UNIVERSIDAD NACIONAL DE COLOMBIA

Facultad de ingeniería. Departamento de ingeniería Química y Ambiental

Bogotá, Colombia
2019-2

Pre-Report: Temperature control

Universidad Nacional de Colombia
Facultad de Ingeniería
Departamento de ingeniería química y ambiental
Laboratorio de Operaciones de Separación, Reacción y Control
GROUP B
Teacher: Hugo Ricardo Zea Ramírez
Catalina Juliana Anibal González1; Javier Andrés Aponte Zea2; Johana Angélica Guerrero
Amaya3; Julián Camilo Herrera Rodríguez4; Johan Sebastián Quintero Rueda5; Lina María
Torres Betancourt6
1: cjanibalg@unal.edu.co 2: jaapontez@unal.edu.co; 3: joaguerreroam@unal.edu.co;
4: julcherrerarod@unal.edu.co; 5: josquinteroru@unal.edu.co; 6: limtorresb@unal.edu.co.

I. INTRODUCTION

Drying is a widely used technique in the food industry to increase its shelf life and enhance its
organoleptic properties; characteristics that will improve the value of the final product. There are
different techniques in order to complete a drying process and they would be selected based on the
material we are drying and of it is going to be either direct or indirect drying. In this report we are
studying the possibility of implementing the drying process to dry peas.

Fluidized bed dryers represent an interesting alternative for the food industry since this process could:
increase the mass transfer and increase the heat exchange. However, is important to control this
system since it depends on a lot of factors like: the gas inlet temperature and the temperature of the
sample of peas. Consider that the temperature for the peas should never go above 50C so we don’t
impact negatively the organoleptic properties.

II. OBJECTIVES

General objective:

Set a control system for a fluidized bed dryer with a sample of peas (Pisum Sativum)

Specific objectives:

Study the variation of relative humidity of the air at the output in function of a change of temperature
on the inlet gas.

Evaluate the temperature control on the upper zone of the fluidized bed changing the temperature
from the gas inlet.

Study the perturbations, generated on the controlled variable when you alter the set point.

III. THEORETICAL FRAMEWORK

Controllers:

A controller is an electronic device that determines the action that must be undertaken to satisfy the
requirements of a process. For this reason, the right functioning of a process depends on the success
 UNIVERSIDAD NACIONAL DE COLOMBIA
Facultad de ingeniería. Departamento de ingeniería Química y Ambiental
Bogotá, Colombia
2019-2

of the control. This leads us to see the importance of the type of controller chosen because of it
depends the corrective actions. The controllers may be divided into the following categories according
to Smith (1997)

o Feedback controller:

The way this controller takes a decision to keep a control point is through the calculation based on the
difference between the controlled variable and the control point. According to the generation fo the
action of the controller, it may be divided into:

o Two position control (ON/OFF):

This controller has only two positions, completely open and completely closed. In case the process
variable is greater than the Set Point (SP), the controller does not emit a signal and in case of being
lower than the SP, the signal of the controller is 100%. This type of controller has disadvantages due
to mechanical wear and that it works in a certain range, so there will be always oscillations in the
process variables which is not ideal.

o Proportional controller (P):

The proportional controller is one of the simplest controllers, because the outlet is
proportional to the magnitude of the error. Even though this system has a quick response to
some disturbance, this value will always be far from the real value. The reason for this, is that
a difference in the established outlet value (offset) is needed so the system can work. The
equation that describes the behavior is:

𝑚(𝑡) = 𝑚
̅ + 𝐾𝑐 (𝑟(𝑡) − 𝑐(𝑡))

𝑚(𝑡) = 𝑚
̅ + 𝐾𝑐 𝑒(𝑡)
Where,

m(t): Outlet of the controller psig or mA

r(t): Control Point, psig or mA

c(t): Variable that is being controlled, psig or mA; this is the signal that arrives to the
transmitter.

e(t): Error signal, psi or mA; this is the difference between de control point and the variable
that is being controlled.

Kc: Controller Gain, psi/psi or mA/mA

𝑚
̅: Base value, psig or mA.The meaning of this value is the outlet of the controller when the
error is zero; generally fixed during the calibration of the controller in the middle of the scale,
9 psig or 12 mA.

o Proportional Integral Controller (PI):

 UNIVERSIDAD NACIONAL DE COLOMBIA
Facultad de ingeniería. Departamento de ingeniería Química y Ambiental
Bogotá, Colombia
2019-2

Most of the controllers cannot be controlled with a deviation, which means that they must be
controlled in the control point and on these cases some “intelligence” must be added to the
proportional controller to eliminate the deviation. This is the integral action or readjustment
and in consequence is called proportional integral controller (PI). It is described as follows:
𝐾𝑐
𝑚(𝑡) = 𝑚 ̅ + [ 𝑟(𝑡) − 𝑐(𝑡)] + ∫[ 𝑟(𝑡) − 𝑐(𝑡)] 𝑑𝑡
𝜏𝐼

𝐾𝑐
𝑚(𝑡) = 𝑚
̅ + 𝐾𝑐 𝑒(𝑡) + ∫ 𝑒(𝑡) 𝑑𝑡
𝜏𝐼
Where: 𝜏𝐼 = Integration time or readjustment minutes/repetition.

