Faculty of Engineering and Technology
Department of Chemical and Metallurgical Engineering
MEMORANDUM
DIPLOMA IN CHEMICAL ENGINEERING
MODULE : PROCESS CONTROL
MODULE CODE : EHPCO2A
FORMATIVE ASSESSMENT : PRIMARY X SECONDARY CONTINGENCY
DATE : 27 NOVEMBER 2023
DURATION OF ASSESSMENT : 180 MINUTES
ASSESSOR(S) : TSHILENGE, K
MODERATOR(S) : BRINK, C
MARKS : Total = 111
: Full marks = 100
Prof. [Link] 06/11/2023
Examiner
Print Name Signature Date
Mrs CJ Brink 07/11/2023
Moderator
Print Name Signature Date
MEMORANDUM
Consider the simple chemical plant composed of three units: a continuous stirred tank
mixer (CSTM), a continuous stirred tank reactor (CSTR) and a distillation column.
Components A and B enters the mixing tank with volumetric flow rates F 1 and F2 at
temperatures T1 and T2. This mixture is cooled to prevent the chemical reaction from
starting. The heats of solution are strong functions of concentration, thus T 3 depends
on the concentration and temperatures of the feed streams. (heat of solution cannot
be ignored).
In the reactor A and B react to yield C. The reaction is endothermic and direct steam
heating is used to make the reaction happen and to dilute the product to prevent it’s
density becoming too high. Due to the dilution and temperature control in the plant
the densities of the liquids may be assumed to have weak dependences on
concentration and temperature. Therefore, it may be assumed that = 1 = 2 = 3
= 5 = 6 = 7. The same assumption may be made for the heat capacity of all liquids
in the system.
The mixture of C and unreacted A and B enters the distillation column, where A+B is
separated from the top as the overhead product and C is taken as the bottom product.
Assume that all effluent flow rates are proportional to the liquid static pressure that
causes their flow (hydrostatic flow)
This diagram and information must be used for all the questions
Process Control EHPCO2A November 2023 Page 2 of 9
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MEMORANDUM
Question 1
1.1. What are the product specifications, operational constraints and economic considerations for this
simple plant? (The whole plant, not that of separate units) (6)
Product specification:
Keep the flow rate of F6 (product stream from the distillation column) at the
specified level✓
Keep the required concentration (purity) of C in the product stream F6✓
Operational constraints:
Do not overflow the CSTM and CSTR✓
Do not flood the distillation column or let it run dry✓
Economic considerations:
Maximising the profit is equivalent to minimising the operating cost. Operating
cost involves the cost of the raw materials the cooling water used in the CSTM
and condenser and the steam used in the CSTR and re-boiler. ✓✓
any answer that show understanding of the principles and process is acceptable
1.2. What are the disturbances that will affect the control objectives you identified in Question 1.1?
(2)
Feed: The flow rates compositions and temperatures of the streams of the two raw
materials (F1, T1, cA1 and F2, T2, cB2)
Process: The pressure in the distillation column
Environment: The temperature of the coolant used in the CSTM and the condenser of
the distillation column: (For example, if the coolant is water, it will have a different
temperature during the day than during the night)
✓✓any answer that show understanding of the principles and process is acceptable
Look at the ratio control configuration around the CSTM (mixing tank). In this configuration we measure
both flow rates and take their ratio. This ratio is compared to the desired ratio (set point) and the
deviation (error) between the measured and desired ratios constitutes the actuating signal for the ratio
controller
1.3. What are the hardware elements typically associated with a control system. Identify each of
these as given in the ratio control configuration for the CSTM (A to F) and explain their function?
(20)
Chemical Process✓ (F) ✓ – All the material, equipment and operations of the CSTM✓
Measuring Instrument✓ (A) ✓ – The flow measuring devices used to measure F1 and
F2✓
Transducer✓ (B) ✓ – Transduces (Transmitters) are used to convert the signal from the
measuring device to a physical quantity like electric voltage of a pneumatic signal✓
Transmission Lines✓ (C) ✓ – This is needed to carry the measurement signal from the
measuring device to the controller and to carry the control signal from the controller to
the final control element. ✓
Process Control EHPCO2A November 2023 Page 3 of 9
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MEMORANDUM
Controller✓ (D) ✓ – This is typically a computer. Receiving the measurement signal,
compares this to the set point and use the mathematical model to calculate the control
action needed. A signal is sent to the actuator of the final control element. ✓
The recording element✓ will typically form part of this section of the control system. ✓
Final Control Element✓ (F) ✓ – The hardware element that implements the decision
taken by the controller. In this case a valve. ✓
1.4. Draw and explain an alternative configuration of ratio control for the CSTM. (8)
We measure the flow rate of the
wild stream (FA in this diagram)
F2 ✓and multiply it by the desired
ratio✓. The result is that the
flow rate that F1 (stream B in this
diagram) should have and
constitutes the set point value
which is compared to the
measured flow rate of F1✓✓. The
deviation constitutes the
actuating signal for the
controller, which adjust the flow
rate of F1 appropriately✓.
