Confirming Pages

CHAPTER

10
BLOCK DIAGRAM OF A
CHEMICAL-REACTOR
CONTROL SYSTEM

T o tie together the principles developed thus far and to illustrate further the procedure
for reduction of a physical control system to a block diagram, we consider in this
chapter the two-tank chemical-reactor control system of Fig. 10–1. This entire chapter
serves as an example and may be omitted by the reader with no loss in continuity.

Set point
composition
Pure A
Controller

m F + rm ≅ F
A
F
c0 Composition
Product measuring
stream element
V, T1, c1, k1 V, T2, c2, k2

Sample
stream

Heating
coil

FIGURE 10–1
Control of a stirred-tank chemical reactor.

205

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206 PART 3 LINEAR CLOSED-LOOP SYSTEMS

10.1 DESCRIPTION OF SYSTEM

A liquid stream enters tank 1 at a volumetric flow rate F cfm and contains reactant A
at a concentration of c0 mol A/ft3. Reactant A decomposes in the tanks according to the
irreversible chemical reaction

A → B

The reaction is first-order and proceeds at a rate

rA
kc

where rA
rate of formation of A, (mol A)/(ft3 · time)

c
concentration of A, mol A/ft3
k
reaction rate constant (a function of temperature), time1 (k1 ≡ tank 1,
k2 ≡ tank 2)

The reaction is to be carried out in a series of two continuous stirred-tank reac-

tors. The tanks are maintained at different temperatures. The temperature in tank 2 is to
be greater than the temperature in tank 1, with the result that k2, the reaction rate con-
stant in tank 2, is greater than that in tank 1, k1. We will neglect any changes in physical
properties due to chemical reaction.
The purpose of the control system is to maintain c2, the concentration of A leav-
ing tank 2, at some desired value in spite of variations in the inlet concentration c0. This
will be accomplished by adding a stream of pure A to tank 1 through a control valve.
We wish to produce a block diagram for the process so that we can simulate its response
to changes in inlet concentration.

10.2 REACTOR TRANSFER FUNCTIONS

We begin the analysis by making a material balance on A around tank 1; thus

dc1  m
V
Fc0  m  F   c1  K
1Vc1 (10.1)

dt  rA
accumulation of A
flow of A into    reaction rate
tank 1 flow of A out of o f A in tank 1
in tank 1 tank 1

where m
molar flow rate of pure A through valve, (lb · mol/min)

rA
density of pure A (lb · mol/ft3)
V
holdup volume of tank, a constant (ft3)

It is assumed that the volumetric flow of A through the valve m/rA is much less than the
inlet flow rate F, with the result that Eq. (10.1) can be written

dc1
V  ( F  k1V ) c1
Fc0  m (10.2)
dt

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CHAPTER 10 BLOCK DIAGRAM OF A CHEMICAL-REACTOR CONTROL SYSTEM 207

This last equation may be written in the form

V dc1 F 1
 c1
c0  m
F  k1V dt F  k1V F  k1V
dc1 1 1/F
t1  c1
c0  m (10.3)
dt 1  k1t 1  k1t

V
where t
residence time for each tank
, (time)
F
V t
t1
effective time constant for tank 1

, (time)
F  k1V 1  k1t

At steady state, dc1/dt
0, and Eq. (10.3) becomes

1 1F
c1s
c0s  ms (10.4)
1  k1t 1  k1t
where s refers to steady state.
Subtracting Eq. (10.4) from Eq. (10.3) and introducing the deviation variables
C1
c1  c1s
C0
c0  c0s
M
m  ms
give
dC1 1 1F
t1  C1
C0  M (10.5)
dt 1  k1t 1  k1t

Taking the transform of Eq. (10.5) yields the transfer function of the first reactor:

Transfer
1/ (1  k1t ) 
C0 ( s )  M ( s ) 
1
function for C1 ( s )
(10.6)
tank 1 t 1s  1  F 

A material balance on A around tank 2 gives

dc2
V
Fc

1  Fc2

 k
2Vc2 (10.7)
dt
 flow of A flow of A reaction rate
accumulation of A into tank 2 out tank 2 of A in tank 2
in tank 2

Rearranging gives
dc2
V  ( F  k2 V ) c2
Fc1
dt
V dc2 F (10.7a)
 c2
c1
F  k2V dt F  k2 V

