compatible hardware. It is especially suitable for a simple task such as light on/off
controller, motor’s direction controller, etc.

Figure 4.11: Arduino UNO R3 board

The Arduino UNO R3 is a perfect choice for those looking to learn about electronics
and coding. Arduino's programming language is C/C++, but programming with Arduino
is much simpler because it only has to communicate with the hardware through libraries
available in the software Arduino IDE[18]. While there are different types of Arduino
boards available today, the Arduino UNO R3 remains popular for educational purposes
and scientific projects. Its superior quality and high performance make it an invaluable
tool for capturing real-time data from sensors and controlling sophisticated laboratory
equipment, among other applications.
Table 4.3. Specifications of Arduino UNO R3 board[19].

Micro- Flash
ATmega328P 32 KB
controller memory

Operating 5V Length 68.6 mm

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voltage

Input voltage 7-12V Width 53.4 mm

14 (of which 6
Digital I/O pins Weight 25 g
provide PWM output)

Analog input
6 Clock speed 16 MHz
pins

4.4. Measuring instruments

To measure the flow rate signals of two liquid streams, we use acrylic flowmeters
brand ZYIA to collect data manually and turbine flowmeter sensors brand DIGITAL
FLOW CO.LTD to collect data through the controller.
4.4.1. Character of flowmeter LZM–25GB

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Figure 4.12: Acrylic flowmeters LZM-25GB

The acrylic flowmeter is a measuring instrument that can directly show the flow rate of
oil, water and other liquids. This type of flow meter requires to be installed vertically
because the working principle is based on the water's thrust acting on the float placed in
the middle of the body. The transparent body is made of acrylic and has graduations that
allow a visual check of the state of the liquid, as well as displaying an internal flow
indicator relative to the calibrated flow scale. In this project, the acrylic flowmeter used is
LZM - 25GB type because of its measuring range.
Table 4.4: Data sheet of LZM-25GB[20]

Working
Model name LZM–25GB 1 MPa
pressure
Measure Liquid 2 – 16
Float SS316
Range gal/min
4 – 60 L/min Max Temp. 60oC

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Gas 7 – 70 m3/h Body Acrylic

Accuracy ± 0.4% Diameter 45 mm
4.4.1.1. Working principle
The acrylic flowmeter operates based on the principle of mutual balance between the
thrust force of the fluid and the gravity of the float. When the liquid flows through,
depending on the flow rate, the float will be lifted up to a position where the thrust is
balanced with gravity[21]. However, due to the existence of buoyancy according to the
Archimedes principle, the float material and the specific gravity of the liquid will affect
the measure of the flowmeter[22].

Figure 4.13: Working principle of acrylic flowmeter

4.4.1.2. Role
In this project, we use LZM - 25GB as a testing device to compare and evaluate data
from pumps and flow sensors to detect deviations and calibration.
4.4.2. Characteristics of turbine flowmeter DGTT-015S
Table 4.5: Sensor technical data[23]

Item (Model Name) DGTT-015S

Accuracy (Standard Installation
± 0.5%
Position)

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Maximum Working Pressure 500 Kg/cm2

Fluid & Ambient Temperature -40 to 80°C
Flow-Rate Range (±1%) 400 - 5,000L/H
Pulse Unit 0.00277L/P (361 P/L)
Power Voltage 3 - 24V DC
Output Signal NPN Open Collector
Connection PT3/4 (External Thread)
Rotor: Polyamide + Ferrite
Main Materials Casing: 304 Stainless Steel
Shaft: 304 Stainless Steel
Black (-) GROUND
Wiring Red (+) POWER
White (-) SIGNAL

Figure 4.14: Turbine flowmeter DGTT-015S

4.4.2.1. Working principle

The digital flowmeter DGTT-015S operates based on Hall's law, which states that
whenever a magnetic field is put in a direction that is perpendicular to the flow of the
electric current in a conductor, the potential difference (Hall potential) is generated at two
opposite sides of the Hall bar. This potential is used to detect if the sensor is in the
proximity of a magnet or not. The ratio between the Hall potential and the current
flowing through the Hall bar is called the Hall resistance, which characterizes the
material that makes up the Hall bar (a semiconductor)[24], [25].

