Accepted Manuscript

Title: Simulation and control of a complex nonlinear dynamic

behavior of multi-stage evaporator using PID and Fuzzy-PID
controllers

Authors: Om Prakash Verma, Gaurav Manik, Vinay Kumar

Jain

PII: S1877-7503(17)30368-X
DOI: http://dx.doi.org/doi:10.1016/j.jocs.2017.04.001
Reference: JOCS 649

To appear in:

Received date: 5-12-2016

Revised date: 24-3-2017
Accepted date: 1-4-2017

Please cite this article as: Om Prakash Verma, Gaurav Manik, Vinay Kumar
Jain, Simulation and control of a complex nonlinear dynamic behavior of multi-
stage evaporator using PID and Fuzzy-PID controllers, Journal of Computational
Sciencehttp://dx.doi.org/10.1016/j.jocs.2017.04.001

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Simulation and control of a complex nonlinear dynamic behavior of
multi-stage evaporator using PID and Fuzzy-PID controllers

Om Prakash Verma1a, Gaurav Manik1b,*, and Vinay Kumar Jain2

1
Department of Polymer and Process Engineering, Indian Institute of Technology Roorkee, India
2
Department of Computer Science and Engineering, Jaypee University of Engineering and Technology, India
E-mail addresses: opiitroorkee@gmail.com1a ; vinay2588@gmail.com2
* Corresponding author email and contact: manikfpt@iitr.ac.in1b,*; +91-132-2714340
HIGHLIGHTS
Highly complex nonlinear first order dynamic model of multi-stage evaporator system
linearized and state space transfer functions developed.
Transient response of system for a set point change in product concentration using
conventional PID controllers explored through simulations.
PID controlling displayed noticeable overshoot, undershoot and integral square error, that may
collectively influence black liquor product quality.
An intelligent Mamdani type Fuzzy Logic-Proportional-Integral-Derivative controller
designed to control product quality efficiently through better controller tuning.

Abstract:

The dynamic model of heptads stage evaporative unit employed in concentrating black liquor
in paper industry show tremendous complexity. In this work, linearization of such a complex
nonlinear model consisting of 14 first order nonlinear differential equations and determination of
the system transfer functions has been explored through an exhaustive state space representation
technique. The transfer functions that relate the product concentration change to liquor flow rate
deviation have been evaluated and presented through this work for the first time. These serve as
an input to design a PID controller and study its response for a set point change in product
concentration. The response analysis indicated a noticeable overshoot, undershoot and Integral
Square Error (ISE), that may collectively influence the product quality. To overcome this issue

1
and to make controlling of product concentration more robust, an intelligent Mamdani type Fuzzy
Logic-Proportional-Integral-Derivative (FLC-PID) controller has been additionally designed and
its response simulated. A comparison of response of FLC-PID and PID indicated that the rise time
of former is larger than the latter. However, FLC-PID response settles faster with ~49% smaller
settling time than PID, possesses zero undershoot, a ~93% reduced overshoot and 21% reduced
ISE. The results demonstrate improved tracking capability, and hence, better control performance
of FLC-PID for transient changes in product concentration.

Keywords: Dynamic Model; Energy Efficiency; Fuzzy Logic Controller; Multi-Stage Evaporator;
PID Controller;

Nomenclature
A Heat transfer area (m2) N Compensated coefficient
a Elements of matrix A PID Proportional-Integral-Derivative
A State matrix s Laplace operator
ADt Airdried ton S Steam flow rate
ANN Artificial neural network SC Steam consumption
B Input matrix SE Steam economy
b Elements of matrix B SISO Single input single output
BFF Backward feed flow T Vapor body temperature (C)
C Output matrix u Input variables
D Feedthrough matrix U Overall heat transfer coefficient (kW/ m2 C)
e Error V Vapor flow (kg/hr)
ERS Energy Reduction Scheme x State variable
f function X Concentration (% dry solid in kg/ total solid in kg)
FLC Fuzzy logic controller y Output variable
g, G Transfer function Y Output matrix
GJ Giga Joule Subscripts
GWh Giga Watt hour c Condensate
h Enthalpy (kJ/kg) f Feed
H Enthalpy of vapor (kJ/kg) i Effect number
HEE Heptads effect evaporator L Liquor
ISE Integral square error p Product
kW kilo Watt s Steam
kWh kilo Watt hour Greek Letters
L Feed flow rate (kg/hr) Latent heat of vaporization (kJ/kg)
M Mass hold up Change/difference
MSE Multi-stage evaporator Time constant
Mtpa Mega ton per annum

1. Introduction
Among the major challenges that developing countries face currently in 21st century and
presumably in near future as well, is the replacement of conventional non-renewable energy fossil

2
fuels by renewable sources such as biomass based byproducts of process industries. One such
biomass source is lignin and is obtained in various forms from processes such as Kraft pulping in
Pulp and Paper (P&P) industry which produce ~80% of the world chemical pulp [1]. The black
liquor, obtained as a byproduct stream of this process, contains typically, 3034% of lignin. This
liquor has a potential to be used as an alternative source fuel to operate mill boiler units [2,3]. It is
estimated that P&P mill stands as worlds 4th and Indias 6th highest energy consuming industry
[4]. On an average, this mill has energy requirement of ~ 10 Metric ton per annum (Mtpa) of coal
and 10.6 GWh of electricity. The steam consumption of ~11-15 ton and ~1,500-1,700 kW of
electricity adds up to a huge annual average specific energy requirement of ~52 GJ per ton of paper
and makes it a highly energy intensive industry. This accounts for almost half of P&P mills
cost [5].
The waste black liquor from the pulp washing contains ~12-14% solids and this needs to be
concentrated to ~40-55% solids before it can be burnt in the recovery furnace. This is accomplished
using a Multi-Stage Evaporator (MSE) unit which helps to improve the energy efficiency of the
biomass based black liquor fuel. The steam and electricity requirements for the MSE have been
estimated to be 3.1 GJ/ Airdried ton (ADt) and 30kWh/ADt, respectively. This huge amount of
energy demand has subjected Indian P&P mills to tremendous pressures to cut their energy and
fuel costs. Therefore, it is very important to accurately model different Energy Reduction Schemes
(ERS) and control these with advance control techniques to maximize their Steam Economy (SE)
and minimize Steam Consumption (SC) [6]. The design and operation of MSE unit is, however,
very complex and depends on their physical structure, their series/parallel arrangements based on
feeding mode of weak black liquor and fresh live steam and the interactions of this process with
the environment [7].
In order to improve the energy efficiency with enhancement of quality of final product in MSE,
it is essential to formulate and simulate the nonlinear steady and transient models of nonlinear
Heptads Effect Evaporator (HEE) steady state process with Backward Feed Flow (BFF). Though
the steady state analysis for MSE has been well explored in literature [811], proper optimization
of its efficiency would require development of suitable advanced control strategies based on their
dynamic simulation. Unfortunately, the area of dynamic modeling and simulation of MSE has not
been extensively investigated. An accurate design of control system shall further help to regulate
the total solids concentration despite presence of large disturbances which may change with the

