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Process Dynamics and Control: By: Gemechu Bushu (AAU)

This document discusses mathematical modeling of chemical processes. It explains that mathematical modeling involves developing mathematical representations of real processes based on principles like mass and energy balances. It provides examples of modeling different unit operations like stirred tanks and blending processes. The modeling process involves defining goals, collecting information, formulating equations, determining solutions, analyzing results, and validating models. The examples show developing models to describe dynamics and control of variables like liquid level, temperature, and composition.

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gebreslassie gereziher
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97 views

Process Dynamics and Control: By: Gemechu Bushu (AAU)

This document discusses mathematical modeling of chemical processes. It explains that mathematical modeling involves developing mathematical representations of real processes based on principles like mass and energy balances. It provides examples of modeling different unit operations like stirred tanks and blending processes. The modeling process involves defining goals, collecting information, formulating equations, determining solutions, analyzing results, and validating models. The examples show developing models to describe dynamics and control of variables like liquid level, temperature, and composition.

Uploaded by

gebreslassie gereziher
Copyright
© © All Rights Reserved
Available Formats
Download as PDF, TXT or read online on Scribd
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Process Dynamics and Control

By: Gemechu Bushu (AAU)

January 11, 2019

By: Gemechu Bushu (AAU) Process Dynamics and Control January 11, 2019 1 / 32
Chapter Two
Theoretical Models of Chemical Processes

Mathematical Modeling is a mathematical abstraction of a real


process.

It is at best approximation of real process.

To analyze the behavior of a process, a mathematical representation


of the physical and chemical phenomenon taking place in it..

The activities leading to the construction of the model is called


modeling.

By: Gemechu Bushu (AAU) Process Dynamics and Control January 11, 2019 2 / 32
The main uses of mathematical modeling are:

To improve understanding of the process

To train plant operating personal

To design control strategy for new plant

To select controller settings

To design the controller law

To optimize process operating conditions

By: Gemechu Bushu (AAU) Process Dynamics and Control January 11, 2019 3 / 32
Six-step modeling procedure

Define goals

Prepare information

Formulate the model

Determine the solution

Analyze results

Validate the model

By: Gemechu Bushu (AAU) Process Dynamics and Control January 11, 2019 4 / 32
We apply this procedure

to many physical systems

overall material balance

component material balance

energy balances

Examples of variable selection

liquid level → total mass in liquid

pressure → total moles in vapor

temperature → energy balance

concentration → component mass

By: Gemechu Bushu (AAU) Process Dynamics and Control January 11, 2019 5 / 32
Overall Material Balance:

Accumulation of mass= Mass in - Mass out

Component Material Balance:

Accumulation of component mass= Component mass in - Component


mass out + Generation of component mass

State variables is a set of fundamental quantities whose value


describe the natural state of a given system.

State equations is a set of equations in the variables which describe


how the natural state of the given system change with time.

By: Gemechu Bushu (AAU) Process Dynamics and Control January 11, 2019 6 / 32
Modeling objectives is to describe process dynamics based on the laws
of conservation of mass, energy and momentum.
Mass Balance (Stirred tank)
Energy Balance (Stirred tank heater)
Momentum Balance (Car speed)

Degree of Freedom: Nf = Nv − Ne; where


NV is the total number of process variables, and
NE is the number of independent equations.

By: Gemechu Bushu (AAU) Process Dynamics and Control January 11, 2019 7 / 32
Mathematical Modeling of Common Chemical Processes
General balances taken in mathematical modeling

Total Mass Balance

dm d(ρV ) X X
= = ρ i Fi − ρj Fj
dt dt
i j

Component Balance on A

dnA d(CA V ) X X
= = CAi Fi − CAj Fj ± rA V
dt dt
i j

Total Energy Balance

dE d(U + K + P) X X
= = ρi Fi hi − ρj Fj hj ± Q
dt dt
i j

By: Gemechu Bushu (AAU) Process Dynamics and Control January 11, 2019 8 / 32
1) Mathematical Model: Surge tank (Liquid)

Modeling objective: Control of tank level

Assumptions: Incompressible flow

By: Gemechu Bushu (AAU) Process Dynamics and Control January 11, 2019 9 / 32
By: Gemechu Bushu (AAU) Process Dynamics and Control January 11, 2019 10 / 32
2) Mathematical Model: A Stirred Tank Heater

Modeling objective: Control of tank level and temperature

Assumptions: Incompressible flow, Tref = 0

By: Gemechu Bushu (AAU) Process Dynamics and Control January 11, 2019 11 / 32
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By: Gemechu Bushu (AAU) Process Dynamics and Control January 11, 2019 14 / 32
By: Gemechu Bushu (AAU) Process Dynamics and Control January 11, 2019 15 / 32
3) Mathematical Model: A Stirred Tank Heater

