Smith & Corripio, 3rd edition

Problem 12-1. Loop interaction for the processes of Fig. 12-1.1.

(a) Blending tank, Fig. 12-1.1(a).
Manipulated variables: flows of each of the two inlet streams.
Controlled variables: product flow and composition.
Increasing the flow of either inlet stream increases the product flow. Increasing the flow of the more
concentrated stream increases the product composition, while increasing the flow of the more dilute
stream decreases the product composition. This means the interaction is positive (the two loops
help each other): when the flow of the stream controlling the product composition increases, the
flow controller decreases the flow of the other stream; as the two inlet streams have opposite
effects on the product composition, the change caused by the product flow controller changes the
composition in the same direction.
(b) Chemical reactor, Fig. 12-1.1(b).
Manipulated variables: coolant flow and reactants flow. Assume the product flow is manipulated to
control the level in the reactor.
Controlled variables: flow and reactant composition in the product stream.
As the reactor is cooled, the reaction must be exothermic.
The coolant flow has a negative effect on the temperature and no direct effect on the
composition.
The reactants flow has a positive effect on the reactant composition and, if the feed is at a
lower temperature than the reactor, a negative effect on temperature.
So, at first glance it appears that there is no intercation between the loops, but the interaction
comes through the effect or reactant composition and temperature on each other through the
reaction rate.
When the reactants composition is not controlled, an increase in coolant flow causes a decrease in
reactor temperature; this decreases the reaction rate and increases the reactants concentration,
resulting in a higher reaction rate and temperature than if the reactants composition were kept
constant. So, controlling the composition constant results in a smaller change in reactor
temperature when the coolant flow is changed. Similarly, if the temperature is not controlled, an
increase in reactants flow increases in reactants concentration and the reaction rate resulting in an
increase in temperature, so that the increase in reaction rate is higher than if the temperature is
kept constant. So, controlling the temperature constant results in a larger increase in composition
when the temperature is allowed vto increase.
So, for this particular case, it appears that the interaction is negative with respect to the
temperature loop, and positive with respect to the composition loop. This is unusual.
(c) Evaporator, Fig. 12-1.1(c).
Manipulated variables: valve on feed line, steam flow, and product flow.
Controlled variables: evaporator level, product composition, and througput.
Opening the valve on the feed line increases the throughput and the level in the evaporator, and
decreases the product composition by diluting the contents of the evaporator.
Increasing the steam flow increases the vaporization rate, decreasing the level and increasing
the product composition by removing the solvent.
Increasing the product flow decreases the level and increases the throughput, but it has no
direct effect on the product composition.
As the level must be controlled, the effect of each manipulated variable on the controlled variables
depends on which manipulated variable is used to control the level. Let us assu,e that the feed valve
is used to control the level, since the feed is the largest of the three streams and the level must be
controlled tightly in an evaporator. Then, an increase in steam causes the feed flow to increaseto
maintain the level constant; this increases the throughput and also the product composition, since
there is a net increase in the flow of solute into the eveporator. An increase in product flow
increases the feed flow to maintain the level constant; this increases the throughput and decreases
the product composition, since there is a net increase in the rate of solvent into the evaporator.
The interaction is positive: three positive effects and one negative. When the troughput is
maintained constant the steam and product flows must be chnaged in opposite directions causing
the product composition to change more than if the throughput is allowed to vary. Similarly, when
the product composition is maintained constant, the steam and product flows must change in the
same direction causing the throughput to change more than if the composition is allowed to vary.
(d) Paper-drying machine, Fig. 12-1.1(d).
Manipulated variables: stock feed flow and steam flow.
Controlled variables: moisture content and dry-basis weight (fibers per unit area) of the product.
Assume that the water is removed at a constant rate by mechanical means (filtration) in the first
part of the machine.
Increasing the stock feed rate increases the moisture content and the dry-basis weight.
increasing the steam rate decreases the moisture content and has no direct effect on the
dry-basis weight.
It appears that there is no interaction.
(e) Distillation column, Fig. 12-1.1(e).
Manipulated variables: Coolant flow to the condenser, steam flow to the reboiler, reflux flow,
distillate product flow, and bottoms product flow.
Controlled variables: distillate and bottoms product compositions, condenser accumulator and
column bottom levels, and column pressure.
Coolant rate has a negative effect on the column pressure and a positive effect on the
accumulator level.
Steam flow to the reboiler has positive effects on the bottoms product purity and the column
pressure, and negative effects on the distillate product purity and the column bottom level.
Reflux flow has positive effects on distillate product purity and column bottom level, and
negative effects on bottoms product purity and condehnser accumulator level.
Distillate product rate has a negative effect on the condenser accumulator level and no direct
effect on any of the other variables.
Bottoms product rate has a negative effect on column bottom level and no direct effect on any
of the other variables.
There are positive ad negative interactions between the variables. As the two levels must be
controlled, the interactions depend on which variables are manipulated to control the levels.
Excerpts from this work may be reproduced by instructors for distribution on a not-for-profit basis for testing or instructional purposes
only to students enrolled in courses for which the textbook has been adopted. Any other reproduction or translation of this work
beyond that permitted by Sections 107 or 108 of the 1976 United States Copyright Act without the permission of the copyright owner
is unlawful.
Steady state model: Total mass balance: w
C
w
w
+ w
P
=
Caustic balance: w
C
x
C
w
P
x
P
= (pure water diluent)
Solve for x
P
: x
P
w
C
x
C

w
P
=
w
C
x
C

w
C
w
w
+
=
Open-loop gain matrix:
w
C
w
w
w
P
K
OL
w
P
w
C
x
P
w
C
w
P
w
w
x
P
w
w
|

