Process Dynamics and

Control
W 10:00-12:00

Engr. Rowena B. Carpio

rbcarpio@yahoo.com
Consultation hours:

Course Description
This course combines the mathematical, physical and
chemical concepts for application to process
simulation and control.
This is an introductory part for process control design
and analysis.
Whenever appropriate, MATLAB is used to
demonstrate the behavior of the control system.

Pre-requisite
Differential equations
Transport processes

Course Objectives
1. Develop dynamic (time-dependent)
mathematical models of several chemical
engineering processes
2. Develop transfer functions relating response to
the forcing function
3. Know the response of the process to some
forcing functions (step, impulse, sinusoidal (etc.)
4. Know and analyze feedback control systems and
its stability
5. Analyze the overall plant dynamics and
characteristics

References
TEXTBOOK:
Coughanowr D.R., and Le Banc S. E, Process Systems Analysis and Control ,3rd
Edition, McGraw-Hill, 2008
REFERENCES:
1. Bartelt, T., Instrumentation and Process Control, Australia: Thomson Delmar
Learning, 2007
2. LeBlanc, S. E., Process Systems Analysis and Control, Boston: McGraw-Hill 2009
3. Luyben W.L., Process Modeling, Simulation and Control for Chemical Engineers,
McGraw-Hill, 1990
4. Marlin, T. E., Process Control, Designing Processes and Control Systems for
Dynamic Performance, 2nd Edition, McGraw-Hill, 2000
5. Shinskey, F. G., Process Control Systems, Application, Design and Adjustments,
3rd Edition, McGraw-Hill, 1988.
6. Seborg, D. E., Edgar, T.F., and Mellichamp D.A., Process Dynamics and Control,
2nd Edition, John Wiley and Sons, 20004.
7. Smith, C. A., Automated Continuous Control, John Wiley and Sons, 2002

Process Dynamics & Control

Process Dynamics

Process Control

Refers to unsteady-state or
transient behavior
Steady-state vs. unsteadystate behavior
Identifying process
parameters that affect the
output or the product.

is an engineering
application that deals with
regulating/ controlling
process variables in order to
maintain the output within
the desired range.
combines chemical process
knowledge and the
understanding of the
dynamics of the systems

Objectives of Process control

Reduce variability
Reduce costs
Increase efficiency
Increase productivity
Ensure safety

Illustrative Example 1
Stirred-tank blending/mixing system

Practical example:
Production of brine solution or salt water from raw seawater for mariculture .

How do we control processes?

1. Identify:
Controlled variable (or output variable)
Manipulated variable (or input variable)
Disturbance variable (or load variable)
2. Design Question
3. Process design equation (i.e. at steady state condition,
unsteady-state or transient condition)
- governed by (or combination of) physical, chemical or energy
principle.

4. Control Question
5. Control strategy

How do we control processes?

Illustrative Example 1 : Stirred-tank blending/mixing system (cont.)
Controlled variable (or output variable): x
Manipulated variable (or input variable): w2
Disturbance variable (or load variable): x1

Design Question:
What value of w2 is required to have X = Xsp?
Process design equation:
Mass balance

Control Question.
Suppose that the inlet concentration x1 changes with time. How can we
ensure that x remains at or near the set point Xsp?

How do we control processes?

Illustrative Example 1 : Stirred-tank blending/mixing system (cont.)

Possible control strategies

Method 1. Measure x and adjust w2.
Manual control vs. automatic
control
Proportional feedback control
law,
where:
Kc is called the controller gain.
w2(t) and x(t) denote variables that change
with time t.
The change in the flow rate,
is
proportional to the deviation from the set
point, xSP x(t)

Feedback Control

How do we control processes?

Illustrative Example 1
Stirred-tank blending/mixing system

Practical example:
Production of brine solution or salt
water from raw seawater for
mariculture .

How do we control processes?

Illustrative Example 1 : Stirred-tank blending/mixing system (cont.)

Possible control strategies

Method 2. Measure x1 and adjust w2.

Feedforward Control

Feedback vs. Feedforward Control

Feedback

Feedforward

Distinguishing feature:

measure the controlled variable

It is important to make a distinction between

negative feedback and positive feedback.
Advantages:

Corrective action is taken regardless of the

source of the disturbance.

Reduces sensitivity of the controlled variable to

disturbances and changes in the process (shown
later)
Disadvantages:

No corrective action occurs until after the

disturbance has upset the process, that is, until
after x differs from xsp.

Very oscillatory responses, or even instability

Distinguishing feature:

measure a disturbance variable

Advantage:

Correct for disturbance before it upsets the

process.
Disadvantage:

Must be able to measure the disturbance.

No corrective action for unmeasured

disturbances.

Illustrative example 2
Agitated heated tank with hold-up volume V
1. A liquid stream at temperature Ti is available at a constant flow rate of w
in units of mass per time. It is desired to heat this stream to a higher
temperature TR (setpoint).
2. Heated fluid is removed from the bottom of the tank at the flow rate w
as the product of this heating process.
Process variables?
Design question?
Process design equation?
- assumption(s)?
Control questions?
Control strategies?

Illustrative example 2
Agitated heated tank (cont.)
Process Control Variables?
Controlled variable (or output variable) T
Manipulated variable (or input variable) Q
Disturbance variable (or load variable) Ti

Illustrative example 2
Agitated heated tank (cont.)
Design Question?
How much heat (Q) must be supplied by the heater to the
system such that T = TR ?

Illustrative example 2
Agitated heated tank (cont.)
Process Design Equation?
Energy balance
at steady-state condition,
with set point TR
The subscript s
denotes steadystate condition

Assumptions?
1. Tank is perfectly mixed
2. Heat losses are negligible
3. Heat capacity and density () of the fluid are constant

Illustrative example 2
Agitated heated tank (cont.)
Control Question?
Suppose that the inlet temperature Ti changes with time. How
can we ensure that T remains at or near the set point TR?

Illustrative example 2
Agitated heated tank (cont.)
Control Strategy(ies)?
Strategy 1 (Feedback control w/ manual or automatic
proportional control)

Error difference
bet the setpoint
and the value of
controlled variable

Block diagram
Provide a good overall picture of the relationships among
variables in the control system.
This diagram, indicates the flow of information around the
control system and the function of each part of the system.

Block diagram
(Exercise 1)
Develop the block diagram for the stirred-tank
blending control system shown below.

Block diagram
(Group assignment 1, Nov 14, 2012)
Draw a block diagram for the control system
generated when a human being steers an
automobile.