using Simulink
Cheng-Liang Chen
PSE
LABORATORY
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Process Simulation
Simulation of A Gas Process
Consider the gas tank shown below. A fan blows air into a tank, and from the
tank the air flows out through a valve. Suppose the air flow delivered by the fan is
given by
fi(t) = 0.16mi(t)
where fi(t) is gas flow in scf/min, (scf is cubic feet at standard conditions of 60oF
and 1 atm); mi(t) is signal to fan, %. The flow through the valve is expressed by
p
fo(t) = 0.00506mo(t) p(t)[p(t) p1(t)]
where fo(t) is gas flow, scf/min; mo(t) is signal to valve, %; p(t) is pressure in
tank, psia; p1(t) is downstream pressure from valve, psia.
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The volume of the tank is 20 ft3, and it can be assumed that the process occurs
isothermally at 60oF. The initial steady-state conditions are
fi = fo = 8 scfm; p = 40 psia; p1 = 14.7 psia; m
i = m
o = 50 %
An unsteady-state mole balance around the control volume, defined as the fan,
tank, and outlet valve, is
V dp(t)
dn(t)
=
= fi(t) fo(t)
dt
RT dt
= 0.00263 lbmoles/scf is molar density of gas at standard conditions; R = 10.73
psia-ft3/lbmoles-oR is ideal gas law constant; T = 520oR is gas temperature.
Please construct a Simulink model to simulate this process, and shows the
response of the pressure to a step change of 5% in the signal to the inlet fan
(starts from time =5 min.)
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Process Simulation
Simulation of A Gas Process
V dp(t)
= fi(t) fo(t)
RT dt
fi(t) = 0.16mi(t)
(
= 0.00263 lbmole/scf, V = 20 ft3)
p
fo(t) = 0.00506mo(t) p(t)[p(t) p1(t)]
mi(0) = m
i = 50%, mo(0) = m
o = 50%, p1(0) = p1 = 14.7psia
fo(0) = fi(0) = 0.16mi(0) = (0.16)(50) = 8.0 scf/min
p
fo(0) = 0.00506mo(0) p(0)[p(0) p1(0)]
p(0) = 39.8 psia
dp(t)
RT
=
[fi(t) fo(t)]
dt
V
(0.00263)(10.73)(520)
=
[fi(t) fo(t)]
20
= 0.734[fi(t) fo(t)] (now: mi = 55% at t = 5)
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dp(t)
= 0.734[fi(t) fo(t)]
pdt
fo(t) = 0.00506mo(t) p(t)[p(t) p1(t)] fo(0) = 39.8 mi : 50 55%
fi(t) = 0.16mi(t),
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subplot(2,1,1)
plot(dt,p,m,linewidth,2)
ylabel(\bf p(t),Fontsize,14);
title(\bf Gas pressure response to step fan change,Fontsize,14)
subplot(2,1,2)
plot(dt,mi,b,linewidth,2)
ylabel(\bf m_i(t),Fontsize,14);
xlabel(\bf t (min),Fontsize,14);
set(gca,linewidth,3);
% set(gca,Fontsize,14);
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Process Simulation
Simulation of A Stirred Tank Heater
The stirred tank is used to heat a process stream so that its premixed components
achieve a uniform composition. Temperature control is important in this process
because a high temperature tends to decompose the product while a low
temperature results in incomplete mixing. The tank is heated by steam condensing
inside a coil. A proportional-integral-derivative (PID) controller is used to control
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dT (t)
= f (t)cpTi(t) + U A[Ts(t) T (t)] f (t)cpT (t)
dt
An energy balance on the coil, assuming that the coil metal is at the same
temperature as the condensing steam, results in (CM : heat capacitance of coil
metal, Btu/oF; w(t): steam rate, lb/min)
CM
dTs(t)
= w(t) U A[Ts(t) T (t)]
dt
The initial steady-state conditions are T (0) = 150oF and Ts(0) = 230oF. Also the
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initial design conditions are f (0) = 15 ft3/min, Ti(0) = 100oF, and w(0) = 42.2
lb/min.
Construct a Simulink diagram for the simulation of the heater. shows the
responses of the temperatures to a step changes in process flow.