\
|
|
|
|
.
=
1
w
P
x
C
w
C
x
C

w
P
2
1
w
C
x
C

w
P
2
|

\
|
|
.
=
1
w
w
x
C

w
P
2
1
w
C
x
C

w
P
2
|

\
|
|
.
=
x
P
Relative gain matrix: w
C
w
w
mass% % := klb 1000lb :=
Smith & Corripio, 3rd edition
Problem 12-2. Control of caustic dilution process.
3
SP
AT
FC
SP
FT
w
P
x
P
w
FC
FT
FC
FT
SP
SP
Caustic
Water
AC
3
1
2
Problem data:
w
P
40
klb
hr
:= x
P
30mass% :=
x
C
50mass% :=
Assumptions:
Perfect mixing
Constant mass
Manipulated variables:
Flows of water and caustic
w
C
and w
w
Controlled variables:
Product flow and mass fraction: w
P
and x
P
Excerpts from this work may be reproduced by instructors for distribution on a not-for-profit basis for testing or instructional purposes
only to students enrolled in courses for which the textbook has been adopted. Any other reproduction or translation of this work
beyond that permitted by Sections 107 or 108 of the 1976 United States Copyright Act without the permission of the copyright owner
is unlawful.
Notice that the gain of the composition loop is negative, so a direct acting controller is required for
the composition loop.
mass% hr
klb
K
OL
1 1 ,

1 1 ,
1.25 =
The gain is then:
1

1 1 ,
1 66.7 % =
When the flow control loop is closed, the gain of the composition loop increases by
So, in this case, to minimize interaction,
the caustic stream flow, FC-1, must be manipulated to control the product flow
the water inlet flow, FC-2, must be used to control the product composition.
x
P

0.6
0.4
0.4
0.6
|

\
|
.
=
w
C
w
P
w
w
w
P
w
w
w
P
w
C
w
P
|

\
|
|
|
|
.
:=
w
P
w
w
w
C
Relative gains:
x
P
K
OL
1
0.5
1
0.75
|

\
|
.
= K
OL
1
w
w
x
C

w
P
2
klb
hr mass%
1
w
C
x
C

w
P
2
klb
hr mass%
|

\
|
|
.
:=
w
P
w
w
w
C
Open loop gains:
w
C
24
klb
hr
= w
w
16
klb
hr
= w
w
w
P
w
C
:= w
C
w
P
x
P

x
C
:=
Numerical results:
So, the result is as for the regular blender: the pairing that minimizes the interaction is the one in
which the largest of the two inlet flows is used to control the product flow, and the smaller inlet flow
is used to control the product mass fraction.
The interaction is positive (the loops help each other) as the relative gains are positive.
x
P

w
C
x
C

w
C
x
C
w
w
x
C

w
w
x
C

w
C
x
C
w
w
x
C

w
w
x
C

w
C
x
C
w
w
x
C

w
C
x
C

w
C
x
C
w
w
x
C

|

\
|
|
|
|
.
=
w
C
w
C
w
w
+
w
w
w
C
w
w
+
w
w
w
C
w
w
+
w
C
w
C
w
w
+
|

\
|
|
|
|
.
=
w
P
Open-loop gains:
f
2
2 gpm = f
1
1 gpm = f
2
f
o
f
1
:= f
1
f
o
T
o
T
2

T
1
T
2

:=
f
1
T
1
f
o
f
1

( )
T
2
+ f
o
T
o
= Combine balance equations:
(b) Required flows of hot and cold water and the open-loop steady-state gains.
T
o
f
1
T
1
f
2
T
2
+
f
1
f
2
+
=
f
1
c
p
T
1
f
2
c
p
T
2
+ f
o
c
p
T
o
= Enthalpy balance:
f
o
f
1
f
2
+ = f
1
f
2
+ f
o
= Total mass balance:
(a) Develop the model of the process
Assume
Negligible time delay
Constant properties
Reference temperature of 0F
c
p
1
BTU
lb degF
:= 8.33
lb
gal
:=
T
2
80degF := T
1
170degF :=
T
o
110degF := f
o
3gpm :=
Problem data:
TE
TC
Hot
water
Cold
water
S
SP
S
FE
FC
SP
f
1
f
2
f
o
T
2
T
1
T
o
Problem 12-3. Automatic control of a household shower.
Smith & Corripio, 3rd edition
gpm
gal
min
:=
degF R :=
Excerpts from this work may be reproduced by instructors for distribution on a not-for-profit basis for testing or instructional purposes
only to students enrolled in courses for which the textbook has been adopted. Any other reproduction or translation of this work
beyond that permitted by Sections 107 or 108 of the 1976 United States Copyright Act without the permission of the copyright owner
is unlawful.
degF
gpm
K
OL
1 0 ,

1 0 ,
30 =
K
OL
0 1 ,

0 1 ,
1.5 =
The closed-loop gains are:
1

1 0 ,
1 50 % =
The interaction is positive (the loops help each other), as the relative gains are positive. When one
loop is closed, the gain of the other loop increases by:
T
o

0.333
0.667
0.667
0.333
|

\
|
.
=
f
1
f
o
f
2
f
o
f
2
f
o
f
1
f
o
|

\
|
|
|
|
.
:=
f
o
f
2
f
1
The pairing that minimizes interaction is the total flow with the larger of the two inlet streams (in this
case the cold water, f
2
) and the tempearture with the smaller stream (in this case the hot water, f
1
).
T
o

f
1
T
1
T
2

( )

f
1
f
2
+
( )
T
1
T
2

( )
f
2
T
1
T
2

( )

f
1
f
2
+
( )
T
1
T
2

( )
f
2
T
1
T
2

( )

f
1
f
2
+
( )
T
1
T
2

( )
f
1
T
1
T
2

( )

f
1
f
2
+
( )
T
1
T
2

( )

