Laboratory Exercise No.

2
Basic Concepts of Process Dynamics and Control

1. Objective:
The activity aims to understand the basic concepts of process dynamics and control.
2. Intended Learning Outcomes (ILOs):
The students shall be able to:
2.1 Determine the input and output in the different chemical processes.
2.2 Provide instrumentation requirements for a chemical process.
2.3 Identify the different process variables in a chemical process.
2.4 specify the controlled variables (CVs), manipulated variables (MVs) and disturbance variables
(DVs) from the different chemical processes.
3. Discussion:
Most chemical processing plants were run essentially manually prior to the 1940s. Only the most
elementary types of controllers were used. Many operators were needed to keep watch on the many
variables in the plant. Large tanks were employed to act as buffers or surge capacities between various
units in the plant. These tanks, although sometimes quite expensive, served the function of filtering out
some of the dynamic disturbances by isolating one part of the process from upsets occurring in another
part.

With increasing labor and equipment costs and with the development of more severe, higher-capacity,
higher-performance equipment and processes in the 1940s and early 195Os, it became uneconomical and
often impossible to run plants without automatic control devices. At this stage feedback controllers were
added to the plants with little real consideration of or appreciation for the dynamics of the process itself.
Rule-of-thumb guides and experience were the only design techniques.

In the 1960s chemical engineers began to apply dynamic analysis and control theory to chemical
engineering processes. Most of the techniques were adapted from the work in the aerospace and electrical
engineering fields. In addition to designing better control systems, processes and plants were developed or
modified so that they were easier to control. The concept of examining the many parts of a complex plant
together as a single unit, with all the interactions included, and devising ways to control the entire plant is
called systems engineering. The current popular “buzz” words artificial intelligence and expert systems
are being applied to these types of studies.

The rapid rise in energy prices in the 1970s provided additional needs for effective control systems. The
design and redesign of many plants to reduce energy consumption resulted in more complex, integrated
plants that were much more interacting. So the challenges to the process control engineer have continued
to grow over the years. This makes the study of dynamics and control even more vital in the chemical
engineering curriculum than it was 30 years ago.

Feedback control. The traditional way to control a process is to measure the variable that is to be controlled,
compare its value with the desired value (the set-point to the controller) and feed the difference (the error)
into a feedback controller that will change a manipulated variable to drive the controlled variable back to the
desired value. Information is thus “fed back” from the controlled variable to a manipulated variable, as
sketched in the figure below.

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Feed-forward control. The basic idea is shown in the figure below .

The disturbance is detected as it enters the process and an appropriate change is made in the manipulated
variable such that the controlled variable is held constant. Thus we begin to take corrective action as soon
as a disturbance entering the system is detected instead of waiting (as we do with feedback control) for the
disturbance to propagate all the way through the process before a correction is made.

4. Resources:
Elementary Principles of Chemical Processes
Process Modeling, Simulation and Control for Chemical Engineers

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5. Procedure:
1. Explain each of the chemical processes that chemical engineers usually encounter in chemical
plants with a corresponding block diagram noting what enters into it and what comes out. Tabulate
your answers in Table 1.

2. Consider the heat exchanger as shown below:

An oil stream passes through the tube side of a tube-in-shell heat exchanger and is heated by condensing
steam on the shell side. The steam condensate leaves through a steam trap ( a device that only liquid to
pass through, thus preventing “blow through” of the steam vapor). To control the temperature of the oil
leaving in the heat exchanger, a thermocouple is inserted in a thermowell in the exit oil pipe. The
thermocouple wires are connected to a “temperature transmitter”, an electronic device that converts the
millivolt thermocouple output into a 4- to20-milliampere “control signal.” The current signal is sent into a
temperature controller, an electronic or digital or pneumatic device that compares the desired temperature
(the “setpoint”) with the actual temperature, and sends out a signal to a control valve. The temperature
controller opens the steam valve more if the temperature is too low and closes it a little if the temperature is
too high.

In order to provide automatic control of some variable in a process, in the above case temperature,
determine the requirements/instrumentation that must be installed in the system. Also, provide explanation
of its role in the automation. Tabulate your answers in Table 2.

3. Consider the simple schematic sketch of the process configuration and its control system, as
shown below:

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Two liquid feeds are pumped into a reactor in which they react to form products. The reaction is exothermic,
and therefore heat must be removed from the reactor. This is accomplished by adding cooling water to a
jacket surrounding the reactor. Reactor effluent is pumped through a pre-heater into a distillation column
that splits it into two product streams.

