MODELLING AND TEMPERATURE CONTROL OF POLYMERIZATION

CONTINUOUS REACTOR

A Process Dynamics and Control

Submitted to the Faculty of the College of Engineering

Cagayan State University – Carig Campus

In Partial Fulfillment of the

Requirements for the Course of

Bachelor of Science in Chemical Engineering

Ancheta, Nicole Ann K.

Celis, Jasmine

Rhea Joy C. Morales

December 20, 2017

 Table of Contents

Chapter 1: DEVELOPMENT OF THE MODEL…………………………………………1

1.1 Description of the System………………………………………………….1

1.2 Temperature Control……………………………………………………….2

1.3 Cascade Control……………………………………………………………2

1.4 Control System…………………………………………………………….2

1.5 Mathematical Modeling……………………………………………………3

1.5.1 Overall Material Balance………………………………………...4

1.5.2 Energy Balance………………………………………………......4

Chapter 2: DYNAMIC ANALYSIS OF THE SYSTEM…………………………………...7

2.1 Model Parameters and Analysis……………………………………………7
2.2 Transient System Response………………………………………………..8

A. Step Function Response…………………………………………….8

B. Ramp Function Response…………………………………………...9

C. Sine Function Response1………………………………………….10

D. Pulse Function Response…………………………………………..11

Chapter 3: CONTROLLER DESIGN AND TUNING …………………………………...13

3.1 Design of Cascade Control System………………………………………13
3.2 Block Diagram Development……………………………………………14
3.3 PID Control……………………………………………………………...15

References

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 List of Figures

Figure 1. Schematic diagram of the Control system of a Continuous Stirred Tank Reactor
Figure 2.1. Simulink Model for Step Function

Figure 2.2. Graph of Step Function for Jacketed CSTR

Figure 2.3. Simulink Model for Ramp Function

Figure 2.4. Graph of Ramp Function for Jacketed CSTR

Figure 2.5. Simulink Model for Sinusoidal Function

Figure 2.6. Graph of Sinusoidal Function for Jacketed CSTR

Figure 2.7. Simulink Model for Pulse Function

Figure 2.8. Graph of Pulse Function for Jacketed CSTR

Figure 3.1: Cascade Control of CSTR

Figure 3.2: Block Diagram of Cascade Control CSTR

Figure 3.3: Step response of CSTR without controller

Figure 3.4: Step response with un- tuned PID controller

Figure 3.5: Step response of CSTR without disturbance

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 Chapter 1

DEVELOPMENT OF THE MODEL

1.1 Description of the System

Process control persists to play an increasingly central role in manufacturing high

quality polymer products, safely and in an environmentally friendly manner. Synthetic
polymers comprise a substantial part of the modern chemical process industry. Hence, polymer
reactors are important processing units that needs efficient and effective control.
Polymerization reactors exhibit highly nonlinear dynamic behavior and has wide operating
ranges because of the complexity of the physiochemical interactions and the kinetics of the
polymerization reactions.

Polymer reactors may be operated as continuous, batch, or semi-batch. A continuous

process is mainly used for high-volume production of commodity polymers. Low-volume
specialty materials of polymers manufactured for tailoring applications are most efficient for
batch and semi-batch as discontinuous processes.

In this paper, a polymer reactor in continuous process is studied for the following
implications: with continuous processes, there is a reasonable outlook of the effectiveness of
linear controllers because of the operating objective of maintaining the process within a small
neighborhood of the steady-state operating condition, where linear approximations are
reasonably valid. As for batch operation with no such steady-state, linear approximations will
be largely invalid and linear controllers largely ineffective. Aside from the absence of a steady-
state, broad operating ranges in batch operation extend challenges to effective control by
demanding the use of sensors capable of covering a broad range of values and demands
constricted performance on controllers that must function over such broad ranges of operation.
The issue of lack of online measurement and its negative effect on control system design and
implementation is also usually found in batch processing. Thus, a continuous process in
polymerization is more efficient to use.

1.2 Temperature Control

Four modes of operation are identifiable in continuous polymerization processes: Start

up, Steady-state operation, Grade transition, and Shutdown. Regardless of operating mode,

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temperature control is significant in polymerization reactions as these reactions are usually
highly exothermic. In startup and shutdown mode, temperature control is chiefly for safety
assurance while in steady-state operation and grade transition, temperature control is used
indirectly to influence polymer properties because of the strong effect of temperature on
polymer properties.