(
(
(
(
(
(

=
f
1
f
1
f
2
+
f
2
f
1
f
2
+
f
2
f
1
f
2
+
f
1
f
1
f
2
+
|

\
|
|
|
|
.
=
f
o
f
2
f
1
(c) Relative gains and pairing that minimize interaction.
The first row in dimensionless and the
second has units of F/gpm.
T
o
K
OL
1
20
1
10
|

\
|
.
= K
OL
1
f
2
T
1
T
2

( )

f
o
2
gpm
degF
1
f
1
T
1
T
2

( )

f
o
2
gpm
degF

(
(
(
(

:=
f
o
f
2
f
1
K
OL
f
o
f
1
T
o
f
1
f
o
f
2
T
o
f
1
|

\
|
|
|
|
.
=
1
f
1
f
2
+
( )
T
1
f
1
T
1
f
2
T
2

f
1
f
2
+
( )
2
1
f
1
f
2
+
( )
T
2
f
1
T
1
f
2
T
2

f
1
f
2
+
( )
2

(
(
(
(

=
Economy: w
v
E w
S
=
Solute balance: w
F
x
F
w
P
x
P
=
Combine and rearrange: w
F
w
P
E w
S
+ = x
P
x
F
w
P
E w
S
+
( )
w
P
= x
F
1
E w
S

w
P
+
|

\
|
.
=
Control valve gains: w
P
K
vP
m
P
= w
S
K
vS
m
S
=
(b) Steady-state open-loop gains and relative gains.
m
P
m
S
Open-loop gains:
w
F
K
OL
w
F
m
P
x
P
m
P
w
F
m
S
x
P
m
S
|

\
|
|
|
|
.
=
K
vP
K
vP
x
F

E w
S

w
P
2
|

\
|
.

K
vS
E
K
vS
x
F

E
w
P

(
(
(
(
(

=
x
P
Smith & Corripio, 3rd edition
Problem 12-4. Control of an evaporator.
SP
SP
SP
FC
FT
LC
AC
LT
AT
Feed
Product
Vapors
Steam
m
S
m
P
w
F
x
P
w
P
w
S
w
v
x
F
Problem data:
Manipulated variables:
Product and steam valve signals.
m
P
and m
S
Controlled variables:
Feed flow (throughput)
Product composition
w
F
and x
P
Assume the evaporator economy E
is constant.
(a) Steady-state model of the evaporator.
Total mass balance: w
F
w
P
w
v
+ =
Relative gains:

K
vP
K
vS
x
F
E
w
P
K
vP
K
vs
x
F
E
1
w
P
E w
S

w
P
2
+
|

\
|
.

K
vP
K
vS
x
F
E
2
w
S

w
P
2
K
vP
K
vs
x
F
E
1
w
P
E w
S

w
P
2
+
|

\
|
.

K
vP
K
vS
x
F
E
2
w
S

w
P
2
K
vP
K
vs
x
F
E
1
w
P
E w
S

w
P
2
+
|

\
|
.

K
vP
K
vS
x
F
E
w
P
K
vP
K
vs
x
F
E
1
w
P
E w
S

w
P
2
+
|

\
|
.

(
(
(
(
(
(
(
(
(
(
(

=
m
P
m
S
w
F

w
P
w
P
E w
S
+
E w
S

w
P
E w
S
+
E w
S

w
P
E w
S
+
w
P
w
P
E w
S
+
|

\
|
|
|
|
.
=
x
P
The interaction is positive (the loops help each other), as the realative gains are positive.
(c) General pairing strategy.
The pairing the minimizes interaction is:
if the product flow is larger than the vapor flow (E*W
S
), control throughput with the signal to the
valve on the product line and the composition with the signal to the steam valve
if the product flow is smaller than the vapor flow (E*W
S
), control throughput with the signal to
the steam valve and the composition with the signal to the product valve.
Excerpts from this work may be reproduced by instructors for distribution on a not-for-profit basis for testing or instructional purposes
only to students enrolled in courses for which the textbook has been adopted. Any other reproduction or translation of this work
beyond that permitted by Sections 107 or 108 of the 1976 United States Copyright Act without the permission of the copyright owner
is unlawful.
K
OL
1
0.417
0.9
0.563
|

\
|
.
=
x
P
The first row is in klb/klb, and the second is
in mass%/(klb/hr). Relative gains:
w
P
w
S
w
F

w
P
w
P
E w
S
+
E w
S

w
P
E w
S
+
E w
S

w
P
E w
S
+
w
P
w
P
E w
S
+
|

\
|
|
|
|
.
:=
0.6
0.4
0.4
0.6
|

\
|
.
=
x
P
Pairing that minimizes interaction is
control throughput with the product rate
control composition with steam rate
When the feed flow loop is closed, the product composition loop gain changes by
1

1 1 ,
1 66.7 % = The closed-loop gain of the composition loop is:
mass% hr
klb
K
OL
1 1 ,

1 1 ,
0.938 =
Excerpts from this work may be reproduced by instructors for distribution on a not-for-profit basis for testing or instructional purposes
only to students enrolled in courses for which the textbook has been adopted. Any other reproduction or translation of this work
beyond that permitted by Sections 107 or 108 of the 1976 United States Copyright Act without the permission of the copyright owner
is unlawful.
Smith & Corripio, 3rd edition
Problem 12-5. Multivariable control of evaporator of Problem 12-4.
Problem data: x
F
30mass% := x
P
50mass% := w
F
80
klb
hr
:= E 0.9
klb
klb
:=
Combine balance equations to solve for design conditions:
w
P
w
F
x
F
x
P
:= w
S
w
F
w
P