3
operating condition. In order to explore the MSE dynamics, two types of dynamic model, lumped
and distributed, were developed for an industrial four-stage MSE. The results showed that the
distributed model has slightly better predictions than the lumped model, but the lumped model has
comparable performance because their simplicity in structure and the needed less time to simulate
in comparison with the distributed model [12].
It is well known that control of the HEE is challenging due to its highly nonlinear dynamics
and its parameter uncertainties which lead to produce unsatisfactory responses with conventional
PID controllers. In order to improve the performance of PID control to dampen the speed of the
steam flow rate and searching the optimal points in the evaporation process and modeling the
evaporator, the PSO tuning PID control has been proposed to handle the dynamics of a system that
have similar to the process i.e., optimal tuning of PID controller using adaptive hybrid Particle
Swarm Optimization (PSO) algorithm, to solve the problem of parameter estimation for nonlinear
dynamic rational filters [13]. Additionally, Fuzzy Logic Controllers (FLC) have been reported to
successfully control similar highly complex and nonlinear processes [14]. The aim of this paper is
to present a dynamic model of HEE and to design and compare the performance of conventional
PID and advanced FLCs on the basis of system dynamic behavior.
A large number of mathematical models for the MSE system have been reported previously
[1517]. These mathematical models have been developed previously based on linear and
nonlinear modeling. However, nonlinearity is the thumb rule in most of the industrial processes,
rather than an exception. The nonlinearity occurred in the MSE is only due to dependence of one
variable to other. For example, Thermo-Physico properties such as latent heat of vaporization,
enthalpy of the liquor, vapor, viscosity of liquor, fouling effects and boiling point elevation etc.
are highly influenced by vapor temperature of each stage of MSE. Hence, the dynamics of MSE
models is found to be highly complex and nonlinear [9] but the previous studies limited their focus
to single-, double- and triple- effects only [18], with very few studies extending it to a higher
number of effects (up to i = 7) with different ERS [6,19]. The evaluated dynamic response are
then used to study the open and closed loop responses, which are further utilized to design the
conventional PID controller for controlling the byproduct weak liquor concentration [20].
However, one of the major drawbacks of conventional PID controllers is that it is prone to changes
in system parameters and nonlinearities, and difficulty in obtaining zero overshoot [21]. Also, the
inaccuracy in mathematical modeling of such nonlinear and complex dynamic MSE systems

4
highly degrades the controller performance. This motivates an interest in exposing use of another
unconventional alternative technique known as FLC. FLCs are based on Fuzzy Logic theory [22]
and may be employed to overcome such difficulties inherent with PID controller. However, it still
needs to be extended to other types of FLC. In order to reduce the sensitivity and to influence the
sampling time of FLC through computers, a more systematic analysis and design has been
proposed using phase-plane techniques that reduces to tuning of the scaling gains [23]. A digital
structure for FLC was also presented to avoid the influence of the sampling time. In order to utilize
the FLC that corresponds to nonlinear process CSTR, a multi-region FLC controller has been
proposed and issues of tuning the controller and rule combination discussed earlier [24]. Later, the
output (temperature) tracking and disturbance rejection problem of nonlinear CSTR control
systems with uncertainties have been exhaustively explored using classical control PID, Cascade
control, and hybrid intelligent controllers including FLC, adaptive control, and Adaptive Neuro-
Fuzzy Inference System (ANFIS). It was observed that FLC and ANFIS are able to track the set-
point with minimum Integral Square Error (ISE) and produced approximately zero overshoot.
The present work is to demonstrate efficient control and tracking of product concentration with
minimum error of variation of liquor feed flow rate. To achieve this, PID and FLC-PID controllers
have been proposed and designed after determining the Single-Input Single-Output (SISO) transfer
function. However, these transfer functions may only be obtained once the dynamic model of HEE
system has been defined. Hence, the dynamic model in such a case is determined and found to
consist of complex transient equations which are highly nonlinear due to the presence of higher
order of temperature or pressure terms in the thermo-physical correlations. Hence, to obtain the
SISO transfer function of nonlinear dynamic model, it has been found necessary to linearize the
model analytically around steady state. Finally, the linearized dynamic model has been represented
in the state space form to yield the required SISO transfer function.

2. Process description
Conventionally, among backward, forward and mixed feed based configurations BFF based
HEE system has been reported to be most satisfactory to concentrate the weak liquor due to a high
steam or energy efficiency and a low steam consumption [15,25,26]. Therefore, a BFF based
system has been selected in this study for the modeling, simulation and control. Fig. (1) illustrated
the process flow sketch of a BFF based HEE-MSE system which is being operated in a nearby
Indian Kraft Paper Mill located in north India for concentrating weak black liquor.

5
 Successive effects of HEE system have been numbered left to right from 1 to 7 respectively.
The black weak liquor in this BFF configuration enters at the bottom of 7th effect with flow rate,
Lf, concentration Xf and temperature, Tf. The live steam with flow rate S is introduced at the 1st
effect at temperature, Ts = 147C which while concentrating the black liquor moves counter
currently towards the last effect maintained at (T7 = 52C). The vapors from ith effect emerge with
flow rate, Vi, and temperature, Ti, respectively. The final concentrated black liquor as a biomass
fuel product is obtained from the bottom of the first effect with concentration, Xp, and temperature,
T1. The design and operational data required for simulation and control have been acquired from
a paper mill in proximity of Saharanpur city in India, and the same are presented in Table 1.

