{ PDC 1 Control Project }

Production
Of Soap
By
Mohammed Saleh
Mohsen Ghazi
Harith Karim

Supervisor
Thaer Adnan

Dec / 20 /
2023
INTRODUCTION
Soap, a ubiquitous and indispensable product in our daily
lives, has been manufactured for centuries, evolving from
traditional methods to modern industrial production. This project
delves into the intricacies of soap production, focusing on the
Continuous Stirred Tank Reactor (CSTTR) as the chosen process
control unit. Soap production involves a fascinating chemical
transformation, where fats and oils are saponified to create a
variety of cleansing and skincare products. The CSTTR plays a
central role in this process, facilitating precise control of reaction
conditions, ensuring product quality, and maximizing efficiency.

The CSTTR, selected as the core process control unit, is pivotal

in maintaining the optimal environment for the saponification
reaction. Within this reactor, fats or oils are combined with an
alkali solution to form soap through a process known as
saponification. The reactor's design, including its geometry,
mixing mechanism, and temperature control, profoundly
influences the reaction kinetics and the quality of the soap
produced. Efficient mixing and temperature regulation are
essential to ensure uniform product composition and prevent
undesired side reactions.

1
A primary objective of this project is to develop a comprehensive
control system tailored to the CSTTR's operation. This control
system will incorporate advanced algorithms for temperature and
pressure control, as well as precise dosing of reactants. By
maintaining tight control over these parameters, the system
ensures consistent soap production with the desired
characteristics. Additionally, safety features, including monitoring
for deviations and emergency shutdown protocols, will be
integrated to mitigate potential risks.

Furthermore, this project will involve the creation of transfer

functions and Ordinary Differential Equation (ODE) models that
capture the dynamic behavior of the CSTTR during soap
production. These models will enable simulations and
optimization of the control system's performance, allowing for
fine-tuning and adaptation to varying process conditions. The
overarching goal is to develop a robust and adaptive control
system that can efficiently produce soap of the highest quality
while ensuring safety and economic viability.

Mohammed Saleh

2
SCHEMATIC DIAGRAM ( CSTR 1-101)

Feedback Control System :

TC : Temperature Control

LC : Liquid Control

FC : Flow Control

I/P : Error Signal

3
Mohsen Ghazi

SCHEMATIC DIAGRAM ( CSTR 1-101)

FeedFoward-Feedbackward Control System :

LT : Liquid Transmitter

LC : Liquid Control

FC : Flow Transmitter

FT : Flow Control

TC : Temperature Control

TT : Temperature Transmitter

I/P : Error Signal

4
Harith Karim

SCHEMATIC DIAGRAM ( CSTR 1-101)

Feedforward Control System :

TC : Temperature Control

TT : Temperature Transmitter

I/P : Error Signal

5
Mohammed Saleh

BLOCK DIAGRAM ( CSTR 1-101)

Feedback Control System :

Controlled Variables (CV) : T as Temperature C°

Manipulated Variables (MV) : A as Water Flow m3/min

Disturbance Variables (DV) : D as Steam flow KJ/min

Mohsen Ghazi

6
BLOCK DIAGRAM ( CSTR 1-101)

FeedFoward-Feedbackward Control System :

Controlled Variables (CV) (GM) : T as Temperature C°

Manipulated Variables (MV) (GV) : A as Water Flow m3/min

Disturbance Variables (DV) (GD) : D as Steam flow KJ/min

Harith Karim

7
BLOCK DIAGRAM ( CSTR 1-101)

Feedforward Control System :

Controlled Variables (CV) (GM) : T as Temperature C°

Manipulated Variables (MV) (GV) : A as Water Flow m3/min

Disturbance Variables (DV) (GD) : D as Steam flow KJ/min

8
ODES DYNAMIC MODEL FOR SOAP PRODUCTION

To derive the ordinary differential equations (ODEs) for the

dynamic behavior of the Soap production system with a focus on
the reactor (CSTR) unit, we can start by considering the key
processes involved. Let's denote the relevant variables:
C reactant =Concentration of reactant

K=rate constant

Assumptions :

1) Steady-State Conditions: The model assumes steady-state

operating conditions for soap production, neglecting transient

effects during start-up.

