Course: Process Control and Automation

Sheet No 2

2.1 A perfectly stirred, constant-volume tank has two input streams, both consisting of the same
liquid. The temperature and flow rate of each of the streams can vary with time.
a) Derive a dynamic model that will describe transient operation. Make a degrees of freedom
analysis assuming that both Streams 1 and 2 come from upstream units (i.e., their flow rates and
temperatures are known functions of time).
b) Simplify your model, if possible, to one or more
differential equations by eliminating any algebraic equations.
Also, simplify any derivatives of products of variables
Notes:
wi denotes mass flow rate for stream i.
Liquid properties are constant (not functions of
temperature).

2.2 A completely enclosed stirred-tank heating process is used to heat an incoming stream whose
flow rate varies. The heating rate from this coil and the volume are both constant.
a) Develop a mathematical model (differential and algebraic equations) that describes the exit
temperature if heat losses to the ambient occur and if the ambient temperature (Ta) and the
incoming stream’s temperature (Ti ) both can vary.
b) Discuss qualitatively what you expect to happen as Ti and w increase (or decrease). Justify by
reference to your model.
Notes:
ρ and Cρ are constants.
U, the overall heat transfer coefficient, is constant.
As is the surface area for heat losses to ambient.
Ti > Ta (inlet temperature is higher than ambient
temperature).
 Course: Process Control and Automation
Sheet No 2

2.3 Two tanks are connected together in the following unusual way in Fig. E2.3.
a) Develop a model for this system that can be used to find h1, h2, w2, and w3 as functions
of time for any given variations in inputs.
Perform a degrees of freedom analysis. Identify all input and output variables.
Notes:
The density of the incoming liquid, ρ, is constant. The cross-
sectional areas of the two tanks are A1 and A2. w2 is positive
for flow from Tank 1 to Tank 2. The two valves are linear with
resistances R2 and R3.

2.4 Consider a liquid flow system consisting of a sealed tank with non-condensible gas
above the liquid as shown in Fig. E2.4.Derive an unsteady-state model relating the liquid
level h tothe input flow rate qi. Is operation of this system independent of the ambient
pressure Pa? What about for a system open tothe
atmosphere?
You may make the following assumptions:
(i) The gas obeys the ideal gas law. A constant
amount of
mg/M moles of gas is present in the tank.
(ii) The operation is isothermal.
(iii) A square root relation holds for flow through the
valve.

2.5 Two surge tanks are used to dampen pressure fluctuations caused by erratic
operations of a large air compressor. (See Fig. F2.5.)

If the discharge pressure of the compressor is Pd(t) and theoperating pressure of the furnace is
Pf (constant), develop a dynamic model for the pressures in the two surge tanks as well as for
the air mass flows at points a, b, and c. You may assume that the valve resistances are constant,
that the valve flow characteristics are linear, for example, wb = (P1 − P2)/Rb, that the surge
processes operate isothermally, and that the ideal gas law holds.

2.6 A closed stirred-tank reactor with two compartments is shown in Fig. E2.6. The basic idea is
to feed the reactants continuously into the first compartment, where they will be preheated
by energy liberated in the exothermic reaction, which is anticipated to occur primarily in the
second compartment. The wall separating the two compartments is quite thin, thus allowing
heat transfer; the outside of the reactor is well insulated; and a cooling coil is built into the
second compartment to remove excess energy liberated in the reaction. Both tanks are
completely full at all times. Tests are to be conducted initially with a single-component feed
(i.e., no reaction) to evaluate the reactor’s thermal characteristics.
a) Develop a dynamic model for this process under the conditions of no reaction. Assume
that q0, Ti, and Tc all may vary.
b) Make a degrees of freedom analysis for your model identifying all parameters, outputs,
and inputs that must be known functions of time in order to obtain a solution.
 Course: Process Control and Automation
Sheet No 2

2.7 A jacketed vessel is used to cool a process stream as shown in Fig. E2.8. The following
information:
(i) The volume of liquid in the tank V and the
volume of coolant in the jacket VJ remain
constant. Volumetric flow rate qF is constant,
but qJ varies with time.
(ii) Heat losses from the jacketed vessel are
negligible.
(iii) Both the tank contents and the jacket
contents are well mixed and have significant
thermal capacitances.
(iv) The thermal capacitances of the tank wall
and the jacketwall are negligible.
(v) The overall heat transfer coefficient for
transfer betweenthe tank liquid and the
coolant varies with coolant flow rate:
U = Kq0.8
U [=] Btu/h ft2 ∘F
qJ [=] ft3/h
K = constant

2.8 A process tank has two input streams—Stream 1 at massflow rate w1 and Stream 2
at mass flow rate w2. The tank’s effluent stream, at flow rate w, discharges through a
fixed valve to atmospheric pressure. Pressure drop across the valveis proportional to the
flow rate squared. The cross-sectional area of the tank, A, is5 m2, and the mass density of
all streams is 940 kg/m3.
(a) Draw a schematic diagram of the process and write an appropriate dynamic model
Course: Process Control and Automation
Sheet No 2

for the tank level. What is the corresponding steady-state model?

(b) At initial steady-state conditions, with w1 = 2.0 kg/s andw2 = 1.2 kg/s, the tank level is
2.25 m. What is the value of the valve constant (give units)?
(c) A process control engineer decides to use a feed forwardcontroller to hold the level
approximately constant at the set-point value (hsp = 2.25 m) by measuring w1 and
manipulating w2. What is the mathematical relation that will be usedin the controller? If
the w1 measurement is not very accurate and always supplies a value that is 1.1 times
the actual flow rate, what can you conclude about the resulting level control? (Hint:
Consider the process initially at the desired stead state (Hint: Consider the process initially
at the desired steady-state level and with the feedforward controller turned on. Because the
controller output is slightly in error, w2 ≠ 1.2, so the process will come to a new steady state.
What is it?) What conclusions can you draw concerning the need for accuracy in a steady-
state model? For the accuracy of the measurement device? For the accuracy of the control
valve? Consider all of these with respect to their use in a feedforward control system.

2.9 The liquid storage tank shown in Fig. E2.12 has two inlet streams with mass flow rates
w1 and w2 and an exit stream with flow rate w3. The cylindrical tank is 2.5 m tall and 2 m in
diameter. The liquid has a density of 800 kg/m3. Normal operating procedure is to fill the
tank until the liquid level reaches a nominal value of 1.75 m using constant flow rates: w1 =
120 kg/min,w2 = 100 kg/min, and w3 = 200 kg/min. At that point, inlet flow rate w1 is
adjusted so that the level remains constant. However, on this particular day, corrosion
of the tank has opened up a hole in the wall at a height of 1 m, producinga leak whose
volumetric flow rate q4 (m3/min) can be approximated by:

where h is height in meters.

(a) If the tank was initially empty, how long did it take for theliquid level to reach the corrosion
point?
If mass flow rates w1, w2, and w3 are kept constant indefinitely, will the tank eventually
overflow? Justify your answer