The PI controller has two parameters, Kc y 𝜏𝐼 , that must be adjusted for a satisfactory control.
Due to the integral action, in some occasions it tends to produce oscillatory responses of the
controlled variable and therefore reduces the stability of the feedback control. These
oscillations can be tolerated to some degree, as they are sometimes associated with a faster
response. Despite the aforementioned, instability problems can be solved with proper tuning.

o Proportional Integrative derivative controller (PID):

Sometimes another control mode is added to the PI controller, this new control mode is the
derivative action, which is also known as derivation or pre-acting speed; its purpose is to
anticipate where the process is going, by observing the speed to change the error, its
derivative.

The descriptive equation is as follows:

𝐾𝑐 𝑑𝑒(𝑡)
𝑚(𝑡) = 𝑚
̅ + 𝐾𝑐 𝑒(𝑡) + ∫ 𝑒(𝑡) 𝑑𝑡 + 𝐾𝑐 𝜏𝐷
𝜏𝐼 𝑑𝑡

Where: 𝜏𝐷 = Derivation speed in minutes

Therefore, the PID controller has three parameters, Kc, PB, 𝜏𝐼 , 𝜏𝐼 𝑅 and 𝜏𝐷 , which must be
adjusted to obtain satisfactory control. Note that there is only one parameter for shunt
adjustment, rD, which has the same units, minutes, for all manufacturers.

Control Systems:

According to (Quintero, s.f.), there are two main types:

o Open Loop

The signal at the outlet has no influence over the inlet signal. This implies that the programming of
the controller must be of high precision so there are no significant alterations. Nonetheless, in many
cases this is not possible and in presence of disturbances this controller does not work properly.

o Closed loop:
 UNIVERSIDAD NACIONAL DE COLOMBIA
Facultad de ingeniería. Departamento de ingeniería Química y Ambiental
Bogotá, Colombia
2019-2

Closed loops systems used the value of the outlet of the loop and compare it with a set point, obtaining
this way the respective error to make the needed correction. A scheme of a closed loop is shown:

Figure 1. 1A. Open Loops System 1B. Closed Loop system (Pesquality, s.f.)

Controller Tuning:

Controller adjustment methods are classified into two large groups: closed loop methods, and open
loop methods. The first ones are applied with the controller in automatic; the seconds with the
controller in manual. The parameters obtained by these methods are initial parameters, to obtain the
appropriate parameters the integration error criteria can be used.

Next, some of these methods are defined according to Smith (1997):

Ziegler-Nichols method for open loop:

First, a unit step is made in the reference or in the control signal:

Figure 2. Basic scheme of tuning by the Ziegler-Nichols method for open loop
 UNIVERSIDAD NACIONAL DE COLOMBIA
Facultad de ingeniería. Departamento de ingeniería Química y Ambiental
Bogotá, Colombia
2019-2

The open loop response curve must be adjusted to a first-order model with dead time:

𝐾 𝑒 −𝜃𝑠
𝜏𝑠 + 1

To determine the values of K, τ and θ a step must be made in the controller output from a C1 value to
a C2 value and record the values of the controlled variable Y1 and Y2, before and after the step
respectively. The gain K is then:

𝛥𝑌
𝐾=
𝛥𝐶

In order to find the parameter τ it is necessary to know the value of the controlled variable Y that
represents 62.3% of the total step:

𝑌62,3 = 𝑌1 + 0,623 𝛥𝑌

Then the time must be read in which Y=62.3 was obtained and subtract the time in which the variable
recorded the first change:

𝜏 = 𝑡62,3 − 𝑡𝑖𝑛𝑖𝑡𝑖𝑎𝑙

Now the dead time θ is calculated. This is subtracted from the time in which the change was made in
the controller's output to the time in which the controlled variable recorded the first change:

𝜃 = 𝑡𝑖𝑛𝑖𝑡𝑖𝑎𝑙 − 𝑡𝑠𝑡𝑒𝑝

Finally, tuning parameters are calculated Kc, 𝜏𝐼 y 𝜏𝐷 Depending on whether the type of control is P
(proportional), PI (proportional integral) or PID (proportional integral derivative):