E
:= w
P
48
klb
hr
= w
S
35.556
klb
hr
=
From the solution to Problem 12-4, ignoring the valve gains:
Open-loop gains:
w
P
w
S
w
F
K
OL
1
x
F
E w
S

w
P
2
klb
hr mass%
E
x
F
E
w
P
klb
hr mass%
|

\
|
|
.
:=
Relative gains:
The first column is in
mole%/(klb/hr) and the second
in mole%/(lbmole/hr).
y
D
K
OL
3.14
1.71
0.51
0.676
|

\
|
.
= K
OL
x
B
0 1 ,
x
B
0 0 ,

w
S
0 1 ,
w
S
0 0 ,

y
D
0 1 ,
y
D
0 0 ,

w
S
0 1 ,
w
S
0 0 ,

x
B
0 2 ,
x
B
0 0 ,

w
R
0 2 ,
w
R
0 0 ,

y
D
0 2 ,
y
D
0 0 ,

w
R
0 2 ,
w
R
0 0 ,

\
|
|
|
|
|
.
:=
x
B
w
R
w
S
Open-loop steady state gains:
y
D
93.50 91.79 96.88 ( ) :=
x
B
6.22 3.08 8.77 ( ) :=
Butane mole %
w
R
70.0 70.0 75.0 ( ) :=
Reflux flow, lbmole/hr
w
S
24.0 25.0 24.0 ( ) := Steam flow, klb/hr
Case
Test 1 Test 2 Base
Results of tests performed on a smlation of the column:
Manipulated variables:
Steam and reflux flows
Controlled variables:
Bottoms and distillate compositions
The pressure and level loops are
arranged as shown in the figure.
Steam
Bottoms
Distillate
Feed
Condenser
LC
PC
LC
AC
AC
1
2
1
2
LT
AT
LT
AT
PT
Reflux
Problem 12-6. Distillation product composition control.
Smith & Corripio, 3rd edition
w
S
w
R
x
B

K
OL
0 0 ,
K
OL
1 1 ,

K
OL
K
OL
0 1 ,
K
OL
1 0 ,

|
\
|
.

K
OL
K
OL
0 1 ,
K
OL
1 0 ,

|
\
|
.

K
OL
K
OL
0 0 ,
K
OL
1 1 ,

K
OL

(
(
(
(
(
(

:=
1.697
0.697
0.697
1.697
|

\
|
.
=
y
D
The interaction is negative (loops fight each other): relative gains are either negative or greater than
unity.
Pairing the minimizes interaction:
control distillate composition with reflux rate
control bottoms composition with steam rate
Closed-loop gain of distillate control loop:
K
OL
1 1 ,

1 1 ,
0.398 =
mole% hr
lbmole
Excerpts from this work may be reproduced by instructors for distribution on a not-for-profit basis for testing or instructional purposes
only to students enrolled in courses for which the textbook has been adopted. Any other reproduction or translation of this work
beyond that permitted by Sections 107 or 108 of the 1976 United States Copyright Act without the permission of the copyright owner
is unlawful.
K
OL
f
1
x
0
x
1

( )
f
2
x
0
x
2

( )
+
f
p
2 day
kbl
|

\
|
.
2

f
1
y
0
y
1

( )
f
2
y
0
y
2

( )
+
f
p
2 day
kbl
|

\
|
.
2

1
f
0
x
1
x
0

( )
f
2
x
1
x
2

( )
+
f
p
2 day
kbl
|

\
|
.
2

f
0
y
1
y
0

( )
f
2
y
1
y
2

( )
+
f
p
2 day
kbl
|

\
|
.
2

1
f
0
x
2
x
0

( )
f
1
x
2
x
1

( )
+
f
p
2 day
kbl
|

\
|
.
2

f
0
y
2
y
0

( )
f
1
y
2
y
1

( )
+
f
p
2 day
kbl
|

\
|
.
2

(
(
(
(
(
(
(
(
(
(

:=
Steady-state open-loop gains:
kbl
day
f
22.5
24.375
13.125
|

\
|
.
= f
x
0
y
0
1
x
1
y
1
1
x
2
y
2
1
|

\
|
|
.
1
x
p
y
p
1
|

\
|
|
.
f
p
day
kbl
:=
y
p
f
1
y
1
f
2
y
2
+ f
3
y
3
+
f
1
f
2
+ f
3
+
= x
P
f
1
x
1
f
2
x
2
+ f
3
x
3
+
f
1
f
2
+ f
3
+
=
Required inlet flows:
Assume
gasoline properties are a linear
combination of the feed
properties weighted by volume
Constant standar density
f
p
60.0
kbl
day
:=
y
p
7.00 := x
p
89.0 :=
Gasoline
y
5.00
11.00
3.00
|

\
|
.
:= x
97.0
80.0
92.0
|

\
|
.
:=
1. Alkylate
2. Straight run
3. Reformate
RVP Octane Problem data:
FC
FT
FC
FT
FC
FT
SP
AC
AT
1
SP
AC
AT
2
SP
FC
FT
3
SP
SP
SP x y f
f
f
f
1
2
3
Alkylate
Straight run
Reformate
Problem 12-7. Control of gasoline blender of example 12-2.5.
kbl 42000gal := Smith & Corripio, 3rd edition
Oct

