DEPARTMENT OF CHEMICAL,

METALURGICAL AND MATERIALS

ENGINEERING
%

NATIONAL DIPLOMA : CHEMICAL ENGINEERING

PROCESS CONTROL PCT301T

GROUP PROJECT

SURNAME & STUDENT PARTICIPATION

INITIALS NUMBER
MNISI PM 218492045 100%

MBEKWA NA 218133681 100%

LETLAILA I 216350120 100%

NDWAMMBI A 213244469 30%

DUE DATE : 07 JANUARY 2022

 ABSTRACT

Plant wide control is a holistic approach about being able to integrate process design
with process control at the level of the whole plant. The main objective is ensuring a
stable and flexible operation when the plant is affected by a variety of disturbances,
that includes any changes in production rate and the quality of the raw material feed
in the CSTR. A key topic is the control of variables which can be controlled by
feedback/ feedforward mechanisms or by relying on the fail-safe valve design. The
process is prone to problems such as the snowball effect, which is the steady-state
phenomenon caused by a small change in load variable creating a large change in
recycle flow rate around the system. (Luyben, 1999).
Given the unreliability and unpredictability of electronic signals during upset
conditions, such protection cannot really be relied on in lieu of pressure relief
devices. It is therefore advisable to have a more reliable control system such as the
High Integrity Protective system in place, in order perfectly optimize any future
behaviour of the plant.

1
TABLE OF CONTENT

CONTENT PAGE
INTRODUCTION 2
METHODOLOGY 3-6
DISCUSSION OF RESULTS 7-8
CONCLUSIONS 9
AND RECOMMENDATIONS

REFERRENCES 10
CALCULATIONS 11-21

GROUP-EVALUATION 25-27

2
INTRODUCTION
Process control is simply described as the ability to monitor and adjust any
process by making use of control systems to yield the desired output: It is widely
used to maintain the quality, greatly improve the performance of a process, enhance
process safety and satisfying environmental constraints whilst ensuring that the
process is profitable. Process control is implemented in industries such as
automotive, mining, dredging, oil refining, pulp and paper manufacturing and power
generating plants.

For the purpose of this report we look at the production of MPN, which is obtained by
reacting methanol with acetonitrile ( methanol and acetonitrile are organic acids
commonly used as the mobile phase in reverse-phase chromatography). The
process consists of two units the CSTR and a distillation column forming an
interacting system. Due to the complex nature of this process a plant wide control is
implemented.

The CSTR: It is the most basic of continuous reactors used in chemical processes.
The jacketed reactor is a self-regulating process, that is the process variables PV
seek a steady operating level if the controller output and major disturbance are held
constant for a specific time, it allows the flow of cooling water to remove the heat
from the exothermic reaction

Distillation column: A fractional distillation (liquid mixtures are separated by

heating, considering a high heat exchange and the liquid and vapour molar rates.
This distillation column separates composite mixtures having different temperatures.
It usually considers a continuous operation, having a constant feed flow through the
feeding tray). In general distillation columns all have the same operating modes
mainly due to the physical variables that interact such as temperature, pressure,
composition, and heating energy.

A typical distillation process consists of a reboiler which provides the heating energy
necessary for evaporation, condenser which provides cooling needed to condensate
vapour and trays where partial separation of mixture is performed due to the
circulation of vapour flow. The operation can be described by a mathematical

3
process, which is able to simplify the analysis and comprehension of the distillation
dynamics, facilitate design of control techniques to enhance the distilled product
quality and the system performance.

METHODOLOGY
In every industry that deals with processes, it is important to have a process control
system. Process control is the regulation / manipulation of variables influencing
the conduct of a process in such a way as to obtain a product of desired quality. For
every process that needs the application of process control the objective of that
specific process needs to be specified. This is the aim that process is meant to
achieve.The objective helps us regulate the set point value to maintain the quality of
the process substance/products. There are single variable processes in which only
one variable is to be controlled as well as multi-variable processes which may
require regulation. The example of the process variable is temperature, pressure and
fluid flow rate.

Manipulated variables,this are the variables that can be adjusted freely by the
human operator or a control mechanism. An example of a manipulated variable is
flow rates of streams that entering or leaving a process that we can change in order
to control the plant.