3. Problem formulation
3.1 Generalized steady state model
The steady state solution has been reported earlier using different numerical and intelligent
techniques such as Gauss Jordan, Gauss elimination, Jacobi iterative, GaussSeidel iterative,
Successive Over Relaxation (SOR), Interior-Point Method (I-PM) and Genetic Algorithm (GA)
for a BFF based heptads system [9,15].The heat transfers balances around shell-tube interface for
the 1st, ith (i = 26)and 7th effect are represented through Eqs. (1)(6).
S1 L2 h2 L1h1 ( L2 L1 ) H 2 0 (1)
U1 A1 (T1 T2 ) S1 (2)
( Li Li 1 )i Li 1hi 1 Li hi ( Li 1 Li ) Hi 1 0 (3)
U i Ai (Ti Ti 1 ) ( Li Li 1 )i (4)
( L7 L6 )7 L f h f L7 h7 ( L f L7 ) H8 0 (5)
U 7 A7 (T7 T8 ) ( L7 L6 )7 (6)
These set of representative energy balance equations yield a set of 14-simultaneous nonlinear
algebraic equations (SNLAE).

3.2 Generalized dynamic model

The dynamic total mass balance across the different effects may be expressed as
1st to 6th effects: dM i
Li 1 Li Vi , , Where i 1 to 6 (7)
dt
7th effect: dM 7
L f L7 V7 (8)
dt
The transient component balance yields

1st effect: d ( M1 X p )
L2 X 2 L1 X p (9)
dt

6
 On simplification yields: dX p L2 ( X 2 Xp ) X pV1
(10)
dt M1
Similarly, Eq. (10) is generalized for 2nd to 6th effects:
dX i L ( X X i ) X iVi
i 1 i 1 , Where i 1 to 6 (11)
dt Mi
And, for the 7th effect: dX 7 L f ( X f X 7 ) X 7V7
(12)
dt M7
The energy balance for the 1st to 7th effect are presented through Eqs.(13)(17)
d [ M 1h(T1 , X p )]
In the 1st effect: L2 h(T2 , X 2 ) S0 L1h(T1 , X p ) V1 H (T1 ) (13)
dt
Simplification of Eq. (13) yield,
d [h(T1 , X p )] L2 [h(T2 , X 2 ) h(T1 , X p )] S Ts V1[ H (T1 ) h(T1 , X p )]
(14)
dt M1
Similarly, for 2nd to 6th effect:
d [h(Ti , X i )] Li 1[h(Ti 1 , X i 1 ) h(Ti , X i )] Vi Ti Vi [ H (Ti ) h(Ti , X i )]
, Where i 2 to 6 (15)
dt Mi

7th effect: d [h(T7 , X 7 )] L f [h(T f , X f ) h(T7 , X 7 )] V6 T6 V7 [ H (T7 ) h(T7 , X 7 )]

(16)
dt M7

The empirical thermo-physical correlations have been developed previously for BFF based
HEE P&P mills [9,10]. These correlations for the enthalpy of black liquor (hL), condensate (hc)
and vapor () with latent heat of vaporization () are presented in Eqs. (17)(20).
hLi (4.187 2.26098 X i )TL i (17)
hci 4.15Ti (18)
Hi (T ) 0.0002045Ti 1.677Ti 2507
2
(19)
i Hi (T ) hc (T ) 0.00020457Ti 2.473Ti 2507
i
2
(20)
After incorporating these correlations, the modified energy balance assumes the following form:
1st effect: dT1 [{L2 (4.187 2.26098 X 2 )(T2 T1 )} S0 (Ts ) V1 (4.15T1 H (T1 )]
(21)
dt M1 (4.187 2.26098 X p )

2nd to 6th effects:

dTi [{Li 1 (4.187 2.26098 X i 1 )(Ti 1 Ti )} Vi 1i 1 (Ti ) Vi (4.15Ti H (Ti )]
, Where i 2 to 6 (22)
dt M i (4.187 2.26098 X i )

7th effect: dT7 [{L f (4.187 2.26098 X f )(T f T7 )} V66 (T7 ) V7 (4.15T7 H (T7 )]
(23)
dt M 7 (4.187 2.26098 X 7 )

4. Model solution
Controlling of such a complex nonlinear system developed and presented is a quite challenging
and tedious task. Therefore, a linear transfer function is needed either in the transfer function

7
(SISO) form or in the state space (MIMO) form. Hence, a linearization strategy has been proposed
to determine such a linear transfer function for the complex systems represented as a nonlinear set
of first order differential equations. The linearization of these equations has been attempted based
on the partial differential equations and Taylor series method similar to previous investigations
[27]. Such a linearization may provide sound understanding of dynamics to implement accurate
non-linear process control only when the operating point remains close to the steady-state
condition around which it has been linearized. Any excessive divergence of operation from steady-
state may deteriorate product quality of the multi-stage evaporators.

4.1 Linearization of dynamic model

Defining the state and input matrix using state and input variables as

x x1 x2 x3 x4 x5 x6 x7 x8 x9 x10 x11 x12 x13 x14 X1 X 2 X 3 X 4 X 5 X 6 X 7 T1 T2 T3 T4 T5 T6 T7 (24)

T T

u u1 u2 u3 u4 u5 u6 u7 L2
T
L3 L4 L5 L6 L7 Lf
T (25)

The state equation for the component mass balance for the 7th effect, the state equation reduces to

( L f x f u7 x7 ) (26)
x7 f 7 ( x, u )
M7
The energy balance yields Eqs. (27)(28) for 1st and 7th effect and Eq. (29) for 2nd to 6th effects.

u2 [(c1 c2 x2 ) x9 (c1 c2 x1 ) x8 )] K1 (Ts x8 ) (u2 u1 )[(c6 c7 x8 ) (c1 c2 x1 ) x8 ] c2 x8 [u2 x2 u1 x1 ] (27)

x8 f 8 ( x, u)
M 1 (c1 c2 x1 )
L f [(c1 c2 x f )T f (c1 c2 x7 ) x14 )] K 7 ( x13 x14 ) ( L f u7 )[(c6 c7 x14 ) (c1 c2 x7 ) x14 ] c2 x14[ L f x f u7 x7 ] (28)
x14 f14 ( x, u )
M 7 (c1 c2 x7 )
u [(c c x ) x (c c x ) x )] K i 7 ( xi 1 xi ) (ui 6 ui 7 )[(c6 c7 xi ) (c1 c2 xi 7 ) xi ] c2 xi [ui 6 xi 6 ui 7 xi 7 ] (29)
xi i 6 1 2 i 6 i 1 1 2 i 7 i f i ( x, u)
M i 7 (c1 c2 xi 7 )
The state equation so obtained is represented by Eq. (30).


x1 f1 ( x, u )
. . .
(30)
. . .


x n f n ( x, u )
where, X is a vector of 14 state variables and u is a vector of 7 input variables.