1.3 Cascade Control

Cascade control improves the dynamic response to load changes by using a secondary
measurement point and a secondary controller; the secondary measurement point is located so
that it recognizes the upset condition before the primary controlled variable is affected. That is
why cascade control scheme is more effective to control reactors temperature in industrial
applications. Another thing is that the use of conventional feedback control for processes with
large time lags or delays is that disturbances are not recognized until after the controlled
variable deviates from its set point. In these processes, correction by feedback control is
generally slow and results in long-term deviation from the set point (Perry, 2008).

Hence, a cascade control would be more competent to employ for designing and
implementing temperature control for polymer reactors.

1.4 Control System

In this paper, we are proposing to control the temperature of the polymerization reactor,
particularly a jacketed CSTR using cascade control scheme with a PID controller. The
manipulated variable in this reactor is the propylene flow rate. The controlled variable is the
temperature ( T ). Disturbance variables includes input variables such as, feed flow rate and
temperature. We will presume that the coolant supply temperature H s is quite stable and thus
not consider it as a disturbance. The general objective of this study is to control the temperature
in the CSTR, in which we will specifically aim to create a model that could hold the temperature
within certain band around the set point, preferable without oscillation, to minimize operator
intervention, and to minimize consumption of utilities. The Schematic diagram of the Control
system of a Continuous Stirred Tank Reactor is shown in Figure 1.

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 coolant
inlet

Figure 1. Schematic diagram of the Control system of a Continuous Stirred Tank

Reactor

1.5 Mathematical Modeling

To improve understanding of the process in the jacketed CSTR, mathematical modeling

is provided in this paper. The mathematical modelling in this chapter will only include model
equations to approximate the real process in the reactor and to see more clearly the cause and
effect relationship between the input and output variables.

In an ideal process, we can assume that there is no heat loss in the reactor, but in real
process heat losses cannot be disregarded since there will always be energy losses. Other
assumptions are listed below.

1. The mixing is assumed to be efficient enough to guarantee homogeneity of the

liquid content within the reactor (perfect mixing).
2. Density,  and heat capacity C p are constant.

3. The coolant is perfectly mixed in the reactor jacket

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1.5.1 Overall Material Balance

From Figure 1, the overall material balance can be written as,

Rate of mass accumulation = Rate of mass input – Rate of mass output

d
M s    m f   m
dt
(1)

dM s
  m f   m
dt
(2)

At constant density, 

dM s
 mf m
dt
(3)

where m f is the acetic anhydride mass flow rate, m is the product flow rate and M s is the

mass of the liquid in the reactor.

1.5.2 Energy Balance

From the Figure 1. The energy balance can be written as,

Rate of change of energy = Input energy – Output energy + Heat provided by steam

 m f T f C p  mC p T  M s H s  H c 
dT
MC p
dt
(4)

 mC p T  m f T f C p  M s H s  H c 
dT
MC p
dt
(5)

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Dividing the equation (2) by ( m f C p ).

Ms
MdT

m
T  Tf  H s  H c 
m f dt m f mf Cp
(6)

But, m  m f

(7)

Also put

M
 p
mf

(8)

Ms
p
dT
 T  Tf  H s  H c 
dt M f Cp

(9)

Let

1
H s  H c   K p
mf Cp

(10)

dT
p  T  Tf  K pM s
dt
(11)

Taking the Laplace Transform of equation (11) we get,

s p T s   T s   T f s   K p M s s 

(12)

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 Kp
T s   T f s   M s s 
1
s p  1 s p  1

(13)

Transfer function between T s  and T f s  :

T s  1

T f s  s p  1

(14)

Transfer function between T s  and M S s  :

T s  Kp

M s s  s  p  1

(15)

The coefficient M S s  represents the process transfer function G p also the coefficient of

T f s  represents the disturbance (load) transfer G d .

