Process Control – EHPBH 3B

Test 2
Date : 14 April 2015 Marks : 80
Time : 2 hours
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There will not be a class today @ 11:00

A (varying concentration)
F2, T2, cA2
Diluted B
F4, T4,
Water C (92% pure vapour)
cB4
F1, T1 F7, T6, cC7 (T6 is
correct)

h Diluted A h2
1 h2 Product h3
F3, T3, a
b F5, T5, cB5, a
cA3 Waste
cC5 h3
Tank 1 F6, T6, cB6,
Dilution Tank h2 b cC6
c
Cooling Water Steam

Tank 2 Tank 3
CSTR Evaporator
A + B → 2C

Assume that the flow rates are volumetric and the compositions are in moles per volume. The effluent
rates are proportional to the liquid static pressure that caused the flow, where relevant. A 1, A2 and A3 are
the cross sectional areas of the three tanks and At1 is the heat transfer area of the cooling coil and At2 of the
heating coil. The reaction in the CSTR is exothermic and have first order kinetics based on component A
as the limiting reagent. The density and heat capacity in the liquid phases may be assumed constant over
the given temperature range.

1. Discuss mathematical modelling by answering the questions below:

Why do we need mathematical modelling to design a process control system?

What are the difficulties typically encountered in developing mathematical models?
In addition to the mass, energy and momentum balances, what other elements are needed to complete the mathematical
models. Explain each one shortly.
(15)

Do NOT spend more than 1 hour on question 2

2. Develop a mathematical model to describe the dilution and CSTR processes above (Do each tank
separately and include the additional elements relevant to this process)
(40)

1
3. The mass, component and energy balances for the evaporator is given as:
dh ( 3 a+3 b ) ρv
A3 =F 5−αh3 b − F
Mass balance: dt ρ 7
dc B 6 F5 dc C7 F5 F
c −c − 6 c −c
V 3 ( B5 B6) V 3 ( C 5 C 7 ) V 3 ( C 6 C 7)
= c −c =
Component balances: dt and dt
dT 6 F 5 λF
= ( T 5 −T 6 ) − 6 .
Energy balance: dt V3 cP
Evaluate the energy balance. Is it correct? Support your answer with the necessary calculations.
(8)

4. Explain the terms state variable and state equation. What are the state variables in Tank 3? Write
down the steady state equations for Tank 3?
(9)

5. What are the fundamental dependant quantities for a typical CSTR?

(4)

6. Do a degrees of freedom analysis (calculate the degrees of freedom) on Tank 1.

(8)

2
 Process Control – EHPBH 3B
MEMO Test 2
Date : 14 April 2015 Marks : 80
Time : 2 hours
------------------------------------------------------------------------------------------------------------------------------------------------------------------------------

A (varying concentration)
F2, T2, cA2
Diluted B
F4, T4,
Water C (92% pure vapour)
cB4
F1, T1 F7, T6, cC7 (T6 is
correct)

h Diluted A h2
1 h2 Product h3
F3, T3, a
b F5, T5, cB5, a
cA3 Waste
cC5 h3
Tank 1 F6, T6, cB6,
Dilution Tank h2 b cC6
c
Cooling Water Steam

Tank 2 Tank 3
CSTR Evaporator
A + B → 2C

Assume that the flow rates are volumetric and the compositions are in moles per volume. The effluent rates are
proportional to the liquid static pressure that caused the flow, where relevant. A1, A2 and A3 are the cross sectional
areas of the three tanks and At1 is the heat transfer area of the cooling coil and At2 of the heating coil. The reaction in
the CSTR is exothermic and have first order kinetics based on component A as the limiting reagent. The density and
heat capacity in the liquid phases may be assumed constant over the given temperature range.

1. Discuss mathematical modelling by answering the questions below:

Why do we need mathematical modelling to design a process control system?