2) Homogeneous Reaction: The saponification reaction is

considered homogeneous, assuming uniform reactant

concentrations throughout the reactor.

3) Constant Properties: The model assumes constant properties

of reactants and products, such as density and heat capacity,

over the specified operating range.

4) Ideal CSTTR: The Continuous Stirred Tank Reactor (CSTTR)

is assumed to operate ideally, without considering non-

9
 idealities such as mixing deviations or residence time

distribution.

5) Single Reaction: The model represents soap production as a

single, simplified saponification reaction without considering

complex reaction kinetics or side reactions.

6) No Phase Changes: The model does not account for phase

changes (e.g., vaporization or condensation) during soap

production.

7) Negligible Heat Loss: Heat losses to the surroundings are

neglected, assuming that the CSTTR is well-insulated.

8) Constant Flow Rates: The flow rates of reactants into the

CSTTR are assumed to be constant during the production

process.

Degree of freedom (DOF)

DOF → Number of Variables – Number of Equations

DOF → 2 – 2 = 0

10
Material Balance :

d C reactant Fin
= .¿
dt V

Energy Balance :

dT
ρ . Cp . V . =U . A ( Tin−T )+ Q rxn (1.2)
dt

ρ=isthe density of the system

C p=is the heat capacity of the system

V =is the volume of the reactor

dT
=is the rate of change of temp
dt

A=isthe heat transfer area

Qrxn=the heat generated ∨absorbed by the saponificationreaction

TRANSFER FUNCTION ( CSTR 1-101 )

Mass Flow in – Mass Flow out = Rate of Accumulation of
Mass
dVp
q p−q o p= ( V = Ah )
dt

11
q−q o= A
dp
( h
q = (1.1)
dt o R )
(q = Rh )=A dhdt ( 1.2)
o

At steady state

(q = Rh )=A dhdt ( 1.3)

o

Subtracting Eq (3) from Eq (2)

( q−q s ) − R
h−h s
( qo =A
d ( h−h s )
dt )
→ let Q=( q−q s ) , H=(h−hs )

dH H aH
A + =Q → AR + H =RQ
dt R aT

Taken LaPlace for both side :

(Ʈ ¿¿ s +1) H (s)=R Q(s) ¿

Where Ʈ = A R
H(s ) R R
= → H(s )= Q
Q(s ) Ʈ s +1 Ʈ s+1 (s )

Mohammed Saleh

CHECKING RESPONSE MODEL

Step Input Response : (u ( t )=U 0 )

 System gain : K = 7

 Time constant : Ƭ =4 secounds

 Step magnitude : A = 1

12
 K
 Transfer Function : H (s)=
Ƭ s +1

1
 Input constant : U =
(s)
s+1

The output in LaPlace domain is :

7
∗1
4 s+1
Y (s)=
s

Inverse LaPlace transform gives :

−t
γ ( t ) =7(1−e 4 )

Mohsen Ghazi

CHECKING RESPONSE MODEL

Ramp Input Response : (u ( t )=K .t )

 System gain : K = 7

 Time constant : Ƭ =4 secounds

 Ramp slope : A = 1

13
 2
 Transfer Function : H (s)=
4 s +1

1
 Input constant : U =
(s)
s
3

The output in LaPlace domain is :

7
∗1
4 s+1
Y (s)= 3
s

Inverse LaPlace transform gives :

t
e−
4
γ ( t ) =7(t−4+ 4 )

Harith Karim

CHECKING RESPONSE MODEL

Sin Input Response : (u ( t )= A sin ( wt ))

 System gain : K = 7

 Time constant : Ƭ =4 secounds

 Sin amplitude : A = 1

14
 Frequency : w=1 rad /sec
2
 Transfer Function : H (s)=
4 s +1

1
 Input constant : U =
(s)
s
3

The output in LaPlace domain is :

7
∗1
4 s+1
Y (s)= 2
s +1

Inverse LaPlace transform gives :

4
γ ( t ) =7 sin ⁡(t +∅ )
√ 1+16

15