Chemical Engineering Course (undergraduate)

Pengendalian Process
(Process Control)
Presented by:
Achmad Chafidz M. S., S.T., M.Sc.
Chemical Engineering Department, Semarang State University

Universitas Negeri Semarang (UNNES)

Semester Genap 2015/2016

Handbooks
1. Thomas E. Marlin
Process Control, Designing Processes and
Control System for Dynamic Performance,
2nd edition, 2000, McGraw-Hill International
2. Dale E. Seborg
Process Dynamics and Control, 2nd edition,
2004, John Wiley & Sons, Inc.
3. William L. Luyben
Process modeling, simulation, and control
for chemical engineers, 2nd edition, 1990,
McGraw-Hill International

CHAPTER 3 : MATHEMATICAL
MODELLING PRINCIPLES
Outline of the lesson.

Reasons why we need dynamic models

Six (6) - step modelling procedure
Many examples
- mixing tank
- CSTR
- draining tank

WHY WE NEED DYNAMIC MODELS

Feed material is delivered periodically, but the process
requires a continuous feed flow. How large should should
the tank volume be?
Periodic Delivery flow
Continuous
Feed to process

Time

We must provide
process flexibility
for good
dynamic performance!

WHY WE NEED DYNAMIC MODELS

The cooling water pumps have failed. How long do we have
until the exothermic reactor runs away?
Temperature

Dangerous

A
time

Process dynamics
are important
for safety!

WHY WE DEVELOP MATHEMATICAL MODELS?

Input change,
e.g., step in
coolant flow rate

Process

Effect on
output
variable

T
A

Math models
help us answer
these questions!

How does the

process
influence the
response?

How far?
How fast

Shape

SIX-STEP MODELLING PROCEDURE

1. Define Goals
2. Prepare
information
3. Formulate
the model

- Specific design
- Specific numerical values at what time will the
liquid in the tank overflow
- Functional relationship How would the flow
rate and tank volume influence the time that the
overflow will occur

4. Determine
the solution

5. Analyze
Results
6. Validate the
model

SIX-STEP MODELLING PROCEDURE

1. Define Goals
2. Prepare
information

Sketch process &

identity the system
Identify variables of
interest

3. Formulate
the model

Collect data & state

assumptions

4. Determine
the solution

Examples of variable selection

liquid level total mass in liquid

5. Analyze
Results

pressure total moles in vapor

6. Validate the
model

concentration component mass

temperature energy balance

T
A

Variable(s) are the

same for any
location within
the system!

SIX-STEP MODELLING PROCEDURE

1. Define Goals
2. Prepare
information
3. Formulate
the model
4. Determine
the solution

5. Analyze
Results
6. Validate the
model

What type of equations do we use first?

Conservation balances for key variable

How many equations do we need?

Degrees of freedom = NV - NE = 0

What after conservation balances?

Constitutive
equations, e.g.,
Q = h A (T)
rA = k 0 e -E/RT

Not
fundamental,
based on
empirical data

SIX-STEP MODELLING PROCEDURE

1. Define Goals
2. Prepare
information
3. Formulate
the model
4. Determine
the solution

5. Analyze
Results

CONSERVATION BALANCES
Overall Material

Accumulati on of mass mass in mass out

Component Material
Accumulati on of component component

component
mass
mass
in

mass out
generation of

component mass

Energy*

6. Validate the
model
* Assumes that the system volume does not change

SIX-STEP MODELLING PROCEDURE

1. Define Goals
2. Prepare
information
3. Formulate
the model
4. Determine
the solution

5. Analyze
Results
6. Validate the
model

CONSERVATION BALANCES
Energy*
Which can be written for a system with constant volume
as:
Accumulati on

H PE KEin H PE KEout
U PE KE
Q - Ws

SIX-STEP MODELLING PROCEDURE

1. Define Goals
2. Prepare
information
3. Formulate
the model
4. Determine
the solution

5. Analyze
Results
6. Validate the
model

Our dynamic models will involve

differential (and algebraic) equations
because of the accumulation terms.

dC A
V
F (C A0 C A ) VkC A
dt
With initial conditions
CA = 3.2 kg-mole/m3 at t = 0
And some change to an input
variable, the forcing function, e.g.,
CA0 = f(t) = 2.1 t (ramp function)

SIX-STEP MODELLING PROCEDURE

1. Define Goals
2. Prepare
information
3. Formulate
the model
4. Determine
the solution

5. Analyze
Results
6. Validate the
model

We need to solve simple models analytically

to provide excellent relationship between
process and dynamic response, e.g.,

C A (t ) C A (t ) t 0 ( C A0 )K(1 e t / )
for t 0
Many results will have the same form!
We want to know how the process
influences K and , e.g.,
F
V
K

F kV
F Vk
Steady-state gain

Time constant

SIX-STEP MODELLING PROCEDURE

1. Define Goals
2. Prepare
information
3. Formulate
the model
4. Determine
the solution

5. Analyze
Results
6. Validate the
model

We can solve complex models numerically,

e.g.,

dC A
V
F (C A0 C A ) VkC A2
dt
Using a difference approximation for the
derivative, we can derive the Euler method.