What are the difficulties typically encountered in developing mathematical models?
In addition to the mass, energy and momentum balances, what other elements are needed to complete the mathematical models. Explain
each one shortly.
(15)
It is often the case that we have to design a control system for a chemical process before the
process has been constructed. In such a case we cannot rely on an experimental procedure,
and we need a different representation of the chemical process in order to study its dynamic
behaviour. This representation is usually given in terms of a set of mathematical equations
(differential or algebraic) whose solution yields the dynamic or static behaviour of the chemical
process we examine.
(Often the physical equipment of the chemical process we want to have not been constructed. Consequently we cannot
experiment to determine how the process reacts to various inputs and therefore cannot design the appropriate control
system (Even if the equipment is available the experimentation is very expensive). Therefore we need a simple
description of how the process reacts to various inputs, and this is what the mathematical models can provide to the
control designer.)

Difficulties arising from poorly understood chemical and physical phenomena

Difficulties caused from inaccurate values of various parameters
Difficulties caused from the size and complexity of the resulting model

3
Transport rate equations - describes the rate of mass, energy and momentum transfer between
a system and its surroundings.

Kinetic rate equations - describes the rates of chemical reactions taking place in a system.

Reaction and phase equilibria relationships - describes the equilibrium situations reached during
chemical reaction or by two or more phases.

Equations of state - describes the relationships among the intensive variables describing the
thermodynamic state of a system.

2. Develop a mathematical model to describe the dilution and CSTR processes above (Do each tank separately and
include the additional elements relevant to this process)
(40)

Tank 1 - Dilution Tank

Mass Balance

dρV 1
=ρF 1 +ρF 2−ρF 3
dt

ρ assumed average over the temperature range

dV 1
=F 1 +F 2 −F3
dt

V 1 =A 1 h1
F 3=α ( h 1−h 2a )
dh1
A1 =F1 +F 2 −α ( h1 −h2 a )
dt 

Component Balance

dc A 3 V 1
=0 F 1 +c A 2 F 0 −c A 3 F 3
dt
dV 1 dc A 3
cA3 +V 1 =c A 2 F 2−c A 3 F3
dt dt
dc A 3
c A 3 ( F1 + F2 −F 3 ) +V 1 =c A 2 F2 −c A 3 F 3 ; ( There is no A in F1 )
dt
dc A 3
c A 3 ( F2 −F 3 ) + V 1 =c A 2 F 2−c A 3 F3
dt
dc A 3
V1 =c A 2 F 2 −c A 3 F 3 −c A 3 ( F 2 −F3 )
dt
dc A 3
V1 =c A 2 F 2 −c A 3 F 2
dt
dc A 3 F2
dt
=
V1
( c A 2 −c A 3 )


4
Energy Balance

dρV 1 c P T 3
=ρc P F 1 T 1 +ρc P F 2 T 2 −ρc P F 3 T 3
dt

ρ and c P assumed average over the temperature range

dV 1 T 3
=F 1 T 1 +F2 T 2 −F3 T 3
dt
dV 1 dT 3
T3 +V 1 =F 1 T 1 +F 2 T 2 −F 3 T 3
dt dt
dT 3
T 3 ( F 1 +F 2−F 3 ) +V 1 =F 1 T 1 +F2 T 2 −F3 T 3
dt
dT 3
V1 =F 1 T 1 +F 2 T 2 −F 3 T 3 −T 3 ( F 1 +F 2 −F3 )
dt
dT 3 F 1 F
= ( T 1−T 3 ) + 2 ( T 2 −T 3 )
dt V1 V1 

Tank 2 - CSTR

Mass Balance

dρV 2
=ρF 3 +ρF 4 −ρF 5
dt

ρ assumed average over the temperature range

dV 2
=F 3 +F 4 −F 5
dt

V 2 =A 2 h (2 b+2c )
dh( 2 b+2 c )
A2 =α ( h1−h2a ) +F 4 −F 5
dt 

5
Component Balance

dn A 5 dc A 5 V 2
= =c A 3 F3 +0 F 4 −0 F5 −rV 2
dt dt
dn A 5 dV 2 dc A 5
=c A 5 +V 2 =c A 3 F 3−rV 2
dt dt dt
dc A 5
c A 5 ( F3 +F 4 −F5 ) +V 2 =c A 3 F 3 −rV 2 ; ( There is no A in F 4 and F5 AND c A5=0 )
dt
dc A 5
=0 ; ( c A 3 F 3 =rV 2 )
dt 

