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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
A → B
rA kc
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
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
V
where t residence time for each tank , (time)
F
V t
t1 effective time constant for tank 1 , (time)
F k1V 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
Rearranging gives
dc2
V ( F k2 V ) c2 Fc1
dt
V dc2 F (10.7a)
c2 c1
F k2V dt F k2 V
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:
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
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
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)
M K v rA P (10.12)
where M m 1 . 25 rA m 1 . 0
P p 10 . 5
1.75
1.5 Slope = Kv
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.
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 K m C2 (10.15)
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)
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
C R cR cRs
et d s e0.5s
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.
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.
(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
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.
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