1
0.375
0.375
0.281
0.313
0.406
0.281
1.062
0.219
|

\
|
.
= y
p
RVP
f
p
Flow
Pairing to minimize interaction:
Use alkylate (stream 1) to control the gasoline octane
Use the reformate (stream 3) to control the gasoline Reed vapor pressure
Use the straight run (stream 2) to control the product flow.
These are the same pairings as in Example 12-2.5.
Design of static decoupler, as in Example 12-3.3.
To use the recommended pairing with the decoupler, we must swap columns 2 and 3 in the
iopen-loop gain matrix, and recalculate the inverse matrix. The new inverse matrix is matrix B
with the second and third rows swapped. The decoupler is then, from Eq. 12-3.11:
Oct RVP Flow
m
1
m
2
m
3
f
1
Alkylate
D
B
0 0 ,
B
0 0 ,
B
2 0 ,
B
0 0 ,
B
1 0 ,
B
0 0 ,
B
0 1 ,
B
2 1 ,
B
2 1 ,
B
2 1 ,
B
1 1 ,
B
2 1 ,
B
0 2 ,
B
1 2 ,
B
2 2 ,
B
1 2 ,
B
1 2 ,
B
1 2 ,
|

\
|
|
|
|
|
|
|
|
.
:= D
1
0.75
0.25
0.706
1
0.294
0.923
0.538
1
|

\
|
.
= f
3
Reformate
f
2
Straight run
The instrumentation diagram is the same as Fig.
12-3.6.
Excerpts from this work may be reproduced by instructors for distribution on a not-for-profit basis for testing or instructional purposes
only to students enrolled in courses for which the textbook has been adopted. Any other reproduction or translation of this work
beyond that permitted by Sections 107 or 108 of the 1976 United States Copyright Act without the permission of the copyright owner
is unlawful.
Alk St run Ref
f
1
f
2
f
3
x
p
Oct
day
kbl
y
p
RVP
K
OL
0.133
0.033
1
0.15
0.067
1
0.05
0.067
1
|

\
|
.
=
f
p
Flow
Relative gains:
Inverse of the open-loop gains: B K
OL
1
:= B
7.5
1.875
5.625
11.25
4.688
15.938
0.375
0.406
0.219
|

\
|
.
=
kbl
day
Alk St run Ref
f
1
f
2
f
3

K
OL
0 0 ,
B
0 0 ,

K
OL
1 0 ,
B
0 1 ,

K
OL
2 0 ,
B
0 2 ,

K
OL
0 1 ,
B
1 0 ,

K
OL
1 1 ,
B
1 1 ,

K
OL
2 1 ,
B
1 2 ,

K
OL
0 2 ,
B
2 0 ,

K
OL
1 2 ,
B
2 1 ,

K
OL
2 2 ,
B
2 2 ,

\
|
|
|
.
:=
x
p
Obtain the relative gains by Eq. 12-2.13, page 422:
B
0.03089
0.01256
0.03592
6.43731
3.8685
8.29331
0.31641
0.06809
1.29688
|

\
|
.
= B K
OL
1
:= K
OL
119
0.37
0.930
153
0.767
0.667
21
0.050
1.033
|

\
|
.
:=
Obtain the open-loop steady-state gains by setting s = 0 in the transfer functions:
(a) Relative gains and pairings that minimize interaction.
DCF, kg/liter
FML, liters/s G s ( )
119
217 s 1 +
0.37
500 s 1 +
0.930
500 s 1 +
153
337 s 1 +
0.767
33 s 1 +
0.667 e
320 s
166s 1 +
21
10 s 1 +
0.050
10 s 1 +
1.033
47s 1 +
|

\
|
|
|
|
|
|
.
=
TOR, N-m
Time is in sec
SW, kg/s MW, kg/s SF, kg/s
Models from open-loop tests by Hubert and Woodburn (1983):
Manipulated variables:
SF = solids flow
MW = mill water flow
SW = slurry tank water
Controlled variables:
TOR = mill torque
FML = flow from mill
DCF = cyclone feed
density
AT
XT
FT
AC
XC
FC
DCF
TOR
FML
Mill
Cyclone
SW
SF
MW
Problem 12-8. Control of a wet grinding circuit.
Smith & Corripio, 3rd edition
Block diagram of decoupled system:
DCF, kg/liter
FML, liters/sec
K
OL
D
32.372
0
0
0
0.258
0
0
0
0.771
|

\
|
.
=
TOR, N-m
Decoupled system gains:
kg/sec kg/sec kg/sec
m
DCF
m
FML
m
TOR
All variables in kg/sec
SW
set
MW
set
SF
kg/s
MW
kg/s
SW
kg/s

K
OL
0 0 ,
B
0 0 ,

K
OL
1 0 ,
B
0 1 ,

K
OL
2 0 ,
B
0 2 ,

K
OL
0 1 ,
B
1 0 ,

K
OL
1 1 ,
B
1 1 ,

K
OL
2 1 ,
B
1 2 ,

K
OL
0 2 ,
B
2 0 ,

K
OL
1 2 ,
B
2 1 ,

K
OL
2 2 ,
B
2 2 ,

\
|
|
|
.
:=
TOR, N-m

3.676
2.382
0.294
1.922
2.967
0.045
0.754
0.415
1.34
|

\
|
.
=
FML, liters/s
DCF, kg/liter
Pairing to minimize interaction:
Control the mill torque TOR with the solids flow SF
Control the flow from the mill FML with the water flow to the mill MW
Control the density of the cyclone feed DCF with the slurry water flow SW
(b) Design a decoupler and draw the block diagram and the instrumentation
diagram of the decoupled system.
Because of the complexity of the transfer functions, and the fact that five of the six interaction
terms are negative, a full dynamic decoupler will probably create unstable poles. So, a static
decoupler is designed. If dynamic compensation is required, lead-lag units may be added and tuned
on-line. The gain matrix is correct for the recommended pairing.
Obtain the decoupler from Eq. 12-3.11, page 432:
m
TOR
m
FML
m
DCF
SF
set
D
1
B
1 0 ,
B
0 0 ,
B
2 0 ,
B
0 0 ,
B
0 1 ,
B
1 1 ,
1
B
2 1 ,
B
1 1 ,
B
0 2 ,
B
2 2 ,
B
1 2 ,
B
2 2 ,
1
|