Table 1. Tuning for open loop according to the Ziegler-Nichols method

It should be taken into account that the integral time 𝜏𝐼 and the derivative time 𝜏𝐷 must have the same
units as the dead time θ (or d on the table). For digital regulators it is advisable to increase θ in the
middle sampling period.
 UNIVERSIDAD NACIONAL DE COLOMBIA
Facultad de ingeniería. Departamento de ingeniería Química y Ambiental
Bogotá, Colombia
2019-2

Ziegler-Nichols method for closed loop:

To find the closed loop tuning parameters it is necessary to find the last gain and the last period. The
ultimate gain is found by increasing the gain of a proportional regulator until constant oscillations are
achieved:

Figure 3. Schematization of the last period

After calculating the last gain and the last period, the tuning parameters can be calculated according
to the type of controller:

Table 2. Tuning table for closed loop according to the Ziegler-Nichols method

Where 𝜏𝐼 and 𝜏𝐷 have the same units as the oscillation period Pct: "Last" period obtained from the
oscillations (minutes). Ku = Last gain determined by increasing controller gain until self-sustaining
oscillation is achieved

IV. MATERIALS Y METHODS

Materials:

 1 kg of peas

Equipment:

 Fluidization system, equipped with sensors, control board and software.

 UNIVERSIDAD NACIONAL DE COLOMBIA
Facultad de ingeniería. Departamento de ingeniería Química y Ambiental
Bogotá, Colombia
2019-2

Figure 4. Fludization equipment.

Figure 5. Fluidization Equipment Control Board and “Shimaden Lite” Software Interface

The fluidization equipment consists of a pump that takes atmospheric air, which enters a heating
cylinder that regulates its temperature by means of a resistor. Subsequently, the air enters the
particulate bed, which passes through to leave a cyclone where the solid particles are separated.

The pump and the pressure and temperature transmitters are connected to a control system that
transmits the information of the different variables and process specifications that are carried out.
The controller is handled by software.
 UNIVERSIDAD NACIONAL DE COLOMBIA
Facultad de ingeniería. Departamento de ingeniería Química y Ambiental
Bogotá, Colombia
2019-2

Procedure:

Figure 6. Procedure for commissioning the equipment.

Figure 7. Procedure for a) Selection of the temperature and working pressure. b) Analysis of the
response time of the temperature controller.
To turn off the equipment, you must first stop the flow of air to the pump, then stop the pump
operation and turn it off, turn off the controller and finally close the software and turn off the
equipment.

V. DATA TABLE

Data collection starts from the moment the disturbance is made until the stabilization of the
equipment.
 UNIVERSIDAD NACIONAL DE COLOMBIA
Facultad de ingeniería. Departamento de ingeniería Química y Ambiental
Bogotá, Colombia
2019-2

Table 3. Data table for both disturbances

Disturbance variable: Air inlet Temperature Disturbance variable: Air inlet velocity
Time (min) Air outlet T (°C) % RH Time (min) Air outlet T (°C) % RH

VI. INVENTORY COSTS

Table 4. Cost of the procedure

Temperature control in fluidized bed costs

Equipement Total Cost Cost of use
Fluidized bed equipement loan $1´400.000 COP $350.000 COP/h
Junior Engineer $720.000 COP $30000 COP/h
Lab Assistant $160.000 COP $40.000 COP/h
Total Cost $2´300.000 COP

Table 5. Equipment and personal cost

Capital Cost
Equipment and personal $2´300.000 COP
Total $2´300.000 COP

VII. RISK ANALYSIS

Risk associated with reactants manipulation: There is no usage of dangerous reactants during this
practice, so there is no need to take this aspect into account.

Personal Protection Equipment: It is necessary the usage of lab coat, helmet and safety glasses, no
further equipment is required.
 UNIVERSIDAD NACIONAL DE COLOMBIA
Facultad de ingeniería. Departamento de ingeniería Química y Ambiental
Bogotá, Colombia
2019-2

Emergency Case Protocol: In general, the possibility of an emergency during this practice is low,
anyways, it is necessary to consider the possible increases in pressure of the equipment due to a
failure, if the pressure starts to rise without control, it is necessary to stop the operation and verify
the failure. In this case is also necessary to be careful with the temperature, because it can suddenly
increase.

VIII. BIBLIOGRAPHY

C. Smith y A. Corripio, (1997) Principles and Practice of automatic Process, New York.

O. C. Quintero (s.f.) «Sistemas de control,» Available at:

http://webdelprofesor.ula.ve/ingenieria/ocamacho/sistemas%20de%20control/ .

Pesquality (s.f.) Open Loop and Closed Loosp Systems Available at:
https://www.pesquality.com/blog/open-loop-and-closed-loop-systems