Identify the different process variables that must be controlled and provide available instrumentation for
each process variable. Tabulate your answers in Table 3.
4. For the heat exchanger in Procedure 2, determine the type of the different variables in the system
as Manipulated Variables (MV), Controlled Variables (CV), Uncontrolled Variables (UV) and Load
Disturbances (LD) or Disturbance Variables (DV). Tabulate your answers in Table 4.

5. For the distillation column in Procedure 3, determine the type of the different variables in the
system as Manipulated Variables (MV), Controlled Variables (CV), Uncontrolled Variables (UV) and
Load Disturbances (LD). Tabulate your answers in Table 4.

6. Consider the schematic diagram of a heat exchanger as shown below:

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A process fluid on the tube side is cooled by cooling water on the shell side, determine the type of the
different variables in the system as Manipulated Variables (MV), Controlled Variables (CV), Uncontrolled
Variables (UV) and Load Disturbances (LD). Tabulate your answers in Table 6.
7. Consider the schematic diagram of continuous-stirred-tank reactor (CSTR) as shown below:

If the reaction is highly exothermic, it is necessary to control the reactor temperature by manipulating the
flow rate of coolant in a jacket or cooling coil. Determine the type of the different variables in the system as
Manipulated Variables (MV), Controlled Variables (CV), Uncontrolled Variables (UV) and Load
Disturbances (LD). Tabulate your answers in Table 7.
8. Consider the thermal cracking furnace as shown below:

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Crude oil is broken down (“cracked”) into a number of lighter petroleum fractions by the heat transferred
from a burning fuel/air mixture. Determine the type of the different variables in the system as Manipulated
Variables (MV), Controlled Variables (CV), Uncontrolled Variables (UV) and Load Disturbances (LD).
Tabulate your answers a Table 8.
9. Consider the schematic diagram of a batch or semi-batch reactor as shown below:

An initial charge of reactants is brought up to reaction conditions, and the reactions are allowed to proceed
for a specified period of time or until a specified conversion is obtained. Batch and semi-batch reactors are
used routinely in specialty chemical plants, polymerization plants ( where a reaction by-product typically is
removed during the reaction), and in pharmaceutical and other bio-processing facilities (where a feed
stream, e.g. glucose, is fed into the reactor during a portion of the cycle to feed a living organism, such as a
yeast or protein). Determine the type of the different variables in the system as Manipulated Variables
(MV), Controlled Variables (CV), Uncontrolled Variables (UV) and Load Disturbances (LD). Tabulate your
answers in Table 9.

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 10. Consider a schematic diagram of a batch digester in a pulp mill as shown below:

Both continuous and semi-batch digesters are used in paper manufacturing to break down wood chips in
order to extract the cellulosic fibers. The end-point of the chemical reaction is indicated by the kappa
number, a measure of lignin content. Determine the type of the different variables in the system as
Manipulated Variables (MV), Controlled Variables (CV), Uncontrolled Variables (UV) and Load
Disturbances (LD). Tabulate your answers in Table 10.

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Course: ECE 006 Laboratory Exercise No.: 1
Group No.: n/a Section: CH42FB1
Group Members: Date Performed: November 11, 2019
Date Submitted: November 11, 2019
Instructor: Engr. Crispulo G. Maranan

6. Data and Results:

1.
Table 1. Different Chemical Processes, Its Block Diagram and Explanation

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 Chemical Process Block Diagram

1 Absorption

Explanation:

Adsorption is the adhesion of atoms, ions or molecules from a gas,

liquid or dissolved solid to a surface.[1] This process creates a film of
the adsorbate on the surface of the adsorbent. This process differs
from absorption, in which a fluid (the absorbate) is dissolved by or
permeates a liquid or solid (the absorbent), respectively. Processes
and apparatuses for catalytic oxidation of VOCs in industrial off-
gases are described, including steady state and unsteady state
processes, a combined adsorption-catalytic process and an
advanced method of ozone induced oxidation for low concentrated
exhausts. On the basis of research and development works a series
of catalytic incinerators, operating in steady state and unsteady state
mode, of various capacity were designed, constructed and tested in
the purification of ventilation air and off-gases from VOCs.