C An C An1

F (C A0 C A ) VkC A2
( t )

n 1

Other methods include Runge-Kutta and

Adams.

SIX-STEP MODELLING PROCEDURE

1. Define Goals
2. Prepare
information
3. Formulate
the model
4. Determine
the solution

Check results for correctness

- sign and shape as expected
- obeys assumptions
- negligible numerical errors

Plot results
Evaluate sensitivity & accuracy

5. Analyze
Results
6. Validate the
model

Compare with empirical data

MODELLING EXAMPLE 3.1. MIXING TANK

Textbook Example 3.1: The mixing tank in the figure has
been operating for a long time with a feed concentration of
0.925 kg-mole/m3. The feed composition experiences a step
to 1.85 kg-mole/m3. All other variables are constant.
Determine the dynamic response.

F
CA0

(Well solve this in class.)

CA

MODELLING EXAMPLE 3.1. MIXING TANK

MODELLING EXAMPLE 3.1. MIXING TANK

The equations are derived based on fundamental
principles, which categorized into: conservation and
constitutive.
The conservation balances are relationships that
are obeyed by all physical systems and valid for
chemical process
General lumped-parameter
system

The conservation equations most often used in

process control are: material (overall and
component), energy, and momentum.

MODELLING EXAMPLE 3.1. MIXING TANK

MODELLING EXAMPLE 3.1. MIXING TANK

Some examples of constitutive equations:

MODELLING EXAMPLE 3.1. MIXING TANK

Model Formulation
Since this problem involves concentrations, overall and component balances
will be prepared
The overall material balances for an increment t is:

MODELLING EXAMPLE 3.1. MIXING TANK

This result, stated as an assumption hereafter, will be used for all tanks with
overflow.
The next step is to formulate a material balance on component A. Since the
tank is well-mixed, the tank and outlet concentration are the same.

MODELLING EXAMPLE 3.1. MIXING TANK

MODELLING EXAMPLE 3.1. MIXING TANK

Mathematical solution

MODELLING EXAMPLE 3.1. MIXING TANK

Mathematical solution with Integrating factor

MODELLING EXAMPLE 3.1. MIXING TANK

MODELLING EXAMPLE 3.1. MIXING TANK

MODELLING EXAMPLE 3.1. MIXING TANK

MODELLING EXAMPLE 3.1. MIXING TANK

MODELLING EXAMPLE 3.1. MIXING TANK

MODELLING EXAMPLE 3.2. CSTR

The dynamic response of a continuous-flow. Stirred-tank chemical reactor
(CSTR) will be determined in this example.

MODELLING EXAMPLE 3.2. CSTR

OR

Karakteristik Model

Time constant()

BESAR berarti respon dinamiknya LAMBAT

KECIL berarti respon dinamiknya CEPAT

Process gain (K)

Perubahan output (respon) dibagi perubahan input

3 Solusi Model Dinamik

Solusi dengan Faktor Integral

Solusi Eksak

Solusi dengan Transformasi LAPLACE

33

MODELLING EXAMPLE 3.3. TWO CSTRs

Two isothermal CSTRs are initially at steady state and
experience a step change to the feed composition to the
first tank. Formulate the model for CA2. Be especially
careful when defining the system!

F
CA0

A B
rA kC A

CA1

V1
CA2

(Well solve this in class.)

V2

MODELLING EXAMPLE 3.3. TWO CSTRs

Dynamic response for example 3.3

MODELLING EXAMPLE 3.5. N-L CSTR

Textbook Example 3.5: The isothermal, CSTR in the figure
has been operating for a long time with a constant feed
concentration. The feed composition experiences a step.
All other variables are constant. Determine the dynamic
response of CA.
Non-linear!
F
CA0

A B
rA kC A2

(Well solve this in class.)

CA

MODELLING EXAMPLE 3.5. N-L CSTR

We solve the linearized model analytically and the non-linear
numerically.

Deviation variables
do not change the
answer, just
translate the values

In this case, the

linearized
approximation is
close to the
exactnon-linear
solution.

MODELLING EXAMPLE 3.6. DRAINING TANK

Textbook Example 3.6: The tank with a drain has a
continuous flow in and out. It has achieved initial steady
state when a step decrease occurs to the flow in. Determine
the level as a function of time.

Solve the non-linear and linearized models.

MODELLING EXAMPLE 3.6. DRAINING TANK

Small flow change:

linearized
approximation is good

Large flow change:

linearized model is
poor the answer is
physically impossible!
(Why?)