In vector notation, the above equation may be generalized as non-linear represented by Eq. (31)

x f ( x, u ) (31)
For the linearization of the state equation the elements of the linearization matrices are defined as:

8
 fi
A [a]ij
x j
x s ,u s
(32)
f
B [b]ij i
u j
x s ,u s

The linear state equation is, hence, represented as

(33)
x Ax Bu
The elements of state matrix, A aij are defined in Eqs. (34)(36).

Where, A aij , where i = 1 to 14 and j = 1 to 14 and for B bij , where i = 1 to 14 and i = 1 to 7.

f1 L f L f f1
a11 1 ; a12 1 2 ; a13 1 0.........a114 0;
x1 x s ,u s M 1 xs ,u s x2 x s ,u s M 1 xs ,u s x3 x s ,u s
x14 x s ,u s

f 2 f 2 L f L
a21 0; a22 2 ; a23 2 3 ;
x1 x2 M 2 x s ,u s x3 M 2 x s ,u s
x s ,u s x s ,u s x s ,u s

f f 2
a24 2 0........a214 0;
x4 x14

x s ,u s x s ,u s

f 3 L f L
a31 0; a32 0; a33 3 ; a34 3 4 ; a35....a314 0;
x3 M 2 x s ,u s x4 M 3 xs ,u s
x s ,u s x s ,u s
(34)
f L f L
a41.... a43 0; a43 4 4 ; a45 4 5 ; a46....a414 0;
x4
x s ,u s M 4 x ,u
s s
x5 x s ,u s M 4 x s ,u s
L L
f 5 f
a51.... a54 0; a55 5 ; a56 5 6 ; a57....a514 0;
x5 M 5 x s ,u s x6 M 5 x s ,u s

x s ,u s x s ,u s

f 6 L f L
a61.... a65 0; a66 6 ; a67 6 7 ; a68....a614 0;
x6 xs ,u s M 6 x s ,u s x7 x s ,u s M 6 x s ,u s

f L
a71.... a76 0; a77 7 7 ; a78....a714 0
x7 M 7 x s ,u s
x s ,u s
Defining the variables and after using these the state matrix elements assume the following form:
w1 u2 u1; w2 u3 u2 ; w3 u4 u3 ; w4 u5 u4 ; w5 u6 u5 ; w6 u7 u6 ; p1 (c1 c2 x1 ); p2 (c1 c2 x2 );

p3 (c1 c2 x3 ); p4 (c1 c2 x4 ); p5 (c1 c2 x5 ); p6 (c1 c2 x6 ); p7 (c1 c2 x7 ) and p f (c1 c2 X f ).

9
 f 8 [ M p {(c x u ) w1 (c 2 x8 ) (c 2 u1 x8 )}] u 2 { p 2 x9 p1 x8 } K 1 (Ts x8 ) w1{c 6 c 7 x8 p1 x8 } c 2 x8 (u 2 x 2 u1 x1 )][c 2 M 1 ]
a81 1 1 2 8 2
x1 x s ,u s ( M 1 p1 ) 2 x s ,u s

f 8 [ c 2 u 2 x 9 c 2 x 8 u 2 f 8 [u 2 p1 K 1 w1 (c 7 p1 ) c 2 (u 2 x 2 u1 x1 )
a82 ; a82 a83 a84 ..... a8 7 0; a88 ;
x 2 x ,u ( M 1 p1 ) x s ,u s x 8 x s ,u s ( M p
1 1 ) x s ,u s
s s

f 8 u2 p2 f 9
a89 ; a810 .... a814 0; a 91 0;
x9 x ,u M 1 p1 x ,u x1 x ,u
s s s s s s

f 9 [ M 2 p 2 {(c 2 x9 u 3 ) w2 (c 2 x8 ) (c 2 u 2 x 9 )}] u 3 { p 3 x10 p 2 x9 } K 2 ( x8 x9 ) w2 {c 6 c 7 x9 p 2 x 9 } c 2 x9 (u 3 x3 u 2 x 2 )][c 2 M 2 ]
a 92 ;
x 2 x ,u (M 2 p 2 ) 2 x s ,u s
s s

f 9 c 2 u 3 x10 c 2 x9 u 3 f 9 K2
a 93 ; a 94 .... a 97 0; a 98 ;
x3 x ,u (M 2 p 2 ) x s ,u s x8 x ,u ( M 2 p 2 ) x ,u

s s s s s s

f u p K 2 w2 (c 7 p 2 ) c 2 (u 3 x3 u 2 x 2 ) f 9 u 3 p3
a 99 9 3 2 ; a ; a a a a 0;
x9 x ,u x10 x ,u ( M 2 p 2 ) x ,u
910 911 912 913 914
s s
(M 2 p 2 ) x s ,u s s s


s s

a101 a102 0;
[ M 3 p 3 {(c 2 x10u 4 ) w3 (c 2 x10 ) (c 2 u 3 x10 )}] u 4 { p 4 x11 p 3 x10 } K 3 ( x9 x10 ) w3 {c 6 c 7 x10 p 3 x10 } c 2 x10 (u 4 x 4 u 3 x 3 )][c 2 M 3 ]
f 10
a103
x3 x ,u x s ,u s
2
(M 3 p3 )
s s