Disturbance variable, this are the variables that are not the result of adjustment
by an operator or a control system. Variables in the process that affects the
controlled variables but cannot be manipulated.For example flow rates,
temperatures, or compositions of streams entering the process.

4
Control loops
A fundamental component of any industrial process control system is a control
loop.Control loops are on the process to maintain the stability of the system and the
desired outcome of the process.

It consists of a process, a measurement, a controller and a final control element.

The information of flow provides the means for control, which allows efficient
utilization of raw materials and energy. If all these elements are well interconnected
which the information can be passed continuously around the loop, this called as
closed-loop control and if a loop is interrupted for any reason, such as when the
controller is placed on manual control, it is considered to be open-loop control

Mathematical modelling
Modelling is the mathematical representation of a process intended to promote
understanding of a real process.Theoretical models of chemical processes are
based on conservation laws such as the conservation of mass and energy.

In modelling we have three types of conservation equations.

 Conservation of Mass
Rate of mass accumulation = rate of mass in – rate of mass out
 Conservation of Component
 Rate of mass accumulation = rate of mass in - rate of mass out + rate of mass
generated -rate of mass consumed
 Conservation of Energy
Rate of energy in - rate of energy out + net rate of heat addition to the system +
net rate of work performed on the system

5
For every modelling done on any process we have a systematic way that helps us
develop the model. The following steps are done.
1. The modelling objectives are stated
2. We then draw the schematic diagram of the process and label all process
variables.
3. We list all the assumptions involved in developing the model.
4. Looking at the process we decide which conservation equation will best
apply then the appropriate conservation equation of mass, component or
energy is applied
5. Equilibrium relation and other algebraic equation are introduce
6. We then perform the degree of freedom analysis.
7. We simplify the model by grouping the like terms and taking out the common
factors.

Transfer function block diagram

Transfer Function is an algebraic expression for the dynamic relation between

a selected input and the output of the process model. It is well represented by a
block flow diagram consisting of block / several blocks which are connected via
signal.

Fail-safe design
For every valve on a process there must be a fail-safe design. A fail-safe design is
specific design made on valves to prevent and mitigate unsafe consequences of the
systems in case of an equipment failure or an unexpected stop of the process.

We have two types of fail-safe designs I. e Fail- Open and Fail- Close.

Fail- Open, this valve is the one which is designed in a way that should go to the
Open position if air failure occurs or the process shuts down unexpectedly.

Fail- Close, this valve is the one which is designed in a way that should go to the
close position if air failure occurs or the process shuts down unexpectedly.

6
DISCUSSION OF RESULTS
The flow of ACN is measure by flow meter F1 and send signal to ratio controller
RC which provide set point of flow controller FC and using feedback
mechanism. The flow of MeOH is measure by flow transmitter F2 and sent
signal to FC which takes action based on error signal which is equal to
measure flow of MeOH and desire flow provided by flow controller. If the flow
is less than desire then it increases the flow rate of MeOH by increasing
opening of valve that send MeoH into the system .

To control the temperature of reactor the cascade control is used. The

temperature of reactor is measured by the temperature transmitter T and sent
signal to temperature controller TC which provide set point to flow controller
FC. The flow of cooling water is measured by flow transmitter FT and sent
signal to flow controller FC which takes action based on error signal which is
equal to measure flow of cooling water to desire fl ow provided by TC. If
temperature of reactor is more than required then it increases the Flow of
cooling water by increasing opening of control valve of incoming cooling water
thus decreasing the temperature to a desired value .

To control the temperature at bottom of column cascade control is used. In

this the temperature is measured by temperature transmitter T and sent signal
to temperature controller TC which provide set point to flow controller FC. The
flow rate of steam is measured by flow transmitter FT and sent signal to flow
controller FC which takes action based on error signal which is equal to
difference in measured flow and desired flow provided by TC. If the
temperature is less than desired then it increases the flow of steam by
increasing opening of control valve that sends steam to reflux.