\
|
|
|
|
|
|
|
|
.
:= D
1
0.407
1.163
1.664
1
2.144
0.244
0.053
1
|

\
|
.
=
R
1
(s)
R
2
(s)
R
3
(s)
M
1
(s)
M
2
(s)
M
3
(s)
SF
MW
SW
TOR
FML
DCF
G
C1
(s)
G
C2
(s)
G
C3
(s)
G
11
(s)
G
12
(s)
G
13
(s)
G
21
(s)
G
22
(s)
G
23
(s)
G
31
(s)
G
32
(s)
G
33
(s)
1.664
-
0.244
0.407
0.053
1.163
2.144
-
-
-
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
-
-
-
Instrumentation diagram of decoupler:
AT
XT
FT
AC XC FC
DCF
TOR
FML
Mill
SW
SF
MW
XY FY AY
-1.664
0..244
-0.407
-0.053
1.163
-2.144
TOR
SP
FML
SP
DCF
SP
3
3 3
The summer devices, XY, FY, and AY, are the decouplers. Each signal into the summer is
multiplied by the factor shown by it (unity if no factor is shown). The factors are not corrected for the
valve gains.
Excerpts from this work may be reproduced by instructors for distribution on a not-for-profit basis for testing or instructional purposes
only to students enrolled in courses for which the textbook has been adopted. Any other reproduction or translation of this work
beyond that permitted by Sections 107 or 108 of the 1976 United States Copyright Act without the permission of the copyright owner
is unlawful.
x
B

1.217
0.217
0.217
1.217
|

\
|
.
=
y
D
m
S
m
R

K
OL
0 0 ,
K
OL
1 1 ,

K
OL
K
OL

( )
0 1 ,
K
OL
1 0 ,

K
OL
K
OL

( )
0 1 ,
K
OL
1 0 ,

K
OL
K
OL
0 0 ,
K
OL
1 1 ,

K
OL

(
(
(
(
(
(

:=
x
B
K
OL
3.0
2.5
0.75
3.5
|

\
|
.
%TO
%CO
:=
y
D
Relative gains, from Eq. 12-2.7, page 418:: m
S
m
R
Obtain the open-loop steady-state gains by setting s = 0 in the transfer functions:
%CO % :=
(a) Relative gains and pairing that minimizes interaction.
%TO % :=
X
B
s ( )
2.5
1 0.35s +
M
R
s ( ) 3.5
1 0.25s +
1 0.35s +
|

\
|
.
M
S
s ( ) =
Y
D
s ( ) 3.0
1 0.11s
1 0.35s +
|

\
|
.
M
R
s ( )
0.75
1 0.35s +
M
S
s ( ) + =
Transfer functions from open-loop step tests (time parameters in hours):
= composition of the light
key in the bottoms product
x
B
= composition of heavy key
in the distillate
y
D
x
B
y
D
m
S
m
R
Manipulated variables:
Reflux flow
Steam flow to reboiler
Controlled variables:
Distillate purity
Bottoms product purity
Steam
Bottoms
Distillate
Feed
Condenser
LC
PC
LC
AC
AC
1
2
1
2
LT
AT
LT
AT
PT
Reflux
Problem 12-9. Decoupler design for distillation product composition control.
Smith & Corripio, 3rd edition
The interaction is negative (loops fight each other): relative gains are negative or greater than one.
Pairing that minimizes interaction:
Control distillate purity with reflux flow
Control bottoms purity with steam flow
(b) Design the block diagram and draw the block diagram for this system.
Y
D
s ( ) 3.0
1 0.11 s
1 0.35 s +
|

\
|
.

0.75
1 0.35 s +
D
1
s ( ) +

(
(

M
S
s ( ) = 0 = D
1
s ( )
3.0
0.75
1 0.11s ( ) =
X
B
s ( )
2.5
1 0.35 s +
D
2
s ( ) 3.5
1 0.25 s +
1 0.35 s +
|

\
|
.

(
(

M
R
s ( ) = 0 =
D
2
s ( )
3.5
2.5
1 0.25s + ( ) =
The first decoupler required a negative lead that will produce an undersirable result in the reflux flow,
so we will use a simple gain. The second decoupler can be implemented, but a small lag must be
included.
D
1
s ( ) 4.0
%CO
%CO
= D
2
s ( ) 1.4
%CO
%CO
1 0.28s +
1 0.03s +
|

\
|
.
=
The second decoupler introduces a net lead of 0.25 hour (15 minutes).
Block diagram of decoupled system:
G
11
(s)
G
12
(s)
G
21
(s)
G
22
(s)
D
1
(s)
D
2
(s)
G
c1
(s)
G
c2
(s)
R
1
(s)
R
2
(s)
M
R
(s)
M
S
(s)
Y
D
(s)
X
B
(s)
+
+
+
+
+
+
+
+
+
+
-
-
Excerpts from this work may be reproduced by instructors for distribution on a not-for-profit basis for testing or instructional purposes
only to students enrolled in courses for which the textbook has been adopted. Any other reproduction or translation of this work
beyond that permitted by Sections 107 or 108 of the 1976 United States Copyright Act without the permission of the copyright owner
is unlawful.
D
2
s ( )
G
P
2 2 ,
s ( )
G
P
2 1 ,
s ( )
=
0.9
1.1
1.5s 1 +
2.0s 1 +
e
1 0.3 ( )s
= G
P
2 2 ,
s ( ) G
P
2 1 ,
s ( ) D
2
s ( ) +

M
2
s ( ) 0 =
D
1
s ( )
G
P
1 1 ,
s ( )
G
P
1 2 ,
s ( )
=
0.81
1.2
2.4s 1 +
1.4s 1 +
e
0.6 1.1 ( )s
= G
P
1 2 ,
s ( ) D
1
s ( ) G
P
1 1 ,
s ( ) +