M
Where,  p  and,
mf

Kp 
1
H s  H c 
mf Cp

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 Chapter 2
DYNAMIC ANALYSIS OF THE SYSTEM
In this chapter, the analytical and matlab simulation will be presented to understand the
dynamic behavior of a jacketed continuous stirred tank reactor. The response of the system will
be studied by the use of the different forcing funcions: step, sinusoidal, impulse and ramp.
2.1 Model Parameters and Analysis
The parameters that will be used in analyzing the system for the temperature control
of the jacketed reactor is presented in table 1.
Parameters Value
Liquid mass 400 kg
Specific heat 1.5306 kJ/kg K
Inlet Coolant Temperature 275 K
Outlet coolant temperature 298 K
Table 1. Model Parameters

From the given data in Table 1 and the transfer function, the values of K p and  p can be

found since it has been denoted from the previous chapter that,

Kp 
1
H s  H c  and  p  M
mf Cp mf

To understand more the system, propylene at different flow rates shown in Table 2 is
introduced and will be studied using the different forcing functions. The process gain and
time constant are also computed.

Propylene Flow rates Process Gain constant Time Constant

(kg/s) (Kp) ( p )

10 1.503 40
20 0.751 20
30 0.501 13.333
Table 2: Propylene flow rates, Process Gain constant and Time constant

In Table 3, the Transfer function of the system is taken at different feed flow rate using the
computed K p and  p .

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 Propylene Flow rate Transfer Function
10 1.503
40 s  1
20 0.751
20  1
30 0.501
13.333s  1
Table 3: Transfer Function of the system at different propylene flow rates

2.2 Transient System Response

Transient Response or natural response is the response of the system to a change from
equilibrium or a steady state (Wikipedia, 2017). By introducing a disturbance (Propylene flow
rate) to the system at first order, the response of the system is determined using simulink models
and step, ramp sinusoidal and pulse functions.

A. Step Function Response

Figure 2.1. Simulink Model for Step Function

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 Figure 2.2. Graph of Step Function for Jacketed CSTR

Considering the first order system disturbed by the inlet flow rate of the propylene, the
transfer function shows a varying process gain, K p and time constant,  p . Studying the plot

of the step response shown in Figure 3, it can be seen that the system did not respond
immediately, but after a time constant of greater than one, the system responded. However, as
the time constant increases, the system might have higher percent response but time for the
process reach stability would take longer.

B. Ramp Function Response

Figure 2.3. Simulink Model for Ramp Function

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 Figure 2.4. Graph of Ramp Function for Jacketed CSTR

In Figure 5, the response of the system is shown using ramp fucntion. The response is almost
the same from the response using the step fuction, the only difference is that the response of
the system started earlier. However, it still takes long for the system to attain stability.

C. Sine Function Response

Figure 2.5. Simulink Model for Sinusoidal Function

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 Figure 2.6. Graph of Sinusoidal Function for Jacketed CSTR

Figure 7 represents the sinusoidal response of the system. It can be seen in the figure
that a decrease of propelyn flowrate, would increase the time constant of the process which
caused the graph to overshoot. This implies that if the flow rate is increased, the temperature
inside the reactor decreases and when the propylene flow rate is decresed, it would cause the
temperature inside the reactor to increase.

D. Pulse Function Response

Figure 2.7. Simulink Model for Pulse Function

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 Figure 2.8. Graph of Pulse Function for Jacketed CSTR

Considering the first-order system disturbed by sinusoidal input. Fig. 8 shows the
simulink model and Fig. 9 shows the graph of pulse response. It can be observed that the system
responds immediately to disturbances, though longer time is needed for the system to attain
steady state.

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 Chapter 3

CONTROLLER DESIGN AND TUNING

The best way to learn about control systems is to design a controller, apply it to the
system and observe the system in operation. One example of systems that use control theory is
Continuous Stirred Tank Reactor (CSTR). The operation of CSTR is disturbed by external
factors such as feed flow rate and temperature. We need to form of control action to alleviate
the impact of the changing disturbances and to keep temperature at desired set point. PID
Control will be used in controlling the CSTR.

3.1 Design of Cascade Control System

In a cascade control configuration shown in figure 3.1, we have manipulated variable

and more than one measurement device.

We can improve the response of the single feedback control to changes in the coolant
temperature by measuring the jacket temperature and taking control action before its effect has
been felt by the reacting mixture.

Tf,mf

Hc
temperature
transformer

set point controller T,m

set point

controller thermocouple

Q removed

coolant T,m
inlet
Hs

Figure 3.1: Cascade Control of CSTR

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3.2 Block Diagram Development

Cascade system contains two parts: the Process I (primary) and the Process II
(secondary). The process I have its output variable we want to control. Process II has an output
that we are no interested in controlling but which affects the output we want to control.