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2 Condensation

Explanation:

In refrigerator recycling plants R11 or pentane is released from the

insulating foam of the refrigerator during shredding. Figure 21.1.22.
shows the Rekusolv process as it is used by a refrigerator recycling
company. At this plant, around 25 refrigerators per hour are recycled
thereby generating 8 kg/h of polluting gases. The Rekusolv plant is
capable of condensing almost all of this. The unit is designed to
operate for 10 to 12 hours before it has to be defrosted. The plant is
operated during the day and is automatically defrosted at night. The
concentration of pollutants in the exhaust gas is reduced from 20 to
40 g/m3 to 0.1 g/m3 – a recovery rate of more than 99.5%.

3 Crystallization

Explanation:

Crystallization can be considered a two-step process beginning with

the “birth” of crystals from a supersaturated solution followed by
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 growth of the crystals to larger sizes. These processes are called

nucleation and crystal growth, respectively and can occur

simultaneously to relieve supersaturation and thereby attain solution
equilibrium. It is the relation between the extent of nucleation to
crystal growth that controls the final crystal size and size distribution
and thus is a crucial control aspect of the crystallization process.

4 Distillation

Explanation:

Vacuum distillation is another viable solution for ammonia recovery.

This process can be justified in case of highly concentrated streams
and when waste heat is available. Vacuum flash distillation
processes have been applied to ammonia recovery from centrate of
manure digested sludge, using as heat source the biogas generated
by the anaerobic digestion

5 Drying

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 Explanation:

A schematic diagram of the spray drying process with a 3-fluid nozzle

is presented. Lysozyme and trehalose were dissolved in deionized
water as the inner feed solution and PLGA was dissolved in variety of
organic solvents and used as the outer feed solution.

6 Evaporation

Explanation:

The figure shows the process flow diagram for the purification of
glycolysed product using two stages evaporation process. Flash
columns were used in modeling both the evaporators. In equilibrium
system, the Gibbs phase rule demonstrates that a mixture of three
components that forms two phases have three degrees of freedom. If
the pressure and temperature are fixed for the process, one degree
of freedom remains (Felder and Rousseau, 2005) which is the
concentration of each outlet streams.

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7 Extraction

Explanation:

Solvent extraction can occur under three processing approaches.

The most common approach employs two phases in contact at
ambient conditions of temperature and pressure, in which the
contaminants are exchanged between the solid matrix and a liquid
solvent. In another approach, liquefied gases, such as propane, are
used as the solvent. Finally, critical solution temperature solvent
extraction systems use solvents, such as aliphatic amines, in which
solubility can be varied over the process operating temperature
range. These processes use liquid–liquid extraction at two different
temperatures. At the lower operating temperatures, the solvents are
miscible, while at the upper temperatures, the two solvents are
completely immiscible.

8 Filtration

Explanation:

Hydrogen cyanide was generated by the dropwise addition of sulfuric

acid to potassium cyanide. The generated vapor was introduced
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 directly into condenser and finally, the aqueous hydrogen cyanide
was collected and stored in a freezer. The fabricated nanofibrous
media, i.e., PAN nanofiber (PAN), metal loaded PAN nanofiber
(PAN-M), and TEDA impregnated metal loaded nanofiber
(PANM-TEDA), were placed into a 1 cm diameter plastic syringe.
Adsorption test apparatus is shown in Figure 1. Gas stream
containing 4 µl HCN and N2, as a carrier gas, was introduced into
the flowmeter and syringe tube containing electrospun filter medias.
The outlet gas was introduced into a 70 ml stirring solution of sodium
carbonate (Na2CO3, 2%). HCN was rapidly hydrolyzed in base to
cyanide ion according to the following reaction. The samples were
taken for measurement of HCN concentration in every 2 min to 16
min.

9 Flash Vaporization

Explanation:

In flash process, a liquid mixture is partially separated and the gas is

allowed to come to equilibrium with the liquid. The graphical
demonstration of the flash process as illustrated. The gas and liquid
phases are then separated.

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10 Heat Exchange/ing

Explanation:

A heat exchanger is a device used to transfer heat from one process

stream to another, without having the two streams mix. These units
are typically made of stainless steel, at least on the pure water side,
and can be stainless steel or carbon steel on the heating/cooling
medium side. A simple tube-in-tube heat exchanger as illustrated. In
this case a hot liquid is going through the shell (outer chamber), and
the cold liquid is passing through the inner chamber, receiving heat
from the shell-side liquid and therefore coming out the tube-side at a
higher temperature.