f c u x c x u f K3
a104 10 2 4 11 2 10 4 ; a105 a106 ...... a108 0; a109 10 ;
x 4 x ,u (M 3 p3 ) x s ,u s x 9 x ,u ( M 3 p 3 ) x ,u

s s s s s s

f 10 u 4 p 3 K 3 w3 (c 7 p 3 ) c 2 (u 4 x 4 u 3 x3 ) f 10 u4 p4
a1010 ; a1011 ; a1012 a1013 a1014 0;
x10 x ,u (M 3 p3 ) x s ,u s x 11 x s ,u s 3 3 x s ,u s
( M p )
s s

a111 a112 a113 0;
f 11 [ M 4 p 4 {(c 2 x11u 5 ) w4 (c 2 x11 ) (c 2 u 4 x11 )}] u 5 { p 5 x12 p 4 x11} K 4 ( x10 x11 ) w4 {c 6 c 7 x11 p 4 x11} c 2 x11 (u 5 x5 u 4 x 4 )][c 2 M 4 ]
a114 (35)
x 4 x ,u 2
s s
(M 4 p 4 ) x s ,u s

f c u x c x u f K4
a115 11 2 5 12 2 11 5 ; a116 a117 a118 a119 0; a1110 11 ;
x5 x ,u (M 4 p 4 ) x s ,u s x10 x ,u ( M 4 p 4 ) x ,u
s s s s s s

f 11 u 5 p 4 K 4 w4 (c 7 p 4 ) c 2 (u 5 x5 u 4 x 4 )
a1111 ;
x11 x ,u (M 4 p 4 ) x s ,u s

s s

f u p
a1112 11 5 5 ; a1113 a1114 0; a121 ....... a124 0;
x12 x ,u ( M 4 p 4 ) x ,u
s s

s s

f [ M p {(c x u ) w5 (c 2 x12 ) (c 2 u 5 x12 )}] u 6 { p 6 x13 p 5 x12 } K 5 ( x11 x12 ) w5 {c 6 c 7 x12 p 5 x12 } c 2 x12 (u 6 x 6 u 5 x5 )][c 2 M 5 ]
a125 12 5 5 2 12 6
x5 x ,u (M 5 p5 ) 2
s s x s ,u s

f c u x c x u f K5
a126 12 2 6 13 2 12 6 ; a127 ...... a1210 0; a1211 12 ;
x 6 x ,u (M 5 p5 ) x s ,u s x11 x ,u ( M 5 p 5 ) x ,u
s s s s s s
f 12 u 6 p 5 K 5 w5 (c 7 p 5 ) c 2 (u 6 x 6 u 5 x5 ) f 12 u 6 p6 f 12
a1212 ; a1213 ; a1214 0; a131 ....... a135 0;
x12 x ,u (M 5 p5 ) x s ,u s x13 x ,u ( M 5 p 5 ) x ,u x1 4 x ,u
s s s s s s s s

f 13 [ M 6 p 6 {(c 2 x13u 7 ) w6 (c 2 x13 ) (c 2 u 6 x13 )}] u 7 { p 7 x14 p 6 x13 } K 6 ( x12 x13 ) w6 {c 6 c 7 x13 p 6 x13 } c 2 x13 (u 7 x 7 u 6 x 6 )][c 2 M 6 ]
a136
x 6 x ,u (M 6 p6 ) 2 x s ,u s

s s

f 13 c 2 u 7 x14 c 2 x13u 7 f 13 K6
a137 ; a138 ...... a1311 0; a1312 ;
x 7 x ,u (M 6 p6 ) x s ,u s x12 x s ,u s 6 6 x s ,u s
( M p )
s s

f u p K 6 w6 (c 7 p 6 ) c 2 (u 7 x 7 u 6 x 6 )
a1313 13 7 6 ;
x13 x ,u (M 6 p6 )
s s x ,
s s u

f 13
a1314 0;
x1 4 x ,u
s s
The last row elements of state matrix, A aij are defined in Eq. (36).

10


a141 . . . . a146 0;

f14 [ M 7 p7 {(c2 x14 L f ) ( L f u 7 )(c2 x14 ) (c2 u 7 x14 )}] [ L f ( p f T f p7 x14 ) K 7 ( x13 x14 ) ( L f u 7 )(c6 c7 x14 p7 x14 ) c2 x14 ( L f X f L7 x7 )][c2 M 6 ] (36)
a147
x7 x ,u ( M 7 p7 ) 2 x s ,u s
s s

f K7 f L f p7 K 7 ( L f u 7 )(c7 p7 ) c2 ( L f x f u 7 x7 )
a148 ...... a1412 0; a1413 14 ; a1414 14 ;
x13 x ,u ( M 7 p7 ) x ,u x14 x ,u ( M 7 p7 ) x s ,u s
s s s s s s

The input matrix, B bij is defined in Eq. (37) below.

f1 x2 X p f1 x2 f f x x f x
b11 ; b12 ; b13 b14 ...... b17 0; b21 2 0; b22 2 3 2 ; b23 2 3 ;
u1 M 1 x ,u u2 M 1 x ,u u1 u2 M 2 x ,u u3 M 2 x ,u

s s s s s s s s

f 3 x4 x3 f 3 x4
b24 b25 ...... b27 0; b31 b32 0; b33 ; b ; b b ...... b 0;
u3 M 3 x ,u u4 M 2 x ,u
34 35 36 37
s s s s

f x x f x
b41 b42 b43 0; b44 4 5 4 ; b45 4 5 ; b46 b47 0; b51 b52 b53 b54 0;
u4 M 4 x ,u u5 M 4 x ,u
s s s s
f 5 x6 x5 f 5 x6 f 6 x7 x6
b55 ; b56 ; b57 0; b61 b62 .. b65 0; b66 ;
u5 M 5 x ,u u6 M 5 x ,u u6 M 6 x ,u
s s s s s s

f 6 x7 f 7 X f x7 (37)
b67 0; b71 b72 .. b76 0; b77
u7 M 6 x ,u u7 M 7 x ,u

s s s s

(4.187 2.26098 x2 )(T2 T1 ) (4.187 2.26098 x3 )(T3 T2 )

b81 ; b82 b83 ...... b87 0; b91 0; b92 ; b93 b94 . . . b97 0;
M 1 (4.187 2.26098 X p ) M 2 (4.187 2.26098 x2 )

