Laboratory Exercise No.

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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 Specifiy 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 Feedback and Control System Laboratory Exercise No.: 1
Group No.: Section: CH42FB2
Group Members: Date Performed: 22/06/2019
Date Submitted: 22/06/2019
Instructor: Engr. Crispulo Maranan

6. Data and Results:

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

Chemical Process Block Diagram

1 Absorption

Explanation : Atomic absorption occurs when a ground state atom

absorbs light of a specific wavelength. The amount of light
absorbed is governed by Beer Lambert’s law and will increase as
the number of atoms of the element in the light path increases.

2 Condensation

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 Explanation: The steam condenser receives the exhaust steam
from one end and comes in contact with the cooling water
circulated within it form the cooling tower. As the low pressure
steam comes in contact with the cooling water, it condenses and
converts into water. It is connected to the air extraction pump and
condensate extraction pump. After the condensation of steam, the
condensate is pumped to the hot well with the help of condensate
extraction pump. The air extraction pump extracts the air from the
condenser and creates the vacuum inside it. The vacuum created
helps in the circulation of cooling water and flow of condensate
downward.

3 Crystallization

Explanation: This clarified juice which is very thin is passed through

a series of boilers for evaporation and it gets transformed to heavy
syrup which is also called mother liquor. This syrup is then
subjected to crystallization process where a seed of crystal is
added in the syrup and crystal growth takes place.

4 Distillation

Explanation: The liquid mixture that is to be processed is known as

the feed and this is introduced usually somewhere near the middle
of the column to a tray known as the feed tray. The feed tray
divides the column into a top (enriching or rectification) section
and a bottom (stripping) section. The feed flows down the column

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 where it is collected at the bottom in the reboiler.

Heat is supplied to the reboiler to generate vapour. The source of

heat input can be any suitable fluid, although in most chemical
plants this is normally steam. In refineries, the heating source may
be the output streams of other columns. The vapour raised in the
reboiler is re-introduced into the unit at the bottom of the column.
The liquid removed from the reboiler is known as the bottom
product or simply, bottoms.

The vapour moves up the column, and as it exits the top of the
unit, it is cooled by a condenser. The condensed liquid is stored in a
holding vessel known as the reflux drum. Some of this liquid is
recycled back to the top of the column and this is called the reflux.
The condensed liquid that is removed from the system is known as
the distillate or top product.

Thus, there are internal flows of vapour and liquid within the
column as well as external flows of feeds and product streams, into
and out of the column.

5 Drying

Explanation: The process may be described by three major phases

(atomization, droplet-to-particle conversion and particle
collection), a solution is pumped to an atomizer, breaking up the
liquid feed into a spray of fine droplets. Then, the droplets are
ejected into a drying gas chamber where the moisture vaporization
occurs, resulting in the formation of dry particles. Finally, using an
appropriate device, the dried particles are separated from the

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 drying medium, being then collected in a tank.

6 Evaporation

Explanation: Acid is added to the feed tank to neutralize

bicarbonate alkalinity in order for the solution to be preheated in
the plate heat exchangers. Antiscalants are also added for
preventing scaling in the preheaters with calcium carbonate.The
pre-heated stream is degassed using steam from the evaporator
(red line in Figure 3) to remove the dissolved carbon dioxide
(alkalinity reduction), dissolved oxygen, and any other non-
condensable gases in order to reduce the potential for corrosion of
the evaporator.

7 Extraction

Explanation: A carbonaceous feedstock, such as crushed coal, is

blended with an aprotic dipolar solvent such as N-methyl
pyrrolidone (NMP) in a Continuously Stirred Tank Reactor (CSTR).
A typical protocol calls for 10 kg of raw coal in 100 liters of solution
at 200C. The resultant slurry must be pumped to a centrifuge

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 which separates the dissolved portion from undissolved coal solids.
The byproduct coal solids are suitable for gasification, or could
possibly be incorporated in a product such as asphalt. The soluble
portion of the coal is typically about 70% or 7 kg of the feed
material, depending on the type of coal selected. The soluble
portion of the coal, solvent extracted coal ore (SECO), is obtained
by evaporating the solvent in a Ross mixer, a heated planetary
mixing system. The evaporated solvent The evaporated solvent is
then condensed and retained for use in subsequent batches.

8 Filtration

Explanation:

In the Bar Rack coarse solids are removed, such as sticks, rags, and
other debris in untreated wastewater by interception. By use of
fine screening even floatable matter and algae are removed. Then
the filtered water will go to the grit chamber.