11 Stripping

Explanation:

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 Steam stripping of wastewater is a distillation process where volatile
organic matter is removed from water. The volatilization of organic
matter is greatly determined by the temperature. Due to the higher
temperature used in steam stripping, compared to air stripping, more
soluble organic matter will be removed than when air stripping is
implemented. No air treatment is needed; the removed components
will be in a concentrated flow that can either be recuperated or must
be destroyed (e.g. via incineration). The principle is based on
reducing the partial pressure of the pollution by heating and by
creating a positive mass transport from the water to the gas phase
via steam injection. A steam stripper consists of a supply pump with
heat exchanger, a packed or dish column, a condenser with a
separation drum and a reflux device, and a decanter. The
wastewater must be free of solid matter, which could block the heat
exchanger.

2.
Table 2. Different Instrumentation Requirements and Its Explanation

Requirements/Instrumentation Explanation

Steam Trap a device used to discharge condensates and non-

condensable gases with a negligible consumption
or loss of live steam. Most steam traps are nothing
more than automatic valves. They open, close or
modulate automatically. The three important
functions of steam traps are:

 Discharge condensate as soon as it is

formed (unless it is desirable to use the

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 sensible heat of the liquid condensate)

 Have a negligible steam consumption (i.e.

being energy efficient)

 Have the capability of discharging air and

other non-condensable gases.

Thermocouple is an electrical device consisting of two dissimilar

electrical conductors forming electrical junctions at
differing temperatures. A thermocouple produces a
temperature-dependent voltage as a result of the
thermoelectric effect, and this voltage can be
interpreted to measure temperature.
Thermocouples are a widely used type of
temperature sensor.

Thermowell are cylindrical fittings used to protect temperature

sensors installed in industrial processes. A
thermowell consists of a tube closed at one end
and mounted in the process stream. A temperature
sensor such as a thermometer, thermocouple or
resistance temperature detector is inserted in the
open end of the tube, which is usually in the open
air outside the process piping or vessel and any
thermal insulation. Thermodynamically, the
process fluid transfers heat to the thermowell wall,
which in turn transfers heat to the sensor. Since
more mass is present with a sensor-well assembly
than with a probe directly immersed into the
process, the sensor's response to process
temperature changes is slowed by the addition of
the well. If the sensor fails, it can be easily
replaced without draining the vessel or piping.
Since the mass of the thermowell must be heated
to the process temperature, and since the walls of
the thermowell conduct heat out of the process,
sensor accuracy and responsiveness is reduced
by the addition of a thermowell.

Temperature Controller an instrument used to control temperatures, mainly

without extensive operator involvement. A

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 controller in a temperature control system will
accept a temperature sensor such as a
thermocouple or RTD as input and compare the
actual temperature to the desired control
temperature, or setpoint. It will then provide an
output to a control element.

3.
Table 3. Different Process Variables and Its Instrumentation

Process Variable Instrumentation

Flow Control Loop A flow control valve regulates the flow or pressure
of a fluid. Control valves normally respond to
signals generated by independent devices such as
flow meters or temperature gauges.

Temperature Control Loop A temperature controller - often called a PID

controller is an instrument used to control
temperature. The temperature controller takes an
input from a temperature sensor and has an output
that is connected to a control element such as a
heater or fan.

Pressure Control Loop A pressure regulator is a control valve that reduces

the input pressure of a fluid or gases to a desired
value at its output. Regulators are used for gases
and liquids, and can be an integral device with an
output pressure setting, a restrictor and a sensor all
in the one body, or consist of a separate pressure
sensor, controller and flow valve.

Level Control Loop A Liquid Level Controller will automatically START

the pump set as soon as the water level falls below
the predetermined level. Liquid Level Control
System provides you the flexibility to decide for
yourself the water levels for operations of pump set
in upper/lower tanks.