(4.187 2.26098 x4 )(T4 T3 ) (4.187 2.26098 x5 )(T5 T4 )
b101 b102 0; b103 ; b104 b105 . . . b107 0; b111 b112 b113 0; b114 ;
M 3 (4.187 2.26098 x3 ) M 4 (4.187 2.26098 x4 )

(4.187 2.26098 x6 )(T6 T5 )
b115 b116 b117 0; b121 b122 . . . b124 0; b125 ; b126 b127 0; b131 b132 . . . b135 0;
M 5 (4.187 2.26098 x5 )

(4.187 2.26098 x7 )(T7 T6 ) ( 4. 187 2.26098 X )( T T )
b136 ; b127 0; b141 b142 . . . b146 0; b147 f f 7
;
M 6 (4.187 2.26098 x6 ) M 7 (4.187 2.26098 x7 )



Now, using the design and operational data presented in Table 1 and the steady state solution, the

evaluated A and B matrix of the state space Eq. (33) are represented by Eqs. (38)(39).

- 7.15 9.77 0 0 0 0 0 0 0 0 0 0 0 0
0 - 9.77 12.58 0 0 0 0 0 0 0 0 0 0 0

0 0 - 12.58 15.66 0 0 0 0 0 0 0 0 0 0

0 0 0 - 15.66 18.72 0 0 0 0 0 0 0 0 0
0 0 0 0 - 18.72 21.65 0 0 0 0 0 0 0 0

0 0 0 0 0 - 21.65 24.52 0 0 0 0 0 0 0
0 0 0 0 0 0 - 24.52 0 0 0 0 0 0 0
A (38)
518.91 186.63 0 0 0 0 0 - 8.55 10.65 0 0 0 0 0
0 - 170.60 53.32 0 0 0 0 - 1.93 - 11.16 13.21 0 0 0 0

0 0 - 179.32 58.76 0 0 0 0 - 1.96 - 14.03 16.17 0 0 0

0 0 0 - 41.83 40.40 0 0 0 0 - 2.08 - 17.05 19.12 0 0
0 0 0 0 - 1.32 43.44 0 0 0 0 - 2.02 - 20.00 21.94 0

0 0 0 0 0 - 12.92 34.97 0 0 0 0 - 1.91 - 22.94 24.81
0 - 1.84 - 26.08
0 0 0 0 0 - 293.33 0 0 0 0 0

11
 - 6.24E - 05 0 0 0 0 0 0
0 - 6.24E - 05 0 0 0 0 0

0 0 - 6.24E - 05 0 0 0 0

0 0 0 - 6.24E - 05 0 0 0
0 0 0 0 - 6.24E - 05 0 0

0 0 0 0 0 - 6.24E - 05 0
0 0 0 0 0 0 - 6.24E - 05 (39)
B
- 0.01444 0 0 0 0 0 0
0 - 0.00337 0 0 0 0 0

0 0 - 0.00308 0 0 0 0

0 0 0 - 0.00181 0 0 0
0 0 0 0 - 0.0017 0 0

0 0 0 0 0 - 0.00122 0
- 0.00101
0 0 0 0 0 0

4.2 State space representation

The linearized state space equation for the system dynamics as determined from the described
model is defined as-

x Ax Bu (state equation)
(40)
y Cx Du (Output equation)

Where the state, input and output vectors are expressed as:
x x1 x14 State variable

T
x2 x3 x4 x5 x6 x7 x8 x9 x10 x11 x12 x13


u L2 L2 s L3 L3s
L4 L4 s L5 L5 s L6 L6 s L7 L7 s L f L fs Input variable
T
(41)

y y1 y2 y3 y4 y5 y6 y7 y8 y9 y10 y11 y12 y13 y14 Output variable
T

The output matrix, C is an identity matrix of order 1414, whereas, feedthrough (or
feedforward) matrix, D is usually zero order, since, the system model does not have a direct
feedthrough.
4.3 Evaluation of SISO transfer function
The SISO input-output transfer function using previously obtained state space Eq. (40) is
defined by:
G(s) C (sI A) 1 B (42)

Where the elements of matrix B correspond to the previously defined input variables. The SISO
input-output transfer function,) gi1 (s), (i 1 7) relating the product concentration at various

12
effects, Xp to X7, to input feed flow rates, L2 to Lf, are computed and expressed as gii (i 1 7) in
Eq. (43).
- 6.24 e 05 ; - 6.24 e 05 ; - 6.24 e 05 ; - 6.24 e 05 ; - 6.24 e 05 ;
g11( s) g 22 ( s) g 33 ( s) g 44 ( s) g 55 ( s)
s 7.146 s 9.774 s 12.58 s 15.66 s 18.72
(43)
- 6.24 e 05 ; - 6.24 e 05
g 66 ( s) g 77 ( s)
s 21.65 s 24.52

5. Design of PID and FLC-PID controllers

The control of black liquor concentration for the HEE is proposed through design of two
different types of controllers, namely PID and Fuzzy-PID controllers. The goal is to track the
product concentration through a feed flow rate control while its set point is changed, and to
compare the dynamic performance of two controllers.

5.1 PID controller

A PID controller may regulate the feed liquor flow rate at feed stage, i.e., the 7th effect, after
receiving a measurement signal of product liquor concentration. PID controller is one of the most
commonly used industrial controller and sends out a control signal, u, that depends on generated
error, e(t). It consist of three parts: proportional, P, with output proportional to error, e(t), integral,
I, with output proportional to weighted sum of all previous errors with integral time, Ti, and
derivative term, D, proportional to derivative of error, with derivative time, Td.
The parallel form of PID controller has been simulated which on tuning using Z-N method
yields -3.9105, -1.8107 and 4.3103 values for P, I and D actions. Mathematically, the
compensated PID controller in time and Laplace domain may be represented by Eqs. (44)(45).
1
t
d
u (t ) K e(t ) e( )d Td e(t ) (44)
Ti 0 dt

1 N
U K P I D (45)
s 1 N
1

s

The value of coefficient, N, for parallel PID compensated filter in Laplace form has been found to
be 34.84.