Modeling objective: Control of tank level and temperature


Assumptions: Incompressible flow, Tref = 0
Perfect mixing; thus, the exit temperature T is also the temperature
of the tank contents.
The inlet and outlet flow rates are equal; thus, the liquid holdup V is
constant.
The density p and heat Process
By: Gemechu Bushu (AAU)
capacity C of the liquid are assumed
Dynamics and Control
to be 16 / 32
January 11, 2019
By: Gemechu Bushu (AAU) Process Dynamics and Control January 11, 2019 17 / 32
By: Gemechu Bushu (AAU) Process Dynamics and Control January 11, 2019 18 / 32
By: Gemechu Bushu (AAU) Process Dynamics and Control January 11, 2019 19 / 32
The effluent flow rate F can be considered either as input or output.
If there is a control valve on the effluent stream so that its flow rate
can be manipulated by a controller, the variable
F is an input, since the opening of the valve is adjusted externally,
otherwise F is an output variable.
By: Gemechu Bushu (AAU) Process Dynamics and Control January 11, 2019 20 / 32
4) Mathematical Model: A Stirred Tank Heater in jacketed Consider a
simple liquid phase, non-isothermal, irreversible, exothermic reaction:
A → B where rA = kCAα , 4Hr = −λ kJ/kmol and the state variables are
V , CA , T , T c .

By: Gemechu Bushu (AAU) Process Dynamics and Control January 11, 2019 21 / 32
The balance performed are

Total mass balance

Component balance on A

Energy balance inside the reactor

Energy balance around the reactor

The assumption taken are

First degree

reference temperature is zero

constant density

constant specific heat capacity

exothermic reaction
By: Gemechu Bushu (AAU) Process Dynamics and Control January 11, 2019 22 / 32
By: Gemechu Bushu (AAU) Process Dynamics and Control January 11, 2019 23 / 32
By: Gemechu Bushu (AAU) Process Dynamics and Control January 11, 2019 24 / 32
By: Gemechu Bushu (AAU) Process Dynamics and Control January 11, 2019 25 / 32
By: Gemechu Bushu (AAU) Process Dynamics and Control January 11, 2019 26 / 32
5) Mathematical Model: A Blending Process stirred-tank system

Develop the dynamics behavior of the process

By: Gemechu Bushu (AAU) Process Dynamics and Control January 11, 2019 27 / 32
By: Gemechu Bushu (AAU) Process Dynamics and Control January 11, 2019 28 / 32
Example 1: A stirred-tank blending process shown in figure below with a
constant liquid holdup is used to blend two streams whose densities (which
does not change during mixing) are both approximately 250kg /m3 .
Assume that the process has been operating for a long period of time with
flow rates of ω1 = 300 kg/min and ω2 = 200 kg/min.

a) Develop the model that describes the dynamics behavior of the


process.

b) What is the steady-state value of output flow rate w?

c) If the output flow rate is 400kg/min, then what is the volume of the
tank at a period of 20 min?

d) If feed compositions (mass fractions) are x1 = 0.35 and x2 = 0.55,


then what is the steady-state value of composition, x?
By: Gemechu Bushu (AAU) Process Dynamics and Control January 11, 2019 29 / 32
Example 2: The liquid storage tank shown in figure below has two inlet
streams with mass flow rates ω1 and ω2 and an exit stream with flow rate
w. The cylindrical tank is 6.5m tall and 2m in diameter. The liquid has a
density of 800kg /m3 . Normal operating procedure is to fill the tank until
the liquid level reaches a maximum value of the tank using constant flow
rates: ω1 = 250kg/min, ω2 = 150kg/min and ω = 300kg/min. Particular
day, corrosion of the tank has opened up a hole in the wall at a height of
2m, producing a leak whose volumetric flow rate q(m3 /min) can be
√
approximated by: q = 0.0625 h − 2 where h is height in meters.
a) If the tank was initially empty, then determine the time to reach leak
point.
b) If mass flow rates ω1 , ω2 and w are kept constant indefinitely, then
determine the maximumProcess
By: Gemechu Bushu (AAU)
value of liquid level when no January
Dynamics and Control
overflow occurs.
11, 2019 30 / 32
By: Gemechu Bushu (AAU) Process Dynamics and Control January 11, 2019 31 / 32
Modeling Difficulties:

Poorly understood processes

Imprecisely known parameters

Size and complexity of a model

By: Gemechu Bushu (AAU) Process Dynamics and Control January 11, 2019 32 / 32

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