9 Flash Vaporization

Explanation: Flash evaporation is the partial vapor that occurs

when a saturated liquid stream undergoes a reduction in pressure
by passing through a throttling valve or other throttling device.
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 This process is one of the simplest unit operations.

10 Heat Exchange/ing

Explanation: Liquid nitrogen (LN2) is supplied to a heat exchanger

where it cools the heat transfer fluid. The heat transfer fluid is
continuously circulated in a loop between the heat exchanger and
the heat load. Heat from the heat load is continuously transferred
to the heat exchanger where it is expelled with the gaseous
nitrogen (GN2) exhaust.

11 Stripping

Explanation: The liquid ammonia coming from the battery limit at a

temperature of 12oC and 18 Kg/cm2(g) is collected in an ammonia
receiving vessel which is operated at medium pressure(17Kg/cm2).
From the ammonia receiver, the liquid ammonia is pumped to the
reactor by two pumps. The first pump is the ammonia booster
pump which is the centrifugal type and supplies the liquid
ammonia at 22Kg/cm2 to the second pump suction. The second
pump is the high-pressure ammonia pump which is a reciprocating-
plunger type. Due to the reciprocating motion of second pump
pulsating takes place in the discharge of booster pump and those
cause the change of loads on booster pump to avoid these booster
pumps and those cause the change of loads on booster pump to
avoid these pulsations a damper is provided in the suction of the
second pump. In the H.P. ammonia pump, the ammonia pressure is

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 increased to 239Kg/cm2 and then goes to an ammonia preheater
where it is preheated to 75oC by L.P. decomposer outlet gases,
H.P. ammonia is used as pressure section contains first and second
stage another one is the high-pressure section contains third and
the fourth stage. First and second stages contain three, the third
stage contains four and fourth stage two numbers of closed type
impellers. Carbon dioxide gas enters first stage suction at
1.5kg/cm2 and 40oC and compressed to 160 Kg/cm2 in four stages.
Intercoolers are provided after the first, second and third stages to
cool the carbon dioxide using cooling water. Along with coolers
knock-out drums are provided between each stage in which
moisture gets separated. Lube oil system provides the lubrication
of the rotating parts. The superheated steam and saturated LS
steam is used as a driving fluid for a steam turbine. Superheated
HS steam is extracted and part of steam is condensed in a
condenser. Condensate is then pumped to D.M. plant.

2.
Table 2. Different Instrumentation Requirements and Its Explanation

Requirements/Instrumentation Explanation

Temperature transmitter is a device that connects to a temperature sensor

to transmit the signal elsewhere for monitoring
and control purposes.

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.

Thermocouple This sense the temperature of the oil in the exit

pipe of the hear exchanger

Steam Valve is a device which will control flow of fluid or

vapor in any system. In case of steam, the major
applications are to reduce the pressure of the
inlet steam for process application. However, in
addition to controlling pressure, a steam control
valve will also control temperature.

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3.
Table 3. Different Process Variables and Its Instrumentation

Process Variable Instrumentation

Temperature Temperature Control Loop

Velocity Flow Control loop

Level Level Control loop

Pressure Pressure control loop

4.
Table 4. Types of the different process variables for a heat exchanger

Process Variable MV/CV/UV/LD

oil feed flow rate F UV

oil inlet temperature TO MV

steam flow rate F MV

oil exit temperature T CV

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

Process Variable MV/CV/UV/LD

feed flow rate MV

feed composition UV

Reflux CV

steam UV

cooling water CV

distillate CV

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 bottoms flow rates MV

distillate product composition CV

bottoms product composition CV

column pressure LD

base liquid level UV

reflux drum liquid level CV

compositions on all the trays LD

MV

temperatures on all the trays

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

Process Variable MV/CV/UV/LD

Exit temperature of the process fluid CV

Cooling water flow rate UV

Variation in inlet temperature LD

Process fluid flow rate MV

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

Process Variable MV/CV/UV/LD

Feed composition MV

Feed flow rate CV

Feed temperature CV

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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 UV

Fuel flow rate CV

Fuel/air ratio CV

Crude oil composition UV

Heating quality of the fuel MV

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 MV

End-point (final) concentration of the batch CV

Desired temperature MV

Flow of reactants (for semi-batch MV

operation)

Cycle time UV

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

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 Digester pressure CV

Cycle time UV

7.Conclusion:

From this experiment, different dynamic controls and chemical processes had been tackled , it allows me to
familiarize the different controls and different process variables of one particular equipment , its appllication
is to find the most efficient and effective design of one particular equipment, in order to be suitable in its
industrial used.

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.

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: CHE 506 Section: _______ ____Sem SY ________
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
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 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
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 June 17, 2017
Printed Name and Signature of Faculty Member Date

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