Fall 2010 Prof.

Kwang Soon Lee

Process Control
Design Project
November 18

Tune the PI-D and the I-PD controllers for one of the following processes following the procedure below.
If you want, you can modify the process to make it more real or can make a new model. Your entire
MATLAB Program needs to be submitted together with your report.

1. Caculate the steady state for the given steady state input.
2. Find the first order plus dead time model around the steady state through experiment by simulation.
3. Tune the PI and the PID controllers using two different methods of your choice. simulate the
closed lopp system for some reference input change and disturbances, and discuss the control system
performance and characteristics.

Process I: CFSTR with 2nd order exthothermic reaction (2A → B).

• Assumptions:
– The volume inside the reactor is constant.
– No temperature distribution inside the jacket

Set point
w, CAF, TF
TC wcsp
Tm 1

Tc

CA, T V
FC
2

Tw
wc

• Controlled variable : temperature inside the reactor (TC)

• disturbance: flow rate of reactant, maximum ±10% deviation from the steady value
• Balance equation:

– Component balance for A

dCA 2
Vρ = w(CAF − CA ) − V ρk0 e−E/T CA (1)
dt

1
 – Energy balance inside the reactor
dT 2
V ρcp = wcp (TF − T ) − U A(T − Tc ) + (−∆H)V k0 e−E/T CA (2)
dt
– Energy balance in the jacket
dTc
Mc cpc = U A(T − Tc ) + wc cpc (Tw − Tc ) (3)
dt
– Dynamics of temperature sensor
dTm
τm + Tm = T (4)
dt
– Dynamics of flow rate actuator
dwc
τc + wc = wcsp (5)
dt
• Parameter values
Constant in Arrhenius expression for reaction rate constant: E = 1422 (K)
Specific heat of reacting mixture: cp = 3.8 (kJ/kg K)
Specific heat of water: cpc = 4.2 (kJ/kg K)
Heat of reaction: −∆H = 2017 (kJ/kg of A)
Constant in Arrhenius expression: ko = 0.09 (m3 /kg min)
Mass of the jacket water: Mc = 1000 (kg)
Heat transfer coefficient: U = 200 (kJ/min m2 K)
Reactor volume: V = 7 (m3 )
Density of reacting mixture: rho = 1281 (kg/m3 )
Time constant of temperature transmitter: τm = 1(min)
Time constant of flow control loop: τc = 3(min)
Effective jacket heat transfer area: A = 12(m2 )

• Steady state input

wc = 476 (kg/min) w = 454 (kg/min)

TF = 339 (K) Tw = 308 (K)
CAF = 144 (kg/m3 )

2
Process II: Flash distillation to separate propane and butane mixture
• Assumptions:
– Liquid level is constant
– Ignore flow rate actuator dynamics except the for steam flow rate

FC

Vapor
V, yp, yb

PC
PT
Fssp

FC
LC
M, cp, T

Fs Feed
Q F, TF, xFp, xFb

FC

Liquid raffinate
L, xp, xb

• Controlled variable: pressure (PC)

• Disturbance: composition of raw mixture, maximum ±20% change from steady value
• Balance equation:

– Component balance for propane

dxp
M = F xF p − Lxp − V yp (6)
dt
– Energy balance
dT
M cp = F cp (TF − T ) − V λp yp − V λb yb + Q (7)
dt
– Staem heat transfer
dQ
τc + Q = λs Fs (8)
dt
– Dynamics of steam flow rate actuator
dFs
τs + Fs = Fssp (9)
dt

3
 – Other required equations

Material balance F =L+V

Vapor pressure of propane Ppvap (mmHg) = exp(6.8040 − 803.81/(T (K) − 26.11))
Vapor pressure of butane Pbvap (mmHg) = exp(6.8090 − 935.86/(T (K) − 34.37))
Mole fractions of vapor and liquid yb + yp = xb + xp = 1
Pressure relationships Pp = Ppvap xp , Pb = Pbvap xb , PT = Pp + Pb
PT yp = Pp , PT yb = Pb

• Parameter values
Average molar heat capacity: cp = 1077 (kJ/kg K)
Moles of liquid in vessel: M = 100 (kmol)
Latent heat of vaporization of propane: λp = 11031 (kJ/kmol)
Latent heat of vaporization of butane: λb = 18324 (kJ/kmol)
Latent heat of vaporization of steam: λs = 2214 (kJ/kg)
Time constant of steam control loop: τs = 3(min)
Time constant of steam chest: τc = 2(min)

• Steady state conditions

F = 20 (kmol/min) Fs = 38 (kg/min) L = 6 (kmol/min)

TF = 320 (K) xF p = 0.7

Project schedule and project team

• Team : 3 students per each team
• Presentation schedule:
• Hand in the report including MATLAB program when you take final exam.