CHE 403

Chemical Process Control

2022-23 Fall Term

Prof. Dr. Selahattin Gültekin

Üsküdar University
Chemical Engineering Department
 Lumped vs. Distributed
Example:
Tubular Heat Exchanger (Distributed Parameter System)

C AT
p
z
  C p AT  t   AzC T  t
z z
p

Divide by ΔT and Δz and take them to zero

T T
AC p   A C p  Q D Q  U Tst  T 
t z
T T
AC p   A C p   DU Tst  T  PDE
t z
Modeling of a Binary Distillation Column

• Top: Nth plate (see Figure 4.12)

• Bottom: 1st plate
In a distillation column of 20 trays we will have:
2N + 4 = 44 differential equations, and
2N + 1 = 41 algebraic equations
Total: 85 equations.
These 85 equations for a binary mixture of a model distillation column still impose good deal of complexity
Difficulties in Mathematical Modeling
Poorly understood physical and chemical processes.
Values of parameters may not be known exactly (Cp,
ρ, k0, etc.).
Complexity of the resulting model:
multicomponent reaction systems the interactions
between the components may not bIn e known exactly.
Vapor-Liquid (V-L) and Liquid-Liquid (L-L) thermodynamic
equilibria may not be clear.
Heat and mass transfer interactions in distillation
columns with non-ideal systems.
 Relationship between Modeling and Process Control
Good mathematical modeling of physical and chemical processes requires a good deal of
experience.

Modeling is a kind of scientific art. Modeling is getting better with experience and good
background.
Mathematical modeling is essential for a good process control.

With mathematical modeling we will see the degrees of

freedom for a given process, and we can go ahead and design

the control of a process.

There is a strict relationship between degrees of freedom and control problems.

Example
 Degree of Freedom
It indicates the number of independent variables to be specified to define the process
completely.
To design a controlled process, all independent variables must be specified for control
purposes. degrees of freedom must be ZERO.
Mathematical model is required to design a control system effectively.
Mathematical modeling may include static and dynamic conditions.

Example: Consider Figure 4.19

Say Q>0
Total mass balance (ρ=constant):
Energy balance:
♯ of variables: Ti, Fi, h, T, Q, F (6)
♯ of independent equations: (2)
We may arbitrarily specify four of six variables. This may be stated
that we have four degrees of freedom.
If somebody would like to reproduce the same system, we must
furnish him with all variables specified.
Shortly, in order to specify a process completely f must be ZERO.
If f=0, the system is exactly defined. v = E
If f>0, the system is underspecified (underdefined) and we do not
have unique solution, rather we have multiple solutions. v > E
If f<0, the system is overspecified. v < E. In general there is no
solution.
Introduction of a control loop into system will reduce the number of
degrees of freedom by 1. Because it relates the measured quantity to
the manipulated variable, thus, introduce an extra relationship
(equation)!
Example:
In the above stirred tank heater:
v = 6, E = 2, f = 4 this is true if F is determined by a pump or
valve. If F is function of h in the system, say (turbulent flow), then we
have an extra equation.
Example: Q is manipulated by T, and F is manipulated by
Let’s consider the stirred heating tank with feedback control loops.
h, therefore, as if we had two extra equations
(loop number 1 and number 2). Therefore, the
number of degrees of freedom reduced by 2,
hence f = 6-4 (two of it from loops) = 2. If we
specify, Fi and Ti then the system will be
completely defined.
 Degrees of Freedom and Process Controller
Generally f > 0, therefore, we will have infinite number of solutions. Then what
should we do to reduce f to zero. For that we need to introduce f additional
equations to reduce f to zero so that have a unique behavior (solution).
There are two sources to reduce f:
1. External world
2.The control system
Recall that in our stirred heating tank we had f=4. Fi and Ti are two main
disturbances, and generally they are controlled by the external world. They may
come from an upstream unit on which we have no control. The equations
determining Fi and Ti may not be known by us, nevertheless, they remove two
degrees of freedom.
Having two additional loops for T and h control, then eventually we have f=0. In
other words, the system is completely specified.
What should be considered in modeling for process control?
Modeling is not a trivial task, it must be done carefully. Before we attempt to
model a system for control purposes, we must consider the following points:
What are the control objectives?
What are the disturbances and their impact on the process?
What are the physical and/or chemical processes taking place in the system to
be controlled?
Let us consider each one individually.
1. Control Objectives
a. Ensuring the stability of process, or
b. Suppressing the effects of disturbances, or
c. Optimizing the performance of the plant, or
d. Combination all of the above.
Objectives could be controlling T, P, F, x, V etc.

 Linearization
Most of the real life chemical processes can be modeled by non-
linear differential equations.
Since there is no general solution for non-linear differential
equations, it is essential to linearize a differential non-linear
equation.
 After that, a Laplace Transformation can be applied to get
transformed form (in complex variable) of an algebraic equation.
After rearrangement of the equation one can get the transformed
form of output variable in terms of other variables.
 Finally invers transform will be taken to get the output variable
in time domain.
How can we linearize a non-linear equation? By using Taylor
Series Expansion.
Linearization

df
f  x   f  x0    x  x0 
dx x0
Taylor Series Expansion
 Taylor Series Expansion
This expansion into Taylor series will be very close to the
reality if x0 is very close to x.
The approximation is only exact at the point of linearization.
In process control, x0 is generally representing steady-state
point, deviation from x0 is very small, and therefore Taylor
series expansion can be used safely as far as process control
is concerned.
Linearization