The methanol flow rate controller satisfies the production rate objective since there is
basically a complete on version of the methanol to MNP product. The ACN flow rate
is to be 2% higher than the methanol flow rate in order to achieve the excess ACN as
stipulated by the problem statement (Bequette 2002). All these controls are put in
place in an attempt to stabilize the system as it exhibits a sensitivity in the the

7
recycle flow rate stream to the small disturbances experienced thus creating the
snowball effect which is rectified by having at least one loop in the recycle path
controlled so as to minimize the snow ball effect (Zhan and Grassi 1999).

The results show that a well designed regulatory plant wide control structure is able
to stabilize and linearize the process around the operating set point.

The accurate modelling of the process temperatures with jacket has the potential to
mitigate the risk of thermal runways and enhance process control as it control the
reaction rate of methanol and CAN as well how much product can be produced at
the given period of time.

The process gain describes the rate at which the MNP flows out of the reactor.The
time constant states how fast the reactant turn into products meeting the tank
volume constraints.

8
CONCLUSIONS AND RECOMMENDATIONS
Conclusion
The problem with the design is the snowball effect. The snowball effect is an extreme
sensitivity to the slightest of disturbances. Having a slight disturbance could affect
the flowrate of the recycle stream tremendously. The recycle stream has some inert
materials in it. The snowball effect will require an introduction of a purge stream in
order for the process to run optimally but will however be costly. Having a control
loop in the recycle stream and controlling its flow to minimize the snowball effect is a
less costly method and the most efficient.

Recommendations
Using a flow controller to regulate the mixed stream (recycle + ACN) flow rate by
manipulating the distillate (recycle) flow rate; this allows the control structure to
minimize the snowball effect. The distillate level controller manipulates the fresh ACN
flow control valve.

The recommended/improved design includes flow control of a recycle loop stream. ,

the reactor outlet stream is flow controlled. The reactor is level controlled by
manipulating the ACN feed-flow valve. In addition, a reactor concentration sensor is
used to improve control.

The improved design also makes use of fail open valves instead of fail close valves.
Using fail closed valves is more dangerous than using fail open valves. If the valves
were fail close the system will overheat from a lack of cooling.

If the valves are fail close the cooling water will no longer flow and cool the system.
This will also cause an increase in pressure which might result in an explosion. If it
fails open, the engine will merely run cooler than designed, the only negative
consequence being decreased efficiency.

9
LIST OF REFERRENCES

1. Bequette, B Wayne. (2002). Process control: modelling, design, and

simulation. Prentice Hall PTR.
2. Del Carmen Tellez-Anguiano A. et al. (2017). Mathematical Modelling of
Batch Distillation Columns: A Comparative Analysis of Non-Linear and
Fuzzy Models. (article)
3. https://www.cheresources.com/invision/topic/19424-control-valves/
4. https://controlguru.com/design-level-of-operation-for-the-jacketed-stirred-
reactor-process/
5. Luyben W.L, Tyreus B.D, and Luyben M.L. (1999). Plantwide Process
Control. McGraw Hill, New York.
6. Stephanopoulos G. (1984). Chemical Process Control. Prentice Hall,
Englewood Cliffs. NJ.
7. Zhan Q and Grassi V.G. (1999). Dynamic Matrix Control of a Speciality
Chemical Plant with Different Plantwide Control Structures. In proceedings
of the 1999 American Control conference.

10
ANSWES TO THE QUESTIONS
The process is an interacting process as there is a recycle stream from the
distillation to the blender which directly affects the ACN feed into the CSTR.

1.
OBJECTIVE:
To produce MPN at a specified rate whilst satisfying purity constraints
(purity of 98%)

2.
PROCESS VARIABLES:
INPUTS are the disturbances and the manipulated variables I.e reflux flow rate,
recycle stream, level of condensate , ACN feed flowrate,reactor temperature,
temperature of steam, methanol feed flowrat and pressure of distillate

OUTPUTS are the controlled variables I.e The liquid level of reactor, MPN product
from the distillation colum

DISTURBANCES: reflux flow rate, recycle stream, level of condensate and Cooling
water flowrate.

MANIPULATED:ACN feed flowrate, reactor temperature, temperature of steam,

methanol feed flowrate, pressure of distillate

11
CONTROLLED: The liquid level of reactor, MPN product from the distillation column

3.