Chen CL
Process Simulation
Simulation of A Stirred Tank Heater
dT (t)
dt
dTs (t)
dt
=
=
UA
1
f
(t)[T
(t)
T
(t)]
+
i
V
V cv [Ts (t)
1
CM {w(t) U A[Ts (t) T (t)]}
o
3
T (t)],
T (0) = 150oF
Ts(0) = 230oF
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10
Process Simulation
Simulation of A Stirred Tank Heater
Response of heater outlet temperature and steam chest temperature
to a step change in process flow
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Process Simulation
Simulation of A Stirred Tank Heater
Subsystem Block for The Stirred Tank Heater
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Process Simulation
Simulation of A Batch Bioreactor
Many important specialty chemical products are produced in bioreactors by
processes such as fermentation. Most of these processes are carried out in batch
mode by filling a tank with a substrate solution and inoculating it with a small
amount of biomass. The biomass, feeding on the substrate, reproduces to produce
the desired product, until the substrate is consumed. This example is presented
here to show some of the special characteristics of biochemical processes.
A dynamic model of the growth of the biomass concentration x(t) and of the
consumption of the substrate concentration, s(t), is given on a per unit volume
bsis as follows:
dx(t)
= (t)x(t)
dt
ds(t)
1
=
dt
y(t) (t)x(t)
where y is the yield in biomass per unit mass of substrate and (t) is the biomass
growth rate function (h1). This growth rate function is analogous to the kinetic
models used to model chemical reactors. It is designed to match experimental
data. Here we will use the Monod model with adaptability wich has the following
form:
d(t)
s(t)
= m
(t)
dt
k + s(t)
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where is the adaptability parameter, and k and m are the parameters of the
model. Please use Simulink to simulate the model with the following data:
= 15h1, k = 0.5g/liter, s(0) = 2.5g/liter, (0) = m = 1.2h1, and
x(0) = 0.001g/liter.
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Process Simulation
Simulation of A Batch Bioreactor
dx(t)
dt
d(t)
dt
ds(t)
1
= (t)x(t)
=
dt
y (t)x(t)
h
i
s(t)
= m k+s(t)
(t)
= 15 h1, (0) = m = 1.2
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Process Simulation
Simulation of A Pressure Tank
A stray bullet fired by a careless robber punctures the compressed air tank at a gas
station. The mass balance of air in the tank is
p
d(t)
V
= wi(t) Ao 2(t)[p(t) po]
dt
where
M
p(t)
RT
wi(t) kg/s, is the inlet flow from the air compressor, V = 1.5 m3, is the volume of
(t) =
the tank, Ao = 0.785 cm2, is the area of the bullet hole, M = 29 kg/kmole, is the
molecular weight of air, R = 8.314 kPa-m3/kmole-K, is the ideal gas law
constant, and temperature T is assumed constant at 70oC, po = 500 kPa gauge.
Use Simulink to simulate the process and plot the response of the pressure in the
tank.
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Process Simulation
Simulation of A Pressure Tank
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Process Simulation
Simulation of A Mixing Tank
Computer-room Exercise
Consider the mixing process shown below. Assume
that the density of the input and output streams
are very similar and that the flow rates f1 and
f2 are constant.
It is desired to understand
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Process Simulation
Simulation of A Nonisothermal Chemical Reaction
Computer-room Exercise
Consider a stirred-tank reactor with reaction A B
as shown below. To remove the heat of reaction the
reactor is surrounded by a jacket through which a
cooling liquid flows.
lbmoles of A reacted
ft3-min
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where the frequency factor ko and energy of activation E are constants. The
following Table gives the steady-state values of the variables and other process
specifications. It is desired to find out how the outlet concentrations of A and B,
and the outlet temperature respond to changes in the inlet concentration of A,
cAi(t); the inlet temperature of the reactant Ti(t); the inlet temperature of
cooling liquid Tci(t); and the flows f (t) and fc(t).
Process information
V =
E=
=
Hr =
A=
Vc =
13.26 ft3
27, 820 Btu/lbmole
55 lbm/ft3
12, 000 Btu/lbmole
36 ft2
1.56 ft3
ko =
R=
Cp =
U=
Cpc =
Steady-state values
CAi(t) =
Tc =
cA(t) =
Tci(t) =
0.5975 lbmole/ft3
602.7oR
0.2068 lbmole/ft3
540oR
Ti(t) =
f=
T (t) =
fc(t) =
635oR
1.3364 ft3/min
678.9oR
0.8771 ft3/min
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Assume the reactor is initially at the design conditions. Use Simulink to simulate
the process and plot the response of the reactor temperature to a step change of
0.25 ft3/min in process flow, and of 0.1 ft3/min in coolant flow.
f (t)cAi(t) f (t)cA(t) V rA(t) =
rA(t) =
f (t)CpTi(t) U A[T (t) Tc(t)] f (t)CpT (t) V rA(Hr ) =
fc(t)cCpcTci(t) + U A[T (t) Tc(t)] fc(t)cCpcTc(t) =
dcA(t)
V
dt
koeE/RT (t)c2A(t)
dT (t)
V Cv
dt
dTc(t)
VccCvc
dt