4.
Table 4. Types of the different process variables for a heat exchanger
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 Process Variable MV/CV/UV/LD

oil feed flow rate F UV

oil inlet temperature TO UV

steam flow rate F CV

oil exit temperature T MV

5.
Table 5. Types of the different process variables for a distillation column

Process Variable MV/CV/UV/LD

feed flow rate UV

feed composition UV

Reflux LD

steam CV

cooling water CV

distillate MV

bottoms flow rates UV

distillate product composition MV

bottoms product composition MV

column pressure CV

base liquid level CV

reflux drum liquid level CV

compositions on all the trays UV

temperatures on all the trays UV

6.
Table 6. Types of the different process variables for a heat exchanger

Process Variable MV/CV/UV/LD

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 Exit temperature of the process fluid MV

Cooling water flow rate CV

Variation in inlet temperature UV

Process fluid flow rate LD

7.
Table 7. Types of the different process variables for a continuous-stirred-tank reactor (CSTR)

Process Variable MV/CV/UV/LD

Feed composition UV

Feed flow rate UV

Feed temperature UV

8.
Table 8. Types of the different process variables for a thermal cracking furnace
Process Variable MV/CV/UV/LD

Furnace temperature CV

Amount of excess air in the flue gas LD

Fuel flow rate MV

Fuel/air ratio UD

Crude oil composition UV

Heating quality of the fuel CV

9.
Table 9. Types of the different process variables for a batch or semi-batch reactor
Process Variable MV/CV/UV/LD

Reactor temperature CV

Coolant flow rate CV

End-point (final) concentration of the batch MV

Desired temperature CV

Flow of reactants (for semi-batch LD

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 operation)

Cycle time CV

10.
Table 10. Types of the different process variables for a batch digester in a pulp mill

Process Variable MV/CV/UV/LD

End-point (final) concentration of the batch MV

Digester temperature CV

Digester pressure CV

Cycle time CV

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7.Conclusion:

For this experiment, students were able to familiarize themselves with different unit processes such as
breaking down of crude oil into a number of lighter petroleum fractions and extraction of cellulosic fibers
from wood chips for the production of papers. From certain examples, students were able to determine what
are the different inputs and outputs used in those chemical processes. The students were also provided
basic concepts of process dynamics and control that involves different types of variables such as
manipulated, controlled and disturbance variables.

8. Further Readings:
Seborg Dale E., Edgar, Thomas F., and Mellichamp Duncan A. (2004). Process Dynamics and
Control. Singapore: Wiley.
Wiley.
Knopf, F. C. (2012). Modeling, analysis and optimization of process and energy systems.Hoboken,
New Jersey: John Wiley and Sons.
Velten, K. (2009). Mathematical modeling and simulation: introduction for scientists and engineers.
Singapore: Wiley-VCH.

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9. Assessment (Rubric for Laboratory Performance):
TECHNOLOGICAL INSTITUTE OF THE PHILIPPINES
RUBRIC FOR MODERN TOOL USAGE
(Engineering Programs)
Student Outcome (e): Use the techniques, skills, and modern engineering tools necessary for engineering
practice in complex engineering activities.
Program: Chemical Engineering Course: ECE 006 Section: CH42FB1 2nd Sem SY 2019-2020
Performance Unsatisfactory Developing Satisfactory Very Satisfactory Score
Indicators 1 2 3 4
1. Apply Fails to identify Identifies Identifies modern Recognizes the
appropriate any modern modern techniques and is benefits and
techniques, techniques to techniques but able to apply constraints of
skills, and perform fails to apply these in modern
modern discipline- these in performing engineering tools
tools to specific performing discipline-specific and shows
perform a engineering discipline- engineering task. intention to apply
discipline- task. specific them for
specific engineering engineering
engineering task. practice.
task.
2. Demonstrate Fails to apply Attempts to Shows ability to Shows ability to
skills in any modern apply modern apply fundamental apply the most
applying tools to solve tools but has procedures in appropriate and
different engineering difficulties to using modern effective modern
techniques problems. solve tools when solving tools to solve
and modern engineering engineering engineering
tools to problems. problems. problems.
solve
engineering
problems.
3. Recognize Does not Recognizes Recognizes the Recognizes the
the benefits recognize the some benefits benefits and need for benefits
and benefits and and constraints of and constraints of
constraints constraints of constraints of modern modern
of modern modern modern engineering tools engineering tools
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 engineering engineering engineering and shows and makes good
tools. tools. tools. intention to apply use of them for
them for engineering
engineering practice.
practice.
Total Score
Mean Score = (Total Score / 3)
Percentage Rating = (Total Score / 12) x 100%
Evaluated by: Engr. Crispulo G. Maranan
Printed Name and Signature of Faculty Member Date

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