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A B

Figure 4.15: Applications of Hall effect in measuring rotor speed

when the tooth of the wheel is far the magnetic field (A) and when they are close to the field (B)

In the digital flowmeter, the fluid will flow into the sensor, causing it to rotate with an
angular velocity proportional to the flow rate. The angular velocity of the rotor leads to
the creation of a change in the distance of the wheel relative to the magnetic field, which
leads to the generation of an electrical signal: when the tooth of the wheel pass near the
magnetic field, the Hall effect sensor will receive the appearance of Hall voltage and
output a HIGH signal to the control system. From there we will know the total number of
HIGH signal per times, and calculate the flow rate through the flow sensor calibration
equation.
4.4.2.2. Advantage
High precision, especially with low-viscosity substances.
Easy to maintain and check. It can be taken apart without affecting the main pipe
system.
4.4.2.3. Disadvantage
Calibration characteristics are difficult to maintain over long periods and periodic
calibration is required.
Not applicable for high-viscosity flow measurement because as viscosity increases, the
lower limit flow measurement increases, and the measurement range decreases because
of reduced measurement and poor linearity.
Greatly influenced by the change of flow velocity distribution and turbulence.
Only applicable for clean liquids and strainers are usually needed when the sensor is
installed.

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Figure 4.16: Installation caution[23]

4.5. Controlled instruments

To adjust the fluid flow, an electronic valve or a digital pump can be used. In this
project, Water stream is our controlled manipulate and we control the water flow rate by
adjusting the pump capacity of the DC submersible water pump model ZQB-12V of
WEDO brand.
4.5.1. DC submersible water pump
4.5.1.1. Working principle
A DC submersible water pump is a centrifugal pump that is connected to an electric
motor and operates underwater. The main part of the submersible pump is the impeller
which converts the motion energy of the prime mover into kinetic energy[26], [27]. The
liquids are subjected to strong centrifugal forces generated by the high rotation speed of
the impeller. As a result, the fluid loses its kinetic energy in the diffuser, where the
conversion from kinetic energy to pressure energy occurs, leading to being pushed up to
the surface[28].
4.5.1.2. Advantage
Never needs to be priming since it is already submerged in fluid.
Cost-effective that can push large volumes with less energy consumption.
No cavitation threat and silent operation.
Certain submersible pumps can easily handle solids while others are better for liquids.
4.5.1.3. Disadvantage

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Over a period, the seals of the pump can become corroded, leading water to seep into
the engine making it a useless unit that requires repair.
If the submersible pump is not properly inside the water, the pump may get damaged:
the dry running may cause overheating of the pump.
Completely hermetically sealed, as a result pump may get rusted over time.
Not allowable for one-size-fits-all.
When there are impurities in the liquid stream that impact the device, it will become
unusable until repaired.
4.5.2. Characteristics of pump ZQB-12V
Table 4.6: ZQB-12V data sheet

Item (Model ZQB–12V Maximum Flow 4 m3/h

name) Rate
Working Low pressure Water column 8m
Pressure height
Power Voltage DC 12V Weight 3 kg
Maximum 180 W Material Stainless Steel
Power

Figure 4.17: Mini DC submersible water pump ZQB-12V

4.6. Other instruments

4.6.1. Centrifugal pump MCD-25S

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Difference to Water stream, Ethanol stream is an uncontrolled manipulate and also a

disturbance of our system. Compared to any type of pump, centrifugal pump MCD-25S is
more energy efficient and it can highly maintain process flowrate. This is important
because of the reduction of the disturbance as much as possible. The capacity of the
pump is chosen according to the requirements of the system However, period calibration
may be required and we measure that our pump still only reaches 32 L/Min.

