CHEMICAL ENGINEERING 3P04 PROCESS CONTROL TUTORIAL #5 2008

1. The continuous stirred tank chemical reactor shown in the Figure 1 is to be analyzed. Assumptions and data for deriving a dynamic model are given below.
i) ii) iii) iv) v) vi) the tank is well mixed the density is constant, and the heat capacity (CpCv) is constant the heat of reaction, Hrxn=0; heat transfer, Q=0; work, W=0 A B, rate of reaction, rA= - k0e-E/RTCA [mole/ (volume*time)] system is initially at steady-state flow in and out [volume/time] and the volume are constant
T0 F CA0 CA V T A B

Figure 1. CSTR

Goal: Determine the concentration of A when the inlet temperature changes in a step, T0. A. Starting from the basic balances, derive the differential equation(s) that describe the dynamic behavior of component A. B. Express the equations derived in Part A as linear (or linearized, as needed) equations in deviation variables. Identify the steady-state gains and the time constants. C. Using the results in Part B, solve for the temperature and concentration for a step. 1. (10 points) Derive the analytical expression for T'(t). 2. (15 points) Derive the analytical expression for CA'(t). D. Sketch the shapes of the responses for T'(t) and CA'(t) in response to the input. Be as specific as possible in defining features of the transient response. E. Using the results in previous parts, answer the following questions for the relationship between T0 CA. Briefly justify your answers. 1. 2. 3. 4. 5. What is the order? Is the response stable? Is the response over-, critically, or underdamped? Is the steady-state gain proportional to V/F? Does the time constant (or time constants) depend on the value of temperature?

2.

In this question, we will consider the most common flow meter, the orifice meter. Sketch a pipe with an orifice meter, describe the measurements taken, and how the flow rate is determined from the measurements taken (i.e., the principle and the resulting equation). In the sketch, identify the non-recoverable pressure drop and discuss why this is important. Identify two situations (process conditions) when the orifice meter should not be used. The system in Figure 2 is a cylindrical tank that has gas entering and leaving. The roof of fixed mass (m) floats on the gas, i.e., it moves up and down depending on the amount of gas in the vessel, and no gas can leak from at roof-wall interface. The gas inlet flow rate is determined by a compressor and valve (not shown), so that the inlet flow rate is independent of the pressure in the tank. There is no reaction occurring in this vessel. The pressure is low, so that the gas behaves as an ideal gas. Is the position of the roof (L) self-regulatory or non-self-regulatory for changes in the inlet flow rate? Explain your answer clearly based on modelling and/or physical reasoning.
Cross sectional area A

a.

b. c. 3.

m L Fin
Figure 2. Process system for Question 3.

The control valve is partially opened and fixed in this position.

Fout

3. We recognize the importance of determining whether a process system is self-regulatory

(which tends to reach a steady-state after a disturbance) or non-self-regulatory (which does not achieve a steady-state after a step input). The non-self-regulatory process variable requires control by a computer or close supervision by a person. The question addresses a floating roof gas holder. This question is from the end-of-chapter questions in Chapter 5 (Q5.14c) of the textbook. It builds on the learning from the liquid level problems throughout the course, the definition of self-regulatory in Chapter 5, and the constantvolume gas holder in question 5.14d that was covered in a tutorial. We note the following from the physical system. 1. 2. 3. 4. The volume in the holder changes The pressure of the gas in the holder is constant . This conclusion follows from (a) the roof mass being constant and (b) the cross sectional area being constant. From the ideal gas law, the volume of gas in the vessel is proportional to the moles of gas at any time. The flow out does not depend on the amount of gas in the holder. This is because the pressure in the tank is constant.
Fout = K v ( v ) Ptan k P 2

= constant for this problem statement

with

Ptank = constant P2 = exhaust pressure after valve v = valve % open (constant) Kv = constant depending on valve manufacture = density (constant because pressures are constant) The flow out depends on the tank pressure and the % valve opening, both of which are constant. Therefore, the flow out of the tank is constant in this scenario in which the valve position is not changed.

5.

We proceed to formulate a model of the process. Variable: System: Balance: Volume of gas in the vessel. Since the area is constant, the volume will give the level of the roof. The volume in the vessel below the roof. In this case, the system dimensions change with time. To determine the total mass (or moles for this non-reacting system), we develop a total mass balance. (accumulation) = (in) (out)

with m= mass and , we can formulate the following total mass balance
{( m )t +t ( m )t } = {( t )Fin ( t )Fout }

We can divide by delta time and take the limit as delta time approaches 0 to give

dm = Fin Fout dt

Applying the ideal gas law and the assumption that the temperature is constant,
dm P( MW ) dV P ( MW ) dL = = = Fin Fout A dt RT dt RT dt

We have a model for the behaviour of the roof level, L. This model for the level of the roof demonstrates that the derivative of the level is independent of the level, i.e., the level does not influence the right-hand side of the equation. For a non-self-regulatory variable, the variables derivative is independent of the variable itself.

The flow in is independent of the level and pressure in the vessel, by the problem statement. The flow out depends on the pressure in the vessel and the % valve opening. Neither of these depends on the level. Also, the density out depends on the vessel pressure, which does not depend on the level. Thus, we conclude that the roof level is non-self-regulatory. It is unstable and requires automatic control using a computer or close supervision by a person.