✓✓✓
1.5. Design a cascade control configuration to keep the temperature T 3 in the tank at the desired
value. (5)
✓✓✓✓✓
1.6. Explain why ratio control is classified under feed-forward control and cascade control under feed-
back control. (4)
In the ratio control configuration the disturbances F2 are measured✓ and feed-forward control
is defined as systems where the disturbance is measured and the control action taken before
the effect of the disturbance it is felt by the system✓
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MEMORANDUM
In the cascade control system the control objective T3 ✓is measured and feed-back control is
defined as systems where the control objective is measured and the control action is taken
after the effect of the disturbance is felt by the system. ✓
any answer that show understanding of the principles and process is acceptable
1.7. What does it mean when we describing a feed-back control configuration as a proportional-integral
controller. (3)
This is a proportional-plus-reset controller
The output to the actuator (action taken by the final control element) is proportional to the
error caused by the disturbance✓. This response is repeated until the error is zero again –
reset time✓. (reset time is the time needed by the controller to repeat the initial proportional
action change in its output.) ✓
any answer that show understanding of the principles and process is acceptable
1.8. What are the two other reasons for installing a control system? (2)
Suppressing the influence of external disturbances✓
Optimising the performance of a chemical process✓
1.9. Explain why the CSTR is considered an unstable process? Include a graph that shows how the
process will react to a disturbance if a control system is not installed. (4)
The reaction in question is endothermic; it the temperature of the steam coming in is
not high enough the reaction may not take place at all or it may be so slow that very
little of A and B is converted to C. ✓✓
any answer that show understanding of the principles and process is acceptable
Cc5
time
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MEMORANDUM
[54]
Question 2
2.1. Develop a mathematical model for the CSTM (mixing tank) per mole of component A and the
CSTR (reactor). (58)
Continuous stirred tank Mixer
dm d (V )
= = F1 + F2 − F3 ; F3 = h1 and V = A1h1 ✓✓
dt dt
dV dh
= F1 + F2 − F3 = A 1 = F1 + F2 − h1 ✓
dt dt
dn A d (c A3V ) d (c A3 ) d (V ) ✓✓
= =V + c A3 = c A1F1 − c A3F3
dt dt dt dt
V A3 + c A3 (F1 − F3 ) = c A1F1 − c A3F3 ; no A in F2
dc
dt
= (c A1 − c A3 )
dc A3 F1 ✓
dt V
dnB d (cB3V ) d (cB3 ) d (V ) ✓✓
= =V + cB 3 = cB 2F2 − cB3F3
dt dt dt dt
V B3 + cB3 (F2 − F3 ) = cB 2F2 − cB3F3 ; no B in F1
dc
dt
dc B3 F2
= (cB 2 − cB3 ) ✓
dt V
dH d Vhe3
=
( )
= F1he1 + F2he2 − F3he3 − Q ✓✓
dt dt
~ ~
he1 (T1) = he1 (T0 ) + cP1T1 ; he1 (T0 ) = c A1H A + c A1Hs1 ✓✓
~ ✓✓
he2 (T2 ) = he2 (T0 ) + cP2T2 ; he2 (T0 ) = cB 2HB
~ ~ ~
he3 (T3 ) = he3 (T0 ) + cP3T3 ; he1 (T0 ) = c A3H A + cB3HB + c A3 Hs3 ✓✓
( ~ ~ ~
d V c A3H A + cB3HB + c A3 Hs3 + Vc PT3)
dt
( ~ ~
= c A1H A + c A1Hs1 + cPT1 F1 )
(~
+ cB 2HB + cPT2 F2 )
~
( ~ ~
− c A3H A + cB3HB + c A3 Hs3 + cPT3 F3 )
−Q ✓✓