Figure 4.18: Centrifugal pump MCD-25S

Table 4.7: Operating parameters of centrifugal pump MCD-25S

Model MCD 25S Output 370 W

Pipe size 25 m Prequency 50 Hz

Total head 40 m Poles 2P

Suction head 8m Volts 220V

Capacity 45 L/Min AMP 2.8

4.6.2. Contactor CHINT NXC-22

To operate remotely as well as ensure the safety of electrical components during
process operation, the controller system needs a device that can easily make/break the
electric current remotely. In our system, the contactor will play the role of such controlled
devices. This component is widely used in many industrial control fields, especially the

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development of intelligent control contactors. Its performance directly can affect the
safety and stability of the power system and the control system[29].
4.6.2.1. Principle:
An electromagnetic field is generated whenever current flows where the moving coils
attract each other. As a result, the force created by the electromagnet holds the moving
and fixed contacts together. On de-energizing, the contactor spring moves back the
electro-magnetic coil to its initial position and there is no flow of current in the circuit.

A B
Table 4.8: The internal structure of the contactor without power supply (A) and with power supply (B)

4.6.2.2. Advantages:
Safety for technical personnel.
Able to control completely a machine from various control points or stations.
Circuits subjected to currents can be controlled at very high.
The maneuvers are carried out from places far from the motor or other types of loads.
The currents and voltages manipulated with the command devices are or may be small.
Control and automation of equipment and machines with complex processes
4.6.2.3. Disadvantages:
Can easily be damaged or lose performance due to overuse or lack of maintenance.
Contact wear and coil burn are the two most common problems.
Require adequate power to operate, leading to increased electricity consumption
prices.
Over-current flowing through the magnetic contactors causes the primary contacts to
stick, so it requires protection devices such as overload relays and fuses for improved
system protection.

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The life-use is calculated by the number of switching times. After that number of
switching times, the contactor will no longer be able to be used.
4.6.3. CHINT NXR-25
Thermal protection is one of the most important problems in monitoring and protecting
induction machines. There is over 30% of the motor failures are related to stator winding
insulation and thermal overload is one of the main root causes of these failures[30]–[33].
However, due to the high cost of embedded thermal sensors and their difficult
installation, especially for small-to-medium-size systems, thermal relays are broadly used
for mains-fed induction circuits.
4.6.3.1. Working principle
The thermal overload relay working principle is based on the amount of current that
flows in the motor or circuit it’s connected to. It uses this current to recreate the heat and
use that heat to determine when an overload can cause damage: if the temperature of
given system increases higher than the setpoint, the relay operates and disconnects the
faulty components from the rest of the system[19],[20].

A B C
Figure 4.19: The working principle of thermal relay at normal (A), break the faulty components when overload (B),
and break the power to relay (C)

4.6.3.2. Advantages
High accuracy, easy to install and cost-effective.
Operates on a wide range of current and have auto/manual reset options.
Can be used conveniently in single-phase and three-phase motors to protect electrical
motors from overheating.
Allow the motor to be operated at overload for a short time if required.
Certain overload relays have internal trip class selection buttons.
The relays have temperature compensation features for accurate functioning.
4.6.3.3. Disadvantages

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Mostly slow in their response.

Need time to cool down after operating once and have low operation cycles.
Not able to withstand shocks and vibrations.
Not helpful in short-circuit whenever instantaneous tripping of the circuit is important.
Reliably against low-resistance circuits but not suitable for heavy-duty circuits.

Figure 4.20: Magnetic contactor CHINT NXC-22 (A) and Thermal overload relay CHINT NXR-25

In this project, we use CHINT NXC-22 combined with thermal overload relays
CHINT NXR-25 to protect and remote electromagnetic starters/breaker power for
Ethanol’s pump. The model is chosen with a suitable output and input voltage.
4.6.4. Motor IBT-2 driver (BTS7960)
The IBT-2 is a fully integrated high-current half-bridge module for motors. Interfacing
to a micro-controller is made easy by the integrated driver IC which features logic level
inputs, current sense evaluation, slew rate adjustment, dead-time generation, and against
over-temperature, over-voltage, under-voltage, over-current, and short-circuit. This
small-size driver provides a cost-optimized solution for protected high-current pulse
width modulation (PWM) motor drives with very low board space consumption.