M
1
s ( ) 0 =
(b) Design decoupler and show in the block diagram.
Pairing that minimizes interaction:
Control c
1
with m
2

Control c
2
with m
1
The interaction is negative (loops fight each other): relative gains are either negative or greater than
unity.
c
2

1.234
2.234
2.234
1.234
|

\
|
.
=
K
OL
0 0 ,
K
OL
1 1 ,

K
OL
K
OL
0 1 ,
K
OL
1 0 ,

K
OL
K
OL
0 1 ,
K
OL
1 0 ,

K
OL
K
OL
0 0 ,
K
OL
1 1 ,

K
OL
|

\
|
|
|
|
.
:=
c
1
m
2
m
1
Relative gains by Eq. 12-2.7, page 418:
K
OL
0.81
1.1
1.2
0.9
|

\
|
.
:=
Obtain open-loop steady-state gains by setting s = 0 in the transfer functions:
(a) Relative gains and pairing that minimizes interaction.
G
U
s ( )
0.5
2.2s 1 +
1.5
1.8s 1 +
|

\
|
|
.
= G
P
s ( )
0.81e
0.6 s
1.4s 1 +
1.1e
0.3 s
1.5s 1 +
1.2e
1.1 s
2.4s 1 +
0.9e
s
2s 1 +
|

\
|
|
|
.
=
C s ( ) G
P
s ( ) M s ( ) G
PU
s ( ) U s ( ) + =
Problem 12-10. Decoupler design for a 2x2 process.
Smith & Corripio, 3rd edition
The first decoupler term cannot be implemented because it requires a negative delay which would
require knowledge of the signal in the future. So, we will add the negative delay of 0.5 min to the
lead in the lead lag unit, making the new lead:
2.4 0.6 1.1 + ( )min 2.9min =
The decouplers are then:
D
1
s ( ) 0.675
2.9s 1 +
1.4s 1 +
=
D
2
s ( ) 0.818
1.5s 1 +
2.0s 1 +
e
0.7s
=
Block diagram of the complete system:
G
P12
(s)
D
1
(s)
D
2
(s)
G
c1
(s)
G
c2
(s)
R
1
(s)
R
2
(s)
M
2
(s)
M
1
(s)
C
1
(s)
C
2
(s)
+
+
+
+
+
+
+
+
+
+
-
-
G
P11
(s)
G
U1
(s)
G
U2
(s)
G
P22
(s)
G
P21
(s)
+
+
U(s)
Excerpts from this work may be reproduced by instructors for distribution on a not-for-profit basis for testing or instructional purposes
only to students enrolled in courses for which the textbook has been adopted. Any other reproduction or translation of this work
beyond that permitted by Sections 107 or 108 of the 1976 United States Copyright Act without the permission of the copyright owner
is unlawful.
G
v1
s ( ) G
21
s ( )
G
v1
s ( ) G
21
s ( )
G
v2
s ( ) G
22
s ( )
G
v2
s ( ) G
22
s ( ) +
|

\
|
.
M
1
s ( ) +
C
2
s ( ) G
v2
s ( ) G
22
s ( )
G
v2
s ( ) G
12
s ( )
G
v1
s ( ) G
11
s ( )
G
v1
s ( ) G
21
s ( ) +
|

\
|
.
M
2
s ( ) =
If the decouoplers can be implemeted exactly, then:
G
v1
s ( ) G
21
s ( ) D
21
s ( ) G
v2
s ( ) G
22
s ( ) +
( )
M
1
s ( ) +
C
2
s ( ) G
v2
s ( ) G
22
s ( ) D
12
s ( ) G
v1
s ( ) G
21
s ( ) +
( )
M
2
s ( ) =
From the block diagram, the transfer functions are:
Similarly for the other variable:
C
1
s ( ) G
v1
s ( ) G
11
s ( )
G
21
s ( )
G
22
s ( )
G
12
s ( )
|

\
|
.
M
1
s ( ) =
So, the system would be
decoupled.
Simplify:
G
v2
s ( ) G
12
s ( )
G
v2
s ( ) G
12
s ( )
G
v1
s ( ) G
11
s ( )
G
v1
s ( ) G
11
s ( ) +
|

\
|
.
M
2
s ( ) +
C
1
s ( ) G
v1
s ( ) G
11
s ( )
G
v1
s ( ) G
21
s ( )
G
v2
s ( ) G
22
s ( )
G
v2
s ( ) G
12
s ( ) +
|

\
|
.
M
1
s ( ) =
If the decouoplers can be implemeted exactly, then:
G
v2
s ( ) G
12
s ( ) D
12
s ( ) G
v1
s ( ) G
11
s ( ) +
( )
M
2
s ( ) +
C
1
s ( ) G
v1
s ( ) G
11
s ( ) D
21
s ( ) G
v2
s ( ) G
12
s ( ) +
( )
M
1
s ( ) =
From the block diagram, the transfer functions are:
D
21
s ( )
G
v1
s ( ) G
21
s ( )
G
v2
s ( ) G
22
s ( )
= D
12
s ( )
G
v2
s ( ) G
12
s ( )
G
v1
s ( ) G
11
s ( )
=
The decouplers are given in Eq. 12-3.2, page 426:
Problem 12-11. Decoupling of 2x2 process of Fig. 12-3.2--show decoupled
closed-loop transfer functions
Smith & Corripio, 3rd edition
Simplify:
So, the system would be
decoupled.
C
2
s ( ) G
v2
s ( ) G
22
s ( )
G
12
s ( )
G
11
s ( )
G
21
s ( )
|