5.2 Fuzzy logic based PID controller

Industrial controllers such as Proportional-Derivative (PD), Proportional-Integral (PI) and
Proportional-Integral-Derivative (PID) are usually linear in nature, while the most utilized FLC

13
controllers like PD (FLC-PD), PI (FLC-PI), and PID (FLC-PID) operate non-linearly. Among
these types, FLC-PIs are the most common and practical ones followed by FLC-PDs since they
contain the inherent stability (due to proportional action) and possess offset elimination capability
(due to integral action). The performance of FLC-PIs is recognized to be quite satisfactory for
linear first-order systems. However, their performance for higher order systems with integrating
elements and nonlinear systems is inferior due to a large overshoot and excessive oscillations [28].
Such systems may be eventually uncontrollable. FLC-PDs are appropriate for a limited class of
systems and not recommended in the presence of measurement noise and sudden load
disturbances. On the basis of these limitations, PID type FLC has been proposed to improve the
performance of PID controller.

Fuzzy-PID controller may achieve better tracking with optimal control parameters of
overshoot, rise time, settling time, etc. The basic structure of the FLC-PID is shown in Fig. (2)
which is based on a two-dimensional linear rule [29,30]. The Fuzzy controller used in this work is
an inherent variable gain Mamdani FLC-PID controller [31] and uses two linguistic variables, e
and e. It has been illustrated in Fig. (3a). The parallel structure of FLC-PID controller makes use
of two linguistic variables namely, error e(t), and rate of change of error, e(t). The subsequent
block consists of a rule base that indicates the Fuzzy linguistic variables NB, NS, ZE, PS and PB
representing negative big, negative small, zero, positive small and positive big, respectively as
shown in Fig. (3b) and (3c) [29]. These are symmetrical in the universe of discourse. The last block
of Fig. (2) represents the inherent properties of PID controller. The output signal, UFuzy PID is sent
to MSE process and influences the process parameters since it is almost directly proportional to
the input (e). This means that the proposed structure is a good approximation of the PID controller.
However, it includes three parameters (Kp, Ki and Kd) that can be tuned in order to have better
results. Additionally, each part of the proposed structure can be modified to tune controller
performance.

These have been defined here with 5-input and 7-output triangular membership functions with
as many as 75=35 rules. The rule base of the proposed FLC as shown in Fig. (3d) has rules of the
form:
If e(t) is xj and e(t) is yk, then output, qi = aj e(t) + bk e(t) (46)

14
where, i = 1, 2, , 7, j =1, 25, and k =1, 2.7; xj and yk are the membership functions defined
for e(t) and e(t) respectively, and qi is the consequent of the ith rule with real constants, aj and bk.
The derived FLC surface has been shown in Fig. (3e). After designing the Fuzzy rules for each
process gain region, the control response surfaces (output versus control error and change in
control error) are determined. These are depicted in Fig. (3e) for different regions. It may be
observed that even under similar conditions of e(t) and e(t), the control action is different in low-
gain and high-gain regions [24]. In the low-gain region, the control action is more aggressive as
compared to that in the high-gain region. This feature cannot be designed in the regular PID-type
Fuzzy controllers. Another observation is that the control surfaces are fairly nonlinear which
cannot be achieved using conventional PID controllers. The centroid defuzzyfication method has
been used to evaluate the output of FLC controller. Finally, the intermediate output of FLC is used
to get the final output of the fuzzy-PID controller.

5.3 Simulation of PID and Fuzzy-PID controlling action

To make a performance comparison of the effectiveness of proposed PID and Fuzzy-PID
controllers, a set point change is made in the product concentration. To verify the superior
performance of the proposed scheme over PID controller, its performance is compared with the
PID controller and FLC- PID in terms of several performance indices such as Integral Square Error
(ISE). The transfer functions determined earlier (in section 4) to relate product concentration at
each effect with their feed liquor flow rate are used to analyze controlling action of each. Although,
the HEE system is a highly complex and multivariable system, the transfer function considered
here for the simulation is a simpler SISO system. This is justified since the major controlling
variable that dictates the product concentration (single output) has been found previously to be
liquor flow rate (single input) [6]. The two controllers are compared for their performance on the
basis of control parameters namely, delay, rise, settling and peak time(s), and also undershoot,
overshoot, time constant and integral square error (ISE).
The simulated time domain transient responses of the HEE system with PID and Fuzzy-PID
controllers have been shown separately in Fig. (4a) and (4b) respectively, and together compared
in Fig. (4c) over a zoomed section. It is quite clear from these figures that there is a substantial
qualitative difference in the response of these controllers. A sharp difference in integral square
error is also evident from Fig. (4d).

15
 The main purpose of a controller is to track the change in set-point of control variable as soon
as possible with zero or minimum overshoot and error. The performance control parameters for
these two proposed controllers have been shown in Table 2. The simulations for the work have
been performed on Intel(R) Xeon(R) CPU E5-1650 0 @3.20GHz workstation using a developed
MATLAB code. The results show that FLC-PID controller shows a negligible overshoot of 0.0065
compared to 0.0894 for PID controller, ensuring a 92.7% reduction. Likewise, the undershoot for
the former is 0 compared to a marginal 0.1 for the later. Thus, FLC-PID controller achieves one
of the most important desirable requirement of ensuring that black liquor quality remains
unaffected to sudden fluctuations. To track the set-point, again FLC-PID has proven more efficient
because of its relatively lower integral square error (ISE) value. The ISE for FLC-PID is seen to
be reduced from 0.039 to 0.031, a 21% reduction, than that exhibited by PID controller.

A comparison of the speed of transient responses of two controllers indicates that FLC-PID
shows a delay time of 0.0195 compared to 0.025, a 28% improvement in response speed over the
PID controller. Likewise, the FLC-PID response settled 49% (0.08hr versus 0.1193hr for 5%
settling) and 48% (0.0947hr versus 0.14hr for 2% settling) faster than the simpler PID control. The
time constant that defines the ultimate speed of system has been found to be only marginally
reduced from 0.034hr to 0.032hr, a 6% improvement in speed for FLC-PID compared to that of
PID controller. Rise time defined as the time required by the response to reach from 0 to 100%
value of final value has also been captured for two cases. FLC-PID response, however, is found
here to show a compromise and exhibits a 49% increase in rise time to 0.1178hr up from 0.06hr
for PID.