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208 PART 3 LINEAR CLOSED-LOOP SYSTEMS

As with tank 1, Eq. (10.7a) can be written in terms of deviation variables and arranged
to give
dC2 1
t2  C2
C1 (10.8)
dt 1  k2t
where C2 is the deviation variable for tank 2, C2
c2  c2s , and t2 is the effective
time constant for tank 2,
V V F t
t2



F  k2 V 1  k2 ( V F ) 1  k2t

Taking the transform of Eq. (10.8) gives the transfer function for the second reactor:

Transfer
1/ (1  k2t )
function for C2 ( s )
C1 ( s ) (10.9)
tank 2 t 2s  1

To obtain some numerical results, we will assume the following data to apply to
the system:

MWA
100 lb/lb · mol A (molecular weight of A)

rA
0.8 lb · mol/ft3
cos
0 . 1 lb  mol A /ft 3
F
100 cfm
 ms 1 . 0 lb  mol/min 
ms
1 . 0 lb  mol/min  Note:

1 . 25 cfm
 rA 0. 8 lb  mol/ft 3 

k1
1
6
min1 
 k2  k1 because T2  T1
k1
2
3
min1 

V
300 ft3
V 300 ft 3
t


3 min
F 100 cfm

From Eq. (10.4), we can calculate the steady-state concentration of A in tank 1.

1
1 1F 1 lb  mol
c1s
c0s  ms
(0.1)  100 1 (1.0)
0.0733
1  k1t 1  k1t 1

()
1  6 ( 3) 1 2 ft 3
1
2

We can calculate the steady-state concentration of A in tank 2 by using Eq. (10.7a) writ-
ten at steady state (when dc2/dt
0).
1 1 lb  moo l
c2s
c1
(0 . 0733)
0 . 0244
1  k2t s ()
1  3 ( 3)
2 ft 3

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CHAPTER 10 BLOCK DIAGRAM OF A CHEMICAL-REACTOR CONTROL SYSTEM 209

10.3 CONTROL VALVE

The air-to-open control valve selected for the process has the following characteristics.
The flow of A through the valve varies linearly from 0 to 2 cfm as the valve-top pres-
sure varies from 3 to 15 psig. The time constant tv of the valve is so small compared
with the other time constants in the system that its dynamics can be neglected. From
Eq. (10.2) the transfer function for a fast valve is
Q(s )

Kv (10.2)
P (s )
From this relationship, and remembering that Q and P are deviation variables, we can
compute the valve gain using the given data

∆Flow (cfm) 20 1 cfm

Kv



∆Pressure (psi) 15  3 6 p si

Since ms /rA
1.25 cfm, the normal operating pressure on the valve is

1 . 25
ps
3  (15  3)
10 . 5 psig (10.10)
2

Since our mole balances for the tanks are written in terms of molar flow rates
instead of volumetric flow rates (cfm), we would like the valve equation to be written in
terms of molar flow rates as well. Realizing that the volumetric flow rate (cfm) can be
written as m/rA, we can write the equation for the control valve as (see Fig. 10–2)
m /rA  1 . 25

Kv
p  10 . 5
and finally,
m
[1 . 25  K v ( p  10 . 5) ] rA (10.11)

In terms of deviation variables, this can be written

M
K v rA P (10.12)

where M
m  1 . 25 rA
m  1 . 0
P
p  10 . 5

Taking the transform of Eq. (10.12) gives

M (s)  1 ft 3 /min   0 . 8 lb  mol  lb  mol/min

K v rA
   
0 . 133 (10.13)
P (s)  6 psi  ft 3 psi

as the valve transfer function.

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210 PART 3 LINEAR CLOSED-LOOP SYSTEMS

Control Valve Sensitivity

2

1.75

1.5 Slope = Kv

Steady-state flow = 1.25 cfm

1.25
Flow (cfm)

0.75
(p, m/ρ)
0.5

0.25
10.5 psig

0
0 3 6 9 12 15
Pressure (psig)

FIGURE 10–2
Control valve sensitivity.