\
|
.
M
2
s ( ) =
Excerpts from this work may be reproduced by instructors for distribution on a not-for-profit basis for testing or instructional purposes
only to students enrolled in courses for which the textbook has been adopted. Any other reproduction or translation of this work
beyond that permitted by Sections 107 or 108 of the 1976 United States Copyright Act without the permission of the copyright owner
is unlawful.
w
1
50
lb
min
= w
2
50
lb
min
=
So, there is no best pairing and the relative gains are 0.5 for both pairings. As there are no flow
transmitters on the inlet flows, ratio control cannot be implemented. We design then a linear
decoupler.
w w
1
w
2
+ = K
v1
m
1
K
v2
m
2
+ = w K
v1
m
1
K
v2
m2 + = 0 = m
1
K
v2

K
v1
m
2
=
x
w
1
x
1
w
2
x
2
+
w
1
w
2
+
=
x
w
1
w
2
+
( )
x
1
w
1
x
1
w
2
x
2

w
1
w
2
+
( )
2
K
v1
m
1

w
1
w
2
+
( )
x
2
w
1
x
1
w
2
x
2

w
1
w
2
+
( )
2
K
v2
m
2
+ = 0 =
w
2
x
1
x
2

( )
K
v1
m
1
w
1
x
2
x
1

( )
K
v2
m
2
+ 0 = m
2
K
v1
w
2

K
v2
w
1

m
1
=
K
v1
w
max
100%CO
:= K
v2
w
max
100%CO
:= K
v1
1.5
lb
min %CO
= K
v2
1.5
lb
min %CO
=
The gains of the decouplers are:
K
v1

K
v2
1 =
K
v1
w
2

K
v2
w
1

1 =
Smith & Corripio, 3rd edition
Problem 12-12. Decoupler design for blending tank of Example 12-5.1.
AC
SP
AT
SP
w
x
1
1
w
x
w
x
2
2
m
m
1
2
V
FC
FT
Design conditions:
x
1
10mass% := x
2
30mass% :=
w 100
lb
min
:= x 20mass% :=
Valves are linear with constant
pressure drop.
w
max
150
lb
min
:=
Analyzer transmitter AT:
x
min
5mass% := x
max
35mass% :=
At the design conditions: w
1
w
x x
1

x
2
x
1

:= w
2
w w
1
:=
+
SP
AT
SP
w
x
1
1
w
x
w
x
2
2
m
1
m
2
V
FC
FT
FY
AY
3
+
+
-
AC
3
Instrumentation diagram:
FY: summer, keeps flow constant
when the analyzer controller varies
m
2
AY: summer, keeps composition
constant when the flow controller
varies m
1
Both require a bias of:
w
1
K
v1
33.33 %CO =
w
2
K
v2
33.33 %CO =
Excerpts from this work may be reproduced by instructors for distribution on a not-for-profit basis for testing or instructional purposes
only to students enrolled in courses for which the textbook has been adopted. Any other reproduction or translation of this work
beyond that permitted by Sections 107 or 108 of the 1976 United States Copyright Act without the permission of the copyright owner
is unlawful.
Ratio
x
F
x
P
set
= where, at design conditions: w
P
Ratio w
F
=
This is a ratio controller with the ratio adjustable by the output of the composition controller AC:
w
P
x
F
x
P
set
w
F
= x
P
set
x
F
w
F
w
P
=
Want the output of the analyzer controller AC to be the composition:
m
S
w
Fmax
100%CO E K
vS

\
|
.
m
FC
K
vP
E K
vS

\
|
.
m
P
= w
F
set
w
Fmax
100%CO
=
Now, the feed flow setpoint is obtained using a scale factor on the controller output in %CO. This
scale factor is obtained from the maximum expected feed rate over 100%CO:
m
S
w
F
set
E K
vS

K
vP
E K
vS

m
P
= w
S
w
F
set
w
P

E
=
So w
F
set
w
P
E w
S
+ =
Want the output of the feed flow controller FC to be the sum of the vapors and the product:
Decoupler design:
Assume the vapor rate is greater
than the product rate, so that the
steam is used to control the feed
rate and the product to control the
composition.
w
S
K
vS
m
S
=
w
P
K
vP
m
P
=
x
P
x
F
w
F

w
P
=
w
F
w
P
E w
S
+ =
From the solution of Problem 12-4:
SP
SP
SP
FC
FT
LC
AC
LT
AT
Feed
Product
Vapors
Steam
m
S
m
P
w
F
x
P
w
P
w
S
w
v
x
F
Problem 12-13. Non-linear static decoupler for evaporator of Problem 12-4.
Smith & Corripio, 3rd edition
This would work best if a flow controller is installed on the product line, but this is probably too
much of an expense for an evaporator. So, the ratio of the signals are used:
Ratio
x
F
x
P
set
w
Fmax
100%CO K
vP

=
m
P
Ratio m
FC
= where
Instrumentation diagram:
SP
SP
SP
FC
FT
LC
AC
LT
AT
Feed
Product
Vapors
Steam
m
S
m
P
w
F
x
P
w
P
w
S
x
F
FY
AY
3
X
m
FC
Ratio FY: summer, subtracts the
scaled signal to the product valve
from the signal to the seam valve
to maintain the feed flow constant.
AY: multiplier, makes the signal
to the product valve proportional to
the total signal from the feed
controller, scaled, to make the
product flow proportional to the
feed flow and mintain the product
com position constant.
Excerpts from this work may be reproduced by instructors for distribution on a not-for-profit basis for testing or instructional purposes
only to students enrolled in courses for which the textbook has been adopted. Any other reproduction or translation of this work
beyond that permitted by Sections 107 or 108 of the 1976 United States Copyright Act without the permission of the copyright owner
is unlawful.