dn B 5 dc B 5 V 2
= =0 F 3 +c B 4 F 4 −c B 5 F 5−rV 2
dt dt
dn B 5 dV dc
=c B 5 2 +V 2 B 5 =c B 4 F 4 −c B 5 F 5 −rV 2
dt dt dt
dc
c B5 ( F3 +F 4 −F5 ) +V 2 B 5 =c B 4 F 4 −c B 5 F5 −rV 2 ; ( There is no B in F 3 )
dt
dc B 5
V2 =c B 4 F 4 −c B 5 F 5 −rV 2 −c B5 ( F 4 −F 5 )
dt
dc B 5 F 4
= ( c B 4 −c B 5 ) −r
dt V2 

dnC 5 dc C 5 V 2
= =0 F 3 +0 F 4 −cC 5 F 5 +rV 2
dt dt
dnC 5 dV dc
=c C 5 2 +V 2 C 5 =−c B 5 F5 +rV 2
dt dt dt
dc
c C 5 ( F 3 +F 4 −F 5 ) +V 2 C 5 =−c B 5 F5 +rV 2 ; ( There is no C in F3 and F 4 )
dt
dc C 5
V2 =−c B 5 F 5 +rV 2 +c B 5 F 5
dt
dc C 5
=r
dt

r =k 0 e−E /RT c A 3  

6
Energy Balance

dt
= ×
∂T dt( × )(
dH ∂ H dT ∂ H dn A ∂ H dnB ∂ H dnC
+
∂ n A dt
+ ×
∂n B dt
+ ×
)(
∂nC dt )( )
dH
=ρc P F 3 T 3 + ρc P F 4 T 4 − ρc P F 5 T 5 −Q
dt

∂H ∂H ~ ∂H ~ ∂H ~
=ρ Vc P ; =H A ; =H B ; =H C
∂T ∂n A ∂n B ∂ nC
dn A 5 dnB 5 dnC 5
=c A 3 F3 −rV 2 ; =c B 4 F 4 −c B 5 F 5 −rV 2 ; =−c B 5 F 5 +rV 2
dt dt dt

dT ~
ρ Vc P + H A ( c A 3 F 3 −rV 2 ) + ~
H B ( c B 4 F 4 −c B5 F 5 −rV 2 ) + ~
H C ( −c B 5 F 5 +rV 2 ) =…
dt
…=ρc P F 3 T 3 +ρc P F 4 T 4 −ρc P F5 T 5 −Q

~
dT F 3 T 3 F 4 T 4 F 5 T 3 Q HA
=
dt V 3
+
V3
−
V3
− − ( c F −rV 2 )−…
ρV 3 c P ρV 3 c P A 3 3
~
HB ~
H
…− ( c B 4 F 4 −c B 5 F5 −rV 2 ) − C (−c B 5 F5 +rV 2 )
ρV 3 c P ρV 3 c P

Q=UA t 1 ΔT  

7
3. The mass, component and energy balances for the evaporator is given as:
dh ( 3 a+3 b ) ρv
A3 =F 5−αh3 b − F
Mass balance: dt ρ 7
dc B 6 F5 dc C7 F 5 F
= ( c B 5 −c B 6 ) = ( cC 5 −c C 7 )− 6 ( c C 6 −c C 7 )
Component balances: dt V3 and dt V3 V3
dT 6 F 5 λF
= ( T 5 −T 6 ) − 6 .
Energy balance: dt V3 cP
Evaluate the energy balance. Is it correct? Support your answer with the necessary calculations.
(8)
The energy balance is not correct.