10.4 MEASURING ELEMENT

For illustration, assume that the measuring element converts the concentration of A to
an electronic signal. Specifically, the output of the measuring element varies from 4 to
20 mA as the concentration of A varies from 0.01 to 0.05 lb · mol A/ft3. We will assume
that the concentration measuring device is linear and has negligible lag. The sensitivity
(or gain) of the measuring device is therefore
20  4 mA
Km

400
0 . 05  0 . 01 lb  mol/ft 3

Since c2s is 0.0244 lb · mol/ft3, the normal signal from the measuring device is
0 . 0244  0 . 01
( 20  4 )  4 . 0
5 . 76  4 . 0
9 . 7 6 mA
0 . 05  0 . 01
The equation for the measuring device is therefore

b
9.76  K m ( c2  0.0244 )
9.76 mA  400

mA
lb  mol/ft 3
(
c2  0.0244 lb  mol/ft 3 )
(10.14)
where b is the output current (milliamperes) from the measuring device. In terms of
deviation variables, Eq. (10.14) becomes

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CHAPTER 10 BLOCK DIAGRAM OF A CHEMICAL-REACTOR CONTROL SYSTEM 211

B
K m C2 (10.15)

where B
b  9.76 and C2
c2  c2s .

The transfer function for the measuring device is therefore

B(s)

Km (10.16)
C2 ( s )

A measuring device that changes the type of signal between its input and output is
called a transducer; in the present case, the concentration signal is changed to a current
signal. A thermocouple is another example of a transducer. It changes an input tempera-
ture signal to an output electrical signal (millivolts).

10.5 CONTROLLER
For convenience, we will assume the controller to have proportional action and produce
a current output signal. The relation between the controller output signal (milliamperes)
and the error (milliamperes) is

p
ps  K c ( cR  b )
ps  K ce (10.17)

where cR
desired current signal (or set point), mA

Kc
controller gain, mA/mA
e
error
cR  b, mA
In terms of deviation variables, Eq. (10.17) becomes

P
K ce (10.18)

The transform of this equation gives the transfer function of the controller

P (s)

Kc (10.19)
e (s)

Assuming the set point and the signal from the measuring device to be the same when
the system is at steady state under normal conditions, we have for the reference value
of the set point

cRs
bs
9 . 76 mA

The corresponding deviation variable for the set point is

C R
cR  cRs

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212 PART 3 LINEAR CLOSED-LOOP SYSTEMS

10.6 CONTROLLER TRANSDUCER

The output from the controller is an electronic current signal ranging from 4 to 20 mA.
The signal that the control valve requires is a pneumatic signal of 3 to 15 psig. A trans-
ducer is required to convert the current signal from the controller to the pneumatic
signal required by the control valve. We will assume that the transducer is linear and
has negligible lag. The transfer function for the transducer is merely a gain that is given
by Eq. (10.20).
P T (s ) (15  3) psig psig

KT

0 . 75 (10.20)
P (s ) (20  4) mA mA

10.7 TRANSPORTATION LAG

A portion of the liquid leaving tank 2 is continuously withdrawn through a sample line,
containing a concentration measuring element, at a rate of 0.1 cfm. The measuring ele-
ment must be remotely located from the process, because rigid ambient conditions must
be maintained for accurate concentration measurements. The sample line has a length
of 50 ft, and the cross-sectional area of the line is 0.001 ft2.
The sample line can be represented by a transportation lag with parameter
volume (50)(0 . 001)
td


0 . 5 min
flow rate 0.1
The transfer function for the sample line is, therefore,

et d s
e0.5s

10.8 BLOCK DIAGRAM

We have now completed the analysis of each component of the control system and have
obtained a transfer function for each. These transfer functions can now be combined so
that the overall system is represented by the block diagram in Fig. 10–3.

C0

M + 1 1
C'R + P PT M 1 F + 1 + k1τ
C1
1 + k2τ
CR Km Kc KT KvρA C2
mA mA psig lb.moles F τ1s + 1 τ2s + 1
min
−

B
mA
Km e−τd s−

FIGURE 10–3
Block diagram for a chemical-reactor control system.

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CHAPTER 10 BLOCK DIAGRAM OF A CHEMICAL-REACTOR CONTROL SYSTEM 213

An equivalent diagram is shown in Fig. 10–4 in which some of the blocks have
been combined.