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Figure 4.21: DC motor driver IBT-2

Table 4.9: Brief data of DC motor drive IBT-2[36]

Model IBT-2 Control Mode PWM or level

Input Voltage 6 ~ 27Vdc Duty Cycle 0 ~100%
Peak current 43-Amp Board Size 50 x 50 x 43
(mm)
PWM capability Up to 25 kHz Weight 66g
Input power 3.3~5V

4.6.5. Power supply S-120-24

A power supply is an electrical device that transform the inlet electric current, such as
the power mains 220V, to the voltage and current values necessary for powering a load,
such as a motor or electronic device.
For AC/DC power supply, the main job is to convert the alternating current (AC) into
a direct current (DC) voltage, which can be used to power different electrical
components[37], [38].

Figure 4.22: Power supply S-120-24

Table 4.10: Parameters of power supply S-120-24

Model S-120-12 Inlets stability ±0.5%

AC input voltage 110/220V Load stability ±0.5%
DC output 12V DC output power 120W

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voltage
Output voltage ±1% Efficiency 80%
error

4.6.6. 2-phase circuit breaker

A circuit breaker is an automatically operated electrical switch designed to protect an
electrical circuit from damage. A double pole breaker is a type of circuit breaker. It is
used for a specific voltage range. They are usually placed directly above the load and
designed to protect final loads. They are ideal to apply in industrial, commercial, and
residential sectors, and ensure the following functions: protection against short-circuit
and overload currents, isolation, and protection against indirect contact[39], [40].
4.6.7. Fixing terminal block YSFT 030-04 Figure 4.23: 2-phase
circuit breaker LS
Instead of wiring and soldering directly, using terminal blocks as a BKN-C32

connecting bridge is a much better solution because of its flexibility. Terminal Block
wiring is more neat and more orderly allowing for quick identification, making
modification and troubleshooting easier.
The Barrier terminal blocks are those that use screws as the method for clamping the
wires. Depending on the application and environment, the Barrier terminal strip may
have a small lid to protect the wiring. However, when wiring, it’s important to strip the
wire to the correct length and do not over-tightening because the screws can damage the
wires and result in poor or potentially dangerous connections[41].

Figure 4.24: Barrier terminal blocks YSFT 030-04

4.6.8. Emergency Stop Button LA38-11ZS

4.6.9. Selector switch 2 Position LA38

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4.6.10. Indicator light AD16-22D/S31 green

4.7. Electrical cabinet

4.8. Software

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4.9. Lab-scale mixing model

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CHAPTER 5
PUMP CALIBRATION

5.1. Overall

In Chapter 4, we briefly introduced the digital pump ZQB-12 that our team will use in
this project. According to the graduation project of " " (), to calculate the flow rate
4
(L/min) based on the pulse signal, we can multiply the number of pulses with . This
255
coefficient is built based on the ratio between the flow rate when the pump capacity
reaches maximum (4 L/min) and the maximum signal (the controller signal in this project
is in the range 0 - 255).

(L/min) 101\* MERGEFORMAT (.)

However, we do not know whether the above equation is actually correct or not, in this
chapter we decided to do experiments to determine the linear equation between flow rate
and pulse signal emitted from the controller.

5.2. Process of calibration

- Step 1:
- Step 2:
- Step 3:

5.3. Result

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CHAPTER 6
EXPERIMENTAL MODEL

3.1. Shape of the Ethanol – Water mixing model

In this project, the Ethanol – Water mixing system is utilized from the old existing
one, which is designed according to the author's " ". In Chapter 4, we introduced our
system including 1 fixed flow pump (for Ethanol flow control) and 1 controllable pump
(for distilled water flow control). In this Chapter, we calculate and design the modeling
of the flow ratio control and determine the flow rate of water required for dilution to
achieve the desired product concentration.

Figure 6.25. The basic shape of the mixing model

3.2. Modelling equations

3.2.1. Mass balance

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3.2.2. Flow ratio controller model
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3.2.3. Level controller model
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CHAPTER 7
DESIGN AND CALCULATION OF THE CONTROLLER

7.1. Design of flow ratio controller

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7.2. Design of level controller

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7.3. Design of user interface

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CONCLUSION AND FUTURE WORK

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REFERENCE
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