6. Conclusions and discussion

In this paper, an attempt has been made to linearize a complex nonlinear dynamic model of
HEE system and determine the system transfer functions after an exhaustive state space
representation effort. The transfer functions so determined help to design an intelligent Mamdani
type Fuzzy Logic Proportional-Integral-Derivative (FLC-PID) and conventional PID controller,
and thereby, simulate and compare their response to set point change in product concentration.
The simulations indicate that the proposed FLC-PID control scheme offered several advantages
over PID in terms of exhibiting a minimum ISE, approximately zero overshoot and undershoot
with minimum delay, settling, peak time and time constant. Further, since every technique has its

16
own pros and cons, it is quite pertinent to kept these in mind while critically screening one. The
controller designed in this work is not an exception and also possesses some limitations. In this
line of thought, while the FLC-PID exhibited a larger rise time, and hence, slower response initially
than conventional PID, the response is found to settle quite faster to its final value with minimum
overshoot and undershoot. It is proposed that the rise time of the designed FLC-PID may be
reduced through hybridizing it with artificial techniques such as Artificial Neural Network (ANN)
in future.

Acknowledgement
Mr. Om Prakash Verma would like to thank Ministry of Human Resource Development, New
Delhi, India for providing the Senior Research Fellowship for this work and Graphic Era
University, Dehradun to grant study leave to pursue Ph.D. Also, the authors are thankful to
Director of Star Paper Mill, Saharanpur, India for permissions to visit the mill time to time and
collect the real-time plant data. The authors would like to acknowledge Prof. A. K. Ray
(Department of Polymer and Process Engineering) from Indian Institute of Technology Roorkee
for some of his useful suggestions and discussions related to the problem.

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19
 Om Prakash Verma received his B. E. degree in Electronics and Instrumentation in 2008 from
Institute of Engineering and Technology, India and M.Tech in Control and Instrumentation in 2012
from National Institute of Technology (NIT) Jalandhar, India. He is currently pursuing full time
PhD from Indian Institute of Technology Roorkee, India in process modeling, control and
optimization. Before Ph.D., he has worked with the Graphic Era University, Dehradun in
department of Instrumentation and Control Engineering, as an Assistant professor. His current
research interests include modeling, simulation, optimization and control of chemical processes.
He is associated with various reputed international journals as a reviewer including Science
Citation Indexed and Scopus Indexed. He is a life member of Instrument Society of India, India.
He has been published several papers in reputed journals in the field of modeling, simulation and
control of industrial process.

Dr. Gaurav Manik is currently serving as Assistant Professor in the Department of Polymer and
Process Engineering, IIT Roorkee, India. He received his Bachelors in Chemical Engineering
from HBTI, Kanpur (India), and his Masters in Chemical Engineering from the IIT Kanpur
(India). He received his Ph.D. degree from IIT Bombay (India). Prior to working at IIT, Roorkee,
Dr. Manik had some useful research and academic stints in 3M as Senior Manager (Technical),
Birla Institute of Technology and Science, Pilani, India and Bundelkhand Institute of Engineering
and Technology, Jhansi, India. He has also served as Visiting Faculty to Asian Institute of
Technology, Thailand. His research interests include Process modeling and optimization,
Molecular modeling and simulations, Easy-clean hydrophobic and oleophobic coatings. His
academic teaching interests include Process modeling, control and optimization, Mass and heat
transfer, new product development and lifecycle management. He has published a numbers of
papers in reputed journals in the field of Process modeling and optimization, Molecular modeling
and simulations, and has few patent applications to his credit.

Vinay Kumar Jain received his B.E. in Computer Science and Engineering in 2009 from Rajiv
Gandhi Proudyogiki Vishwavidyala, Bhopal, India and received his M.Tech in Computer Science
and Engineering from Jaypee University of Engineering and Technology, Guna, M.P., India in
2012. Now, he is pursuing his Ph.D. degree from Jaypee University of Engineering and
Technology, Guna, M.P., India. He has published several papers in peer-reviewed International
and Scientific Journals. He is also serving has reviewer for several Science Citation Indexed and
Scopus Indexed International Journals.

20
 Fig. 1 Backward feed HEE system

Fig. 2 Formula based structure of Fuzzy-PID controller

(a) (b)

21
 (c) (d)

(e)
Fig. 3 Description of (a) FLC Mamdani property (b) Input membership function (c) Output membership function (d) Rule
base and (e) FLC Surface view

(a) (b)

22
 (c) (d)
Fig. 4 Illustration of (a) PID controller and (b) FLC-PID tracking of set point change in product
concentration (c) Comparison of PID controller and FLC-PID performance for a set-point change and (d)
ISE plot for PID and FLC-PID controller

23
Table 1 Operating parameters of HEE (Data presented here has been taken from a nearby paper mill,
Saharanpur, U.P., India)
Parameter Value (s)
Total number of effects, i 07
Inlet black liquor concentration, Xf 0.118
Inlet liquor temperature, Tf 65 (in C)
Feed flow rate of black liquor, Lf 15.611(in kg/sec)
Last effect vapor temperature (7th effect), T7 52, (in C)
Area, A1-A2, A3 A6 and A7 540,660 and 690 (in m2)
Inlet liquor enthalpy, hf 254.81 (kJ/h)
Exit latent heat of vaporization, 8 2379 (kJ/h)
Mass hold-up for each effects, (For dynamic Analysis), Mi 0 0.833 (kg)
Feed flow sequence Backward feed flow

Table 2 Performance analysis of control parameters

Parameter PID FLC-PID
Delay time (in hr) 0.025 0.0195
Rise time (in hr) 0.0600 0.1178
For 5% 0.1193 0.08
Settling time (in hr)
For 2% 0.14 0.0947
Peak time (in hr) 0.095 0.144
Undershoot 0.1 0
Overshoot 0.0894 0.0065
Time constant 0.034 0.032
Integral square error (ISE) 0.039 0.031

24