CONTROL LOOPS

12
4.

MODELLING
We treat the process as a two-stage process. The first stage being the CSTR; the
CSTR is jacketed to allow easy control of temperature; and the second the
Distillation; in our case we are making use of fractional distillation.

CSTR REACTOR TANK

Mass Balance
accumulation=ṁ¿−ṁ out + generated

ṁ¿ −mass flow rate of feed entering the CSTR

ḿout −mass flow rate of exitingthe CSTR

Material Balance
dx D
⍴V =F ⍴ x Do−F ⍴ x D −k ⍴ V x D
dt

F−feed rate

x Do−mole fraction∈feed

x D −mol fraction∈reactor

⍴−density of mixture

V −volume of mixture

k −rate constant

Heat Balance

13
Qaccumulated =Q ¿ −Qout +Qgenerated −Q removed with jacket

∆ H ¿ x −Q(T )
D

dT
⍴V C p =F ⍴ C p ( T F −T ) +k ⍴ V ¿
dt

Assumption :The reactionis adiabatic thusno ∆ H ∴

dT
⍴V C p =F ⍴ C p ( T F −T )−Q(T )
dt

T F −feed stream temperature

T −reactor temperatue ( product temperature )

C p −specific heat of mixture

Q (T )−heat removed through cooling

∆ H−heat of reaction

k −rate constant

Combining∧simplifying the highlighted equations we get

F
dx D V ( )( x Do−x D )−k x D
Q (T )
dT
=
F k ∆ H xD
−
⍴V Cp ( )
V ( )
( T F −T ) +
Cp ( )
Assumption :The reactionis at steady state thus no change∈t emperature∧concentration

0= ( VF ) ( x Do −x Ds )−k x Ds

k ∆ H x Ds Q ( T )
0= ( VF ) (T −T )+
F s
Cp
−
⍴ V Cp

x Do
x Ds=
kV
1+( )
F

Q(T ) F C p (T F −T S)
x DSE= −
⍴ kV ∆ H kV ∆ H

14
Laplace Transform
The transfer function is obtained as

Vd C A
=F C AO −F C A −VK C A
dt

F C AO d C A C A
= +
V dt τ

V
τ=
KV

τ −time constant

By taking the Laplace transform∧rearanging the highlighted equation ,the transfer function of the

tank is expressed as follows

C A (s ) K Pτ
=
C AO ( s) τs+1

F
K Pτ =
F + KV

K Pτ −gain of transfer function of the tank

V −volume of the tank

F−feed flow rate

C AO −initial concentration of thetank

C A −outlet concentration of tank

15
 K−rate of reactio n

Distillation

In order to design the distillation column model the following assumptions are
considered:

 Binary mixture, the feed contains only two components

 The pressure inside the column is fixed by controlling the cooling water

 Constant relative volatility

 Constant molar flows

 No vapor holdup, the vapor holdup on each tray is negligible

 No heat losses in the body column

 Constant pressure in the body column

 Linear liquid dynamics

 Equilibrium on all stages

 Total condenser, there is no vapor holdup in the condenser

Overall mass Balance

Feed = Product + Distillate

F=W+D

Rate of mass accumulation = rate of mass in – rate of mass out

W= F - D

16
Overall component balance
d F xf W xw D xD
= +
dt dt dt

W −bottom products

x w −bottom product composition

D−distilled product

y D −distilled product composition

Component balance for all stages except feedtray ,overhead behaviour of the light component of

mixture : condenser∧reboiler

d x 1 Ĺ ( x 1−1−X 1 ) + V́ ( y i+ 1−Y i )
=
dt Mi

x i−liquid molar composition of the light component ∈the tray

y i−vapor molar composition of the lighter component

Ĺ−liquid molar flow

V́ −Vapor molar flow

m−mass retained

Assumption : Accumulation∈each stage is constant

dm1
=0
dt

Phase equilibrium is determined by constant k

xi
k=
yi

Such that considering the vaporliquid equilibrium VLE therelative volatility , the vapor composition as a functi

compositionis obtained . This functionis presented as

y=f ( x , a )