Process Control EHPCO2A November 2023 Page 6 of 9
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MEMORANDUM
( ~ ~ ~
)
d V c A3H A + cB3HB + c A3 Hs3 + Vc PT3
dt
=
( ~
) (
+
) (
~
d Vc A3H A d Vc B3HB d Vc A3 Hs3
+
~
)+
d (cPVT3 )
dt dt dt dt
~ d (Vc A3 ) ~ d (Vc B3 ) ~ d (Vc A3 ) d (VT3 )
= HA − c A1F1 + c A3F3 + HB − cB 2F2 + cB3F3 + Hs3 + cP
dt dt dt dt
~ d (Vc A3 ) ~ ~
H A − c A1H AF1 + c A3H AF3 = 0 balance of A into and out off the mixer
dt
~ d (Vc B3 ) ~ ~
HB − HBcB 2F2 + HBcB3F3 = 0 balance of B into and out off the mixer
dt
~ d (Vc A3 ) d (VT3 )
= Hs3 + cP
dt dt
( ~
= c A1Hs1 + cPT1 F1)
+ (cPT2 )F2
( ~
− c A3 Hs3 + cPT3 F3 )
−Q
✓✓✓
~ d (Vc A3 ) d (VT3 )
= Hs3 c A3F1 − c A3F3 + cPV 3 + cPT3
~ dT dV
Hs3 + cP
dt dt dt dt
d (VT3 ) dT dV
partial differenti ation of cP = cPV 3 + cPT3
dt dt dt
d (Vc A3 )
component balance for A = c A3F1 − c A3F3
dt
Hs3 c A3F1 − c A3F3 + cPV 3 + cPT3
~ dT dV
dt dt
= Hs3 c A3F1 − c A3F3 + cPV 3 + cPT3 F1 + F2 − F3
~ dT
dt
( ) (
= c A1Hs1 + cPT1 F1 + (cPT2 )F2 − c A3 Hs3 + cPT3 F3 − Q
~ ~
)
cPV
dT3
dt
( ~ ~
)
= c A1F1 Hs1 − Hs3 + cP F1(T1 − T3 ) + cP F2 (T2 − T3 ) − Q
✓✓✓
dT3 c A1F1 ~
dt
=
cPV
( ~ F
V
)
Hs1 − Hs3 + 1 (T1 − T3 ) + 2 (T2 − T3 ) −
F
V
Q
cPV
✓
Process Control EHPCO2A November 2023 Page 7 of 9
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MEMORANDUM
Continuous Stirred Tank Reactor
dm d (V )
= = F3 + v F4 + F7 − F6 ; F6 = (h2 − h3 ) and V = Ah ✓✓
dt dt
v
F + F − (h2 − h3 )
dV dh
= F3 + v F4 + F7 − F6 = A 2 = F3 + ✓
dt dt 4 7
dn A d (c A6V ) d (c A6 ) d (V )
= =V + c A6 = c A3F3 + c A7F7 − c A6F6 − rV ✓✓✓
dt dt dt dt
d (c A6 )
V + c A6 (F3 + F7 − F6 ) = c A3F3 + c A7F7 − c A6F6 − rV
dt
d (c A6 ) F3
= (c A3 − c A6 ) + F7 (c A7 − c A6 ) − r ✓✓
dt V V
dnB d (cB 6V ) d (cB 6 ) d (V )
= =V + cB 6 = cB3F3 + cB7F7 − cB 6F6 − rV ✓✓✓
dt dt dt dt
d (cB 6 )
V + cB 6 (F3 + F7 − F6 ) = cB3F3 + cB7F7 − cB 6F6 − rV
dt
d (cB 6 ) F3
= (cB3 − cB6 ) + F7 (cB7 − cB6 ) − r ✓✓
dt V V
dnC d (cC 6V ) d (cC 6 ) d (V )
= =V + cC 6 = −cC 6F6 + rV ✓✓✓
dt dt dt dt
d (cC 6 )
V + cC 6 (− F6 ) = −cC 6F6 + rV
dt
d (cC 6 )
= −r ✓✓
dt
dH (T6 , n A , nB , nC ) H dT6 H dn A H dnB H dnC
= + + + ✓
dt T dt n A dt nB dt nC dt
dH (T6 , n A , nB , nC )
= F3cPT3 + v F4cV T4 + v cond + F7cPT7 − F6cPT6
dt ✓✓✓
H H H
= H A (T ) ; = HB (T ) ; = HC (T )
dH ~ ~ ~
= VcP ; ✓✓✓✓
dt n A nB nC
dn A
= c A3F3 + c A7F7 − c A6F6 − rV
dt ✓
dnB
= cB3F3 + cB7F7 − cB 6F6 − rV
dt ✓
dnC
= −cC 6F6 + rV ✓
dt
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MEMORANDUM
+ H A (T )(c A3F3 + c A7F7 − c A6F6 − rV ) + HB (cB3F3 + cB7F7 − cB 6F6 − rV )
dT6 ~ ~
VcP
dt
+ HC (− cC 6F6 + rV ) = F3cPT3 + v F4cV T4 + v cond + F7cPT7 − F6cPT6
~
✓
dT6
VcP = F3cPT3 + v F4cV T4 + v cond + F7cPT7 − F6cPT6
dt
− H A (T )(c A3F3 + c A7F7 − c A6F6 − rV ) + HB (cB3F3 + cB7F7 − cB 6F6 − rV )
~ ~
+ HC (− cC 6F6 + rV )
~
✓
2.2. What are difficulties that we encounter when trying to develop a meaningful and realistic
mathematical description of a chemical process? (3)
Poorly understood processes✓
Imprecisely known parameters✓
Size and Complexity of a model✓
[57]
PAPER TOTAL = 111
FULL MARKS = 100
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