1
C0 K1 =
(1 + k1τ)(1 + k2τ)

+ + 1
CR KKc (τ1s + 1)(τ2s + 1) C2
+
−

e−τds

τ1 = 2, τ2 = 1, τd = 0.5, K1 = 1
4.5
KmKTKvρA
Open-loop gain = KKc = K = 0.09 Kc
F(1 + k1τ)(1 + k2τ) c

FIGURE 10–4
Equivalent block diagram for a chemical-reactor control system (CR is now in concentration units).

Numerical quantities for the parameters in the transfer functions are given in
Fig. 10–4. It should be emphasized that the block diagram is written for deviation
variables. The true steady-state values, which are not given by the diagram, must be
obtained from the analysis of the problem.
The example analyzed in this chapter will be used later in discussion of control
system design. The design problem will be to select a value of Kc that gives satisfactory
control of the composition C2 despite the rather long transportation lag involved in get-
ting information to the controller. In addition, we will want to consider possible use of
other modes of control for the system.

SUMMARY
We have now learned how to analyze a physical system and develop mathematical
models for the various components of the system and then use those models to construct
a block diagram of the model. We will make extensive use of these skills in upcoming
chapters as we study control systems in greater depth.

PROBLEMS
10.1. In the process shown in Fig. P10–1, the concentration of salt leaving the second tank is
controlled using a proportional controller by adding concentrated solution through a con-
trol valve. The following data apply:
(a) The controlled concentration is to be 0.1 lb salt/ft3 solution. The inlet concentration ci
is always less than 0.1 lb/ft3.
(b) The concentration of concentrated salt solution is 30 lb salt/ft3 solution.

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214 PART 3 LINEAR CLOSED-LOOP SYSTEMS

(c) Transducer: The output of the transducer varies linearly from 3 to 15 psig as the con-
centration varies from 0.05 to 0.15 lb/ft3.
(d) Controller: The controller is a pneumatic, direct-acting, proportional controller.
(e) Control valve: As valve-top pressure varies from 3 to 15 psig, the flow through the
control valve varies linearly from 0 to 0.005 cfm.
( f ) It takes 30 s for the solution leaving the second tank to reach the transducer at the end
of the pipe.
Draw a block diagram of the control system. Place in each block the appropriate transfer
function. Calculate all the constants and give the units.
Concentrated solution

Controller

Set point

Salt solution Zero length

1 ft3/min
ci

Transducer
c1 c2

V1 = 3 ft3 V2 = 4 ft3

FIGURE P10–1

Use the process shown in Figs. 10–3 and 10–4 for Prob. 10.2 to 10.5.
10.2. Verify the values of t1 and t2.
10.3. Determine the steady-state value of the controller output ps in milliamperes.
10.4. Use Simulink to simulate the open-loop response of the two chemical reactors to a step
change in the feed concentration C0 from 0.1 to 0.25 lb · mol A/ft3.
10.5. The open-loop process has an upset such that the flow rate to the process instantaneously
rises to 120 cfm (from the original 100 cfm). How does the open-loop block diagram
change? Plot the outlet concentration of A in both reactors as a function of time.
10.6. Two isothermal stirred-tank reactors (Fig. P10–6) are connected by a long pipe that acts
as a pure time delay between the two tanks (no reaction takes place in the pipe). CSTR 1
is at a higher temperature than CSTR 2, but both temperatures remain constant. Assume
constant throughputs and holdups (volumes) and a first-order, irreversible reaction taking
place in each CSTR (A → B). The flow rate through the system is 4 ft3/min, and the delay
time in the pipe is 30 s. The inlet concentration to CSTR 1 is initially at steady state at
1 lb · mol/ft3 and is increased at time 0 through a step change to 2 lb · mol/ft3.
(a) Draw the block diagram for the process, and be sure to include all necessary
constants.
(b) Use Simulink to plot the exit concentration of A from each of the reactors.
(c) Use Simulink to plot the exit concentration of B from each of the reactors.

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CHAPTER 10 BLOCK DIAGRAM OF A CHEMICAL-REACTOR CONTROL SYSTEM 215

DATA
CSTR 1 CSTR 2
1
Rate constant (min ) 0.3 0.15
Volume (ft3) 25 15

Reactor 1 Reactor 2
Dead time = 30 s

FIGURE P10–6

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