Energy Balance

dρc P V 3 T 6
=ρc P F 5 T 5 −ρc P F 6 T 6 −( ρ v c v F 7 T 6 + ρ v F 7 λ ) +Q
dt
dV 3 T 6
ρc P =ρc P F 5 T 5− ρc P F 6 T 6 −( ρ v c v F7 T 6 + ρv F 7 λ ) +Q
dt

( )
dV 3 T 6 ρ v cv ρv λ Q
=F 5 T 5 −F 6 T 6 − F 7 T 6+ F7 +
dt ρc P ρc P ρc P

( )
dV 3 dT 6 ρv c v ρv λ Q
T6 +V 3 =F 5 T 5−F 6 T 6 − F 7 T 6+ F7 +
dt dt ρc P ρc P ρc P

( ) ( )
ρv dT 6 ρ v cv ρv λ Q
T 6 F 5 −F 6 − F 7 +V 3 =F5 T 5 −F 6 T 6− F 7 T 6+ F +
ρ dt ρc P ρc P 7 ρc P

V3
dT 6
dt
=F5 ( T 5 −T 6 )−
[ ρv c v
ρc P
F 7 T 6+
ρv λ
ρc P
F 7−
ρv
ρ
F7 T 6 +
] Q
ρc P

( )
dT 6 F5 cv λF 7 Q
dt
=
V3 ( T 5 −T 6 ) − cP
−1 F 7 T 6 −
cPV 3
+
ρc P

Tank 3 - Evaporator

Mass Balance

dρV 3
=ρF 5 −ρF 6 −ρ v F7
dt
V 3 = A1 h (3 a+3 b ) and F 6 =αh 3b
dV 3 ρv
=F 5−F 6 − F7
dt ρ

Component Balance
dc B 6 V 3
=c B 5 F 5 −c B 6 F6 −0 F 7
dt
dc B 6 V 3
=c B 5 F 5 −c B 6 F6
dt
dc B 6 V 3 dc B 6 V 3
+ =c B 5 F 5 −c B 6 F 6
dt dt
dc B 6
c B6 ( F 5−F 6 −F 7 ) +V 3 =c B 5 F 5−c B 6 F 6 ; there is no B in F7
dt
dc B 6 F 5
= ( c B 5 −c B 6 )
dt V3

8
 dc C 7 V 3
=c C 5 F 5−cC 6 F 6 −c C 7 F 7
dt
dV dc
c C 7 3 +V 3 C 7 =c C 5 F5 −c C 6 F 6 −c C 7 F 7
dt dt
dc B 6
c C 7 ( F 5 −F6 −F 7 ) +V 3 =c C 5 F 5−cC 6 F 6 −c C 7 F 7
dt
dc C 7 F5 F6
= ( cC 5 −c C 7 )− ( c C 6 −c C 7 )
dt V3 V3

4. Explain the terms state variable and state equation. What are the state variables in Tank 3? Write down the
steady state equations for Tank 3?
(9)
State variables - a set of fundamental dependant quantities whose values describe the natural
state of a given system, such mass, energy and momentum characterised by variables such as
density, concentration, temperature, pressure and flow rate.

State equations - a set of equations in the variables given above that will describe how the natural
state of the given system changes with time. These equations are derived from application of
the conservation principle on the fundamental quantities of mass, energy and momentum.

State variables – h3, cB6, cC7 and T6 

Steady-state equations -
F5 αh 3b ρv F 7
0= − −
A3 A3 ρA 3
F
0= 5 ( c B 5 −c B 6 )
V3
F F
0= 5 ( c C5 −c C 7 )− 6 ( c C 6 −c C 7 )
V3 V3 
F5 λF6 Q
0=
V3 ( T 5 −T 6 ) − +
c P V 3 ρc P

5. What are the fundamental dependant quantities for a typical CSTR?

(4)
Total mass of the reacting mixture
Mass of chemical A in the reacting mixture (A because it is the limiting reagent) 
Total energy of the reacting mixture

9
6. Do a degrees of freedom analysis (calculate the degrees of freedom) on Tank 1.
(8)
Variables:
Unknown: *V1, h1, h2(a), F1, F2, *F3, cA2, cA3, T1, T2, T3 = 11*(9)
Constant: , cP, A1, 

¿ V 1 =A 1 h1
¿ F 3=α ( h 1−h 2a )
dh1
A1 =F1 +F 2 −α ( h1 −h2 a )
dt
dc A 3 F 1
= ( c A 1−c A 3 )
dt V1
dT 3 F 1 F2
= ( T 1−T 3 ) + ( T 2 −T 3 )
Equations: dt V1 V1 = 5 *(3) 

Degrees of Freedom = 11 - 5 = 6

10