ChE 401: Process Dynamics and Control

M. Mozahar Hossain PhD PEng

Department of Chemical Engineering
King Fahd University of Petroleum & Minerals
Dhahran 31261, Saudi Arabia
 Without any control
Chapter 1

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 Controlled system
Chapter 1

3
 Uncontrolled
Chapter 1

4
 Chapter 1

5
 Chapter 1

6
 Chapter 1

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Quality control
 Chapter 1

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 Chapter 1

10
 Chapter 1

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Distillation
 Justification of Process Control

Specific Objectives of Control

• Increased product throughput
Chapter 1

• Increased yield of higher valued products

• Decreased energy consumption
• Decreased pollution
• Decreased off-spec product
• Increased Safety
• Extended life of equipment
• Improved Operability
• Decreased production labor

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 CHE-401: Process dynamics & Control
•Importance of control from a business
standpoint
Chapter 1

•What is process control

•Why is control needed
•Types of control used
•How a controller is developed

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 Control Terminology
Controlled variables - these are the variables which
quantify the performance or quality of the final
product, which are also called output variables.
Chapter 1

Manipulated variables - these input variables are

adjusted dynamically to keep the controlled variables
at their set-points.
Disturbance variables - these are also called "load"
variables and represent input variables that can
cause the controlled variables to deviate from their
respective set points.

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 Chapter 1

16
 Chapter 1

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 Control Terminology
Controlled variables - these are the variables which
quantify the performance or quality of the final
product, which are also called output variables.
Chapter 1

Manipulated variables - these input variables are

adjusted dynamically to keep the controlled variables
at their set-points.
Disturbance variables - these are also called "load"
variables and represent input variables that can
cause the controlled variables to deviate from their
respective set points.

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 Chapter 1

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 Chapter
Chapter11

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 Control Terminology(2)

set-point change - implementing a change in the

operating conditions. The set-point signal is
changed and the manipulated variable is adjusted
Chapter 1

appropriately to achieve the new operating

conditions. Also called servomechanism (or "servo")
control.
disturbance change - the process transient
behavior when a disturbance enters, also called
regulatory control or load change. A control system
should be able to return each controlled variable
back to its set-point.

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Chapter 1 Illustrative Example: Blending system

Notation:
• w1, w2 and w are mass flow rates

• x1, x2 and x are mass fractions of component A

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 Assumptions:
1. w1 is constant

2. x2 = constant = 1 (stream 2 is pure A)

3. Perfect mixing in the tank

Chapter 1

Control Objective:
Keep x at a desired value (or “set point”) xsp, despite variations in
x1(t). Flow rate w2 can be adjusted for this purpose.

Terminology:
• Controlled variable (or “output variable”): x

• Manipulated variable (or “input variable”): w2

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• Disturbance variable (or “load variable”): x1
 Design Question. What value of w2 is required to have
x  xSP ?

Overall balance:
0  w1  w2  w (1-1)
Chapter 1

Component A balance:

w1 x1  w2 x2  wx  0 (1-2)

(The overbars denote nominal steady-state design values.)

• At the design conditions, x  xSP. Substitute Eq. 1-2, x  xSP and

x2  1 , then solve Eq. 1-2 for w2 :
xSP  x1
w2  w1 (1-3)
1  xSP
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 • Equation 1-3 is the design equation for the blending
system.
• If our assumptions are correct, then this value of w2 will keep x
atxSP . But what if conditions change?
Chapter 1

Control Question. Suppose that the inlet concentration x1

changes with time. How can we ensure that x remains at or near
the set point xSP ?
As a specific example, if x1  x1 and w2  w2, then x > xSP.

Some Possible Control Strategies:

Method 1. Measure x and adjust w2.

• Intuitively, if x is too high, we should reduce w2; 25

 • Manual control vs. automatic control
• Proportional feedback control law,
w2 t   w2  K c  xSP  x t  (1-4)

1. where Kc is called the controller gain.

Chapter 1

2. w2(t) and x(t) denote variables that change with time t.

3. The change in the flow rate, 2   2 is proportional to

w t w ,
the deviation from the set point, xSP – x(t).

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 Chapter 1

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 Method 2. Measure x1 and adjust w2.

• Thus, if x1 is greater than x1, we would decrease w2 so that

w2  w2 ;

• One approach: Consider Eq. (1-3) and replace x1 and w2 with

x1(t) and w2(t) to get a control law:
Chapter 1

xSP  x1 t 
w2 t   w1 (1-5)
1  xSP

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 Chapter 1

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 • Because Eq. (1-3) applies only at steady state, it is not clear
how effective the control law in (1-5) will be for transient
conditions.

Method 3. Measure x1 and x, adjust w2.

• This approach is a combination of Methods 1 and 2.

Chapter 1

Method 4. Use a larger tank.

• If a larger tank is used, fluctuations in x1 will tend to be damped
out due to the larger capacitance of the tank contents.
• However, a larger tank means an increased capital cost.

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 Classification of Control Strategies

Table. 1.1 Control Strategies for the Blending System

Method Measured Manipulated Category
Variable Variable
Chapter 1

1 x w2 FB
2 x1 w2 FF
3 x1 and x w2 FF/FB
4 - - Design change

Feedback Control:
• Distinguishing feature: measure the controlled variable
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 • It is important to make a distinction between negative feedback
and positive feedback.
 Engineering Usage vs. Social Sciences
• Advantages:
 Corrective action is taken regardless of the source of
Chapter 1

the disturbance.
 Reduces sensitivity of the controlled variable to
disturbances and changes in the process (shown later).
• Disadvantages:
 No corrective action occurs until after the disturbance
has upset the process, that is, until after x differs from
xsp.
 Very oscillatory responses, or even instability… 32
 Feedforward Control:
 Distinguishing feature: measure a disturbance
variable
• Advantage:
 Correct for disturbance before it upsets the process.
Chapter 1

• Disadvantage:
 Must be able to measure the disturbance.
 No corrective action for unmeasured disturbances.

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 Closed-loop Artificial Pancreas
glucose u
setpoint
y
r

controller pump patient sensor

measured glucose

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 Chapter 1

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Chapter 1

Block diagram for temperature feedback control system

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Chapter 1

Figure 1.6 Block diagram for composition feedback control system

on Fig. 1.4.

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 Chapter 1

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 Justification of Process Control

Specific Objectives of Control

• Increased product throughput
Chapter 1

• Increased yield of higher valued products

• Decreased energy consumption
• Decreased pollution
• Decreased off-spec product
• Increased Safety
• Extended life of equipment
• Improved Operability
• Decreased production labor

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 3.2 Economic Incentives - Advanced
Control
 
Chapter 1

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 Chapter 1

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 (days-months) 5. Planning and
Scheduling

(hours-days) 4. Real-Time
Optimization

3b. Multivariable
Figure 1.8 Hierarchy of
Chapter 1

(minutes-hours) and Constraint

Control
process control activities.
(seconds-minutes) 3a. Regulatory
Control

2. Safety, Environment
(< 1 second) and Equipment
Protection

(< 1 second) 1. Measurement

and Actuation

Process
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Chapter 1

Figure 1.10 Major

steps in control
system development

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Chapter 1

Next chapter
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