17
 ai x i
y i=
1+ ( ai −1 ) x 1

a−relative volatility∈tray i

Feed tray component balance

dx w ixi−W xw −Vi yi
=
dt mw

¿ a fractional distillation column , theliquid flows∈both the rectifying∧stripping vary due ¿ feeding flow

2B
V́ = vap
H1 xn+H 1vap ( 1−xn )

2 B−the heating power input

xn−the liquid composition of thelight component

H 1vap−the vaporisationenthalpy of thelight components

vap
H 2 −the vaporisationenthalpy of the heavy component

´ ) V́
L=( 1−R
R−the reflux input
D=V́ − Ĺ
¿
Condenser model

The condenser is considered as tray 1

dx1 V́ y 2− Ĺ x1− D x 1
=
dt m1

Substitute yello highligted equation into ¿ highlited equation ¿ represent the condenser as a function

of the reflux

D=R V́

Substitute ¿ higlighted equation intothe ¿

dx1 V́ y 2− Ĺ x1 R V́ x 1
=
dt m1

a2 x 2
y 2=
1−( a2−1)x 2

non−linear equation that represent condenser dynamics

18
dx1 V́ (a2 x 2) Ĺ x R V́ x 1
= − 1−
dt m1 (1−( a 2−1 ) x2 ) m1 m1

Tray model

Columnbody is formed by a set of n−2 trays

dx1 V́ y i+2−V́ y 1+(x 1−1− Ĺ xi )

=
dt mi

where i=2,3 ,… , n−1

where n isthe total number of trays inclunding a boiler∧condenser , consider the lemon highlighted

non−linear equation that represents the condenser dynamic isas follow :

a1 + x 1+1
¿
ai x i
¿
V́ ¿
V́ (¿ mi ( 1−ai +1−1 ) x i +1 ¿ )−¿
¿
dx1
=¿
dt

Boiler −model

The b oiler is numbered as tray n

dx n V́ xn−V́ yn + Lxn−1−L xn
=
dt mn

Solving V́ represents a function of the heating power QB based of grey highlighted equation

1−x n
x − y n Ĺ ( xn −1−x n)
(
H 1vap xn + H 1 vap (¿¿) n
mn )+
mn
QB
¿
d xn
=¿
dt

1−an−1
a x
considering y n= n¿ n x n ¿

the non−linear equation that represents theboiler

19
 1−a n Ĺ( x n−1−x n)
+
1−( an−1 ) x n mn
dx n 2B x
=( vap )( n ) ¿
dt H 1 x n + H 1 ( 1−x n ) mn
vap

The following equation would be used on calculation that would be

done for each part of the column.

Material balance on stage n

dM n
= Ln+1 - Ln -Vn-1 - Vn
dt

Where

Mn is the liquid holdup on tray n, Ln and Vn are the liquid flow rate and vapor flow
rate that come towards tray n

Material balance for light component on tray n

dM n x n.
dt
= Ln+1xn+1 - Lnxn +Vn-1yn-1 - Vnyn

Material balance at the feed stage

dM f
= Lf+1 - Lf -Vf-1 - Vf +F
dt

20
Component balance at the feed stage

d M f xf .
= Lf+1xf+1 - Lfxf +Vf-1yf-1 - Vfyf + Z f
dt

Where F is the feed flow rate and Zf is the concentration of the light component in
the feed.

The reboiler is also an equilibrium stage with n=1

Mass balance on the reboiler

d M1
= L 2 - V1 - B
dt

Component balance on the reboiler

dM 1 x 1
dt
= L2x2 - V1y1 - Bx1

At the condenser we have n = NT

Mass balance on the condenser

dM NT
= VNT-1 - LNT - D
dt

Component balance on the condernser

dM NT X NT
= VNT -1yNT -1 LNTxNT - DxNT
dt

The composition of the heavy component is related to the composition of the light
component via the relative volatility formula:

21
 α xn
yn = 1+(α −1) x n

5.

22
6. FAIL-SAFE VALVE DESIGN

23
How the valves should operate in case of an unexpected power cut / loss.

ACN flowrate valve: fail close, because allowing the flow of ACN could lead to
improper rations of ACN and methanol reacting to form MPN which could affect the
rate of reaction and the desired quality of ACN product.

