CHEN90032

Process Dynamics and Control

Worksheet 1 – Automatic Control

The feedback controller is the cornerstone of automatic control within the

process industries. A feedback controller takes a measured value for some
important process variable (the controlled variable, c) and continually
compares it to the desired value (the set-point, r) to generate an error signal,
e. Some control algorithm within the controller then operates on the error
signal to arrive at a new value for the manipulated variable m that will bring
the controlled variable back to the desired value in a fast but stable way.

In order to completely define a control system we need to specify which

controlled variables are paired to which manipulated variables (the control
scheme), as well as details of the control algorithm. This worksheet presents
several processes for which we will develop control schemes based upon our
‘chemical engineering intuition’. The majority of this course will be devoted to
understanding how process variables change in time (process dynamics), and
how we can use that information to develop effective control algorithms within
a particular control scheme. Towards the end of the subject we will also see
how process dynamics can guide our pairing of controlled and manipulated
variables to arrive at the optimal control scheme.

W1-1
1) Develop a control scheme for the evaporator depicted below, which has
three controlled and manipulated variables, giving six possible configurations.
Identify (and label on the diagram) the pairs of controlled and manipulated
variables. Explain how you expect the controlled variables to interact with
each of the three manipulated variables.

Controlled variable 1 (c1):

Manipulated variable 1 (m1):

Controlled variable 2 (c2):

Manipulated variable 2 (m2):

Controlled variable 3 (c3):

Manipulated variable 3 (m3):

Vapour, Fv

P
Feed L

Steam, Fs
T

Liquid, Fl

W1-2
2) An absorber-stripper is used to remove CO2 from a mixed stream of H2 and
CO2, as shown below. Design a system to control the temperature, pressure,
and liquid levels in the absorber and stripper units.

CO2

H2

Cooling
Absorber Stripper
Water
Feed Steam

Solvent (MEA)

Cooling
Water

W1-3
3) The chemical plant depicted here converts reactants A and B to the products C and D in an exothermic reaction, then the
products are separated in a binary distillation column. Develop a control scheme including valves and controllers.

A process flow diagram for this chemical plant is provided online as a Microsoft Visio file. Use this file in developing a complete
control scheme.

Cooling
Feed Tank A Water

Distillation
Feed Heater Column Reflux Drum

Feed Tank B

Product D

Cooling Jacketed
Water Reactor
Reboiler Steam

Cooling
Product Cooler
Water

Product C

W1-4