For the CSTR system, process I is the reaction in tank and the controller output is the
temperature. Process II is the jacket and its output effects process I.

The purpose of the slave loop is to correct for all outside disturbances. Without allowing
them to effect the reaction temperature, thus the cascade loop will not function properly if the
master is faster than the slave. Therefore, the measuring and the final control elements in the
secondary loop is considered to be zero order transfer function.

The block diagram of this action is shown below figure 3.2

Set Point PID Output

+ + P Controller Process II Process I
- Controller -

Measuring
Element

Figure 3.2: Block Diagram of Cascade Control CSTR

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3.3 PID Control

As stated by the researchers, an offset can be led by proportional controller between the
actual output and the preferred set points. The cause following this is process input, controller
output and process output that attains fresh equilibrium values prior to error going down to
zero. For the controller output to be proportional with integral of error, desired compensation
is introduced. This is in other words acknowledged as proportional integral control. The
controller output adjusts itself till the error signal is received in controller. Hence the error
signal is drowned to zero by integral of error.

Figure 3.3: Step response of CSTR without controller

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Figure 3.4: Step response with un- tuned PID controller

Figure 3.4: Step response with tuned PID controller

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The figure 3.4 shows that when there is PID control with the system it generates an overshoot
with reference tracking response. The temperature control is found better with addition of two
degree of freedom. In this case, the overshoot been reduced to 0%.

Figure 3.5: Step response of CSTR without disturbance

In the figure, it is seen that the process has an inverse response with delay time as well as
overshoot. To overcome this problem and to obtain a desired response, we are using of PID
controller for that the controller parameters are calculated.

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References
Abdalla, B. K. (2014). Cascade Control of a Continuous Stirred Tank reactor (CSTR).
Khayal, O. M. (July 2016). Control System Design for Continuous Stirred tank Reactor
Using Matlab Simulink.
Perry, R. H. (2008). Perry's Chemical Engineers Handbook (8th Edition ed.). USA: The
McGraw-Hill Companies, Inc.
Singla, R. U. (2010). Analysis of CSTR Temperature Control with Adaptive and PID
Controller (A Comparative Study). IACSIT International Journal of Engineering and
Technology, Vol.2, No.5.
Tanaka, K. (1997). Control of solution MMA Polymerization in a CSTR.
Wikipedia. (September 2017). Transient Response.

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 TECHNICAL REPORT ASSESSMENT RUBRIC
In
Process Dynamics and Control

Name of Student: ______________________________________________________________

Title of Report: __________________________________________________________

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Points
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Style apparent structure or continuity. easily followed. which is easy to follow.
continuity.
Purpose of work is stated, Purpose of work is clearly Purpose is clearly stated
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clearly stated. following work. structure of work. of work.
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& Clearly no knowledge of content. able to elaborate and knowledge of the subject
Knowledge subject matter. explain to some degree. with explanations and
Only basic concepts are elaboration.
No questions are answered. demonstrated and
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Figures, Work is illegible, format Mostly consistent format. Format is generally Format is consistent
Tables and changes throughout, e.g. consistent including throughout including
Graphs font type, size etc. Figures and tables are heading styles and heading styles and
legible, but not convincing. captions. captions.
Figures and tables are
Weight: 8 sloppy and fail to provide Figures and tables are Figures and tables are
intended information. neatly done and provide presented logically and
intended information. reinforce the text.

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 Equations Work fails to follow Many departures from Minor departures from Departmental format is
required format. Failed to required format. Many required format or observed in all equations.
use MS Equation Editor. problems with citation of inconsistencies between Citations consistent with
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Weight: 2 symbols. not properly defined. with citation of equations.
Some symbols not properly
defined.
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& grammatical errors. grammatical errors. grammatical errors. and/or grammatical errors.
Grammar

Weight: 5

Readability Report plagued with Many instances of “noise.” Some instances of “noise.” Report was free of “noise
distractions and ‘noise.” issues.”
Weight: 4
No referencing system Inadequate list of Minor inadequacies in Reference section complete
References used. references or references in references. and comprehensive.
text.
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Instructor/Rater: Engr. CAESAR P. LLAPITAN

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