MeOH flowrate valve: fail close, we can not allow incoming flow of MeoH into the
reactor tank that has stopped working. And our tank is designed to have a fail close
valve. If MeoH is allowed to keep flowing in, the tank will over flow.

Cooling water valve: fail open, an exothermic reaction is taking place giving off heat
energy which can raise temperatures to high dangerous levels thus damaging the

24
tank, so cooling is always needed to keep temperatures within acceptable
boundaries.

Reaction tank valve: Fail close, methoxypropionitrile is corrosive it will be best

stored temporary in the reactor tank than the distillation column during the time of
power outage.

MPN product output valve: Fail Open, this valves allows the end product to flow out
of the system or process. If there was an unexpected stop of our process the end
product will need to be ejected out of the system.

Steam valve: fail close, to avoid overheating and having high temperatures that
could possibly damage the column

Distillation cooling water valve: fail open, to ensure that remaining hot fluid is cooled
by the cold water flowing in thus preventing overheating and damaging the
component.

Reflux valve: fail close, to avoid drop in temperature profile in the column, which will
lead to flooding of top trays and potential decrease in reflux drum level as an
immediate consequence.

Recycle stream valve: fail open, to allow the distillate collecting drum not to oveflow
and bust the pipes because the reflux valve will be closed not allowing the distillate
to pass back into the distillation column.

GROUP-EVALUATION

25
(1) Assign yourself a grade/mark Why did you assign this mark in your self-
evaluation?
90%. We have read extensively on the required material to produce a report,
which we believe demonstrates our understanding of the process and systems
applied and shows that we were able to analyse and tackle the questions as
professional future engineers.

(2) What mark do you think you should get for the project?
90%

(3) Where in your assignment (sections, aspects) did you perform at your
best….And at your worst?

(4) Did you find the class and prescribed material useful?
Yes

(5) Did you use additional sources? If your answer is “yes”, describe or name these
sources.

Yes we did.
8. Bequette, B Wayne. (2002). Process control: modelling, design, and
simulation. Prentice Hall PTR.
9. Del Carmen Tellez-Anguiano A. et al. (2017). Mathematical Modelling
of Batch Distillation Columns: A Comparative Analysis of Non-Linear
and Fuzzy Models. (article)
10. https://www.cheresources.com/invision/topic/19424-control-valves/
11. https://controlguru.com/design-level-of-operation-for-the-jacketed-
stirred-reactor-process/
12. Luyben W.L, Tyreus B.D, and Luyben M.L. (1999). Plantwide Process
Control. McGraw Hill, New York.
13. Stephanopoulos G. (1984). Chemical Process Control. Prentice Hall,
Englewood Cliffs. NJ.
14. Zhan Q and Grassi V.G. (1999). Dynamic Matrix Control of a Speciality
Chemical Plant with Different Plantwide Control Structures. In
proceedings of the 1999 American Control conference.

26
(6) How much time did you spend on the assignment?
We spent 16 days doing the assignment.

(7) Which competencies, areas of knowledge, skills and other qualities did you
need to complete this assignment?
We needed insight demonstration of equation based on the theory /
methodology , reasons with understanding, interpretation of concepts and
theory using our own words.

(8) Did completing this assignment and consulting the relevant sources improve
your competence as a fluid process engineer? Name a few competencies that
you think should be developed further.
Yes it did.

(9) What aspects of the course, study material, and your learning experience would
you like to improve? How?
The modelling part. We are planning on using more information from other
process control textbook ,the internet and youtube videos. To better our
understanding of modelling.

(10) How would you describe the quality of the learning material (tutorial, study
guide, prescribed book)? Please elaborate.
Our study material is perfect but when it comes into the calculations part it is
not presented/designed in a way that allows a student to go through it on their
own as it omits some of the basic foundation of process control calculations.
But the best part is we are lectured by a lecture that knows exactly what
process control is and has good lecturing strategies.

(11) Do the assignment tasks reflect the learning outcomes?

Yes it does.

(12) Were the lecturer and tutor support of an expected standard? Please elaborate.

27
Yes, the lecture was able to even go through each and every part of the
assignment with us to explain what exactly is needed and how exactly it
should be written.

28