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Cascade Control of a Continuous Stirred Tank Reactor (CSTR)

Article · October 2013

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Journal of Applied and Industrial Sciences, 2013, 1 (4): 16-23, ISSN: 2328-4595 (PRINT), ISSN: 2328-4609 (ONLINE)
Research Article
16

Cascade Control of a Continuous Stirred Tank

Reactor (CSTR)
A. O. Ahmed1, G.A. Gasmelseed2, A. B. Karama3 and A.E Musa4
(1)
Faculty of graduate studies and research, University of Karary, Khartoum – Sudan
E-mail: areejomer11@hotmail .com
(2)
Department of Chemical Engineering, Faculty of Engineering, University of Science and Technology
Email: gurashigar@hotmail.com
Telephone: +249919634134
(3)
Faculty of graduate studies, University of Karary, Khartoum – Sudan
(4)
Department of Leather Technology, College of Applied and Industrial Sciences, University of Bahri, Khartoum
– Sudan, P.O.Box 1660
Corresponding author E mail: ali206w@hotmail.com
Telephone: +249919440560
(Received August 01, 2013; Accepted October 16, 2013)


Abstract— Cascade control is commonly used in the control of
chemical processes to reject disturbances that have a rapid effect
on a secondary measured variable, before the primary controlled
variable is affected. In this paper, cascade control strategy is used
to control the temperature inside a jacketed exothermic continuous
stirred tank reactor. The transfer functions of the cascade control
loops were identified from the literature [1]. The ultimate gains for
the secondary and primary loops were determined using direct
substitution, Routh-Hurwitz, Root- locus and Bode methods. To
tune the controllers, the secondary controller was first tuned, and
then the primary controller was tuned using Ziegler-Nichols
technique. The system stability was determined, analyzed and
investigated using Routh and Argand diagram.
Index Terms—: Cascade control, Primary, Secondary loops,
Tuning.
Overview:
1. Cascade control:
Cascade control consists of two sensors, two transmitters,
two controllers and one final control element. The controlled
variable is the reactor temperature. This strategy works as
follows: the primary controller looks at the reactor
temperature ( ) and decides how to manipulate the jacket
temperature ( ) to satisfy its set point. This decision is
transmitted to the secondary controller in the form of a set
point. The secondary controller in turn manipulates the
signal to the valve to maintain the jacket temperature at
the set point provided by the primary controller [3].

I. INTRODUCTION 2. Mathematical model:

T he control of chemical reactors is one of the most

challenging problems in control processes. Considering
that a CSTR is the heart of many processes, its stable and
efficient operation is of paramount importance to the success of
an entire process. Many reactors are inherently unstable. The
instability appears when irreversible exothermic reactions are
carried out in a CSTR (Fig. 1). These reactions tend to produce
a large increment in temperature, forcing the rupture of safety
and reducing the lifetime of the reactor. The solution to this
problem is a temperature control system capable of detecting
the rising of the reactor temperature and quickly removing heat
from the reactor [2].
As the processes requirements tighten, or in processes with
slow dynamics, or in processes with too many or frequently
occurring upsets, the control performance provided by
feedback control may become unacceptable. Cascade control is
a strategy that in some applications significantly improves the
performance provided by feedback control [3].
Mathematical model is used to investigate how the behavior
of a chemical process changes with time under the influence
of changes in the external disturbances and manipulated
variables. Two approaches are in use:
i. Experimental approach:
In this case the physical equipment of the chemical process
is available to the designer. Consequently, the values of
various inputs (disturbance, manipulated variables) are
changed deliberately and through appropriate measuring
devices it can be observed how the outputs (temperature,
pressure, flow rates, concentration) of the chemical process
are changed with time. Such procedure is time and effort
consuming and it is usually quite costly because a large
number of such experiments must be performed [4].
Journal of Applied and Industrial Sciences, 2013, 1 (4): 16-23, ISSN: 2328-4595 (PRINT), ISSN: 2328-4609 (ONLINE) 17
ii. Theoretical approach:
It is quite often the design the control system for a chemical
process is carried out before the process has been
constructed. In such a case it is not possible to relay on the
experimental procedure and a different representation of the
chemical process is needed in order to study its dynamic
behavior. The representation is usually given in terms of a
set of mathematical equations whose solution yields the
dynamic or static behavior of the chemical process [4].
Figure 1: Cascade control of a CSTR
Table 1
Z-N PID controller settings, [2]
Type of controller
P 0.5
PI 0.45
PID 0.6
4. System stability:
Stability is the most important system specification. An
unstable system cannot be designed for a specific transient
response or steady state error requirements. In control loop
the controller must be tuned to obtain satisfactory dynamic
behavior of the controlled variable. Dynamically, a system is
stable of it is response is bounded for all bounded inputs [5].
Different techniques are available to analyze stability of a
closed-loop system:
Routh-Hurwitz:
This technique allows us to compute the number of roots of
the characteristic equation in the right half-plane without
actually computing the values of the roots [4].
3. Ziegler-Nichols (ultimate-cycle method)
Many tuning methods have been proposed for PID
controllers, such as Ziegler-Nichols method, Cohen-Coon
method, Minimum error integral criteria, the systematic Trial
method and quarter–decay ratio method. In Ziegler-Nichols
method the integral time is set to its maximum value and the
derivative time to its minimum. The proportional gain is
slowly increased until the system begins to exhibit sustained
oscillations with a given small step in set point or load
change. The proportional gain and period of oscillation at
this point are the ultimate gain, , and ultimate period,
(Table 1) [6].
0
0
0.5 0.125
Root Locus Analysis:
Root locus is a graphical representation of the roots of the
closed-loop characteristic polynomial as a chosen parameter
(proportional gain) is varied from 0 to infinity [4].
Direct Substitution Analysis
S is substituted by jω in the closed-loop characteristic
equation to find the ultimate gain and the crossover or
ultimate frequency [4].
Frequency Response Analysis:
i. Bode plots:
The magnitude (modulus) and phase angle (argument) are
plotted against frequency [6].
Journal of Applied and Industrial Sciences, 2013, 1 (4): 16-23, ISSN: 2328-4595 (PRINT), ISSN: 2328-4609 (ONLINE) 18

ii. Nyquist plot: A mathematical description of a CSTR is based on

The real and imaginary parts of G(jω) can be plotted on the balance equations expressing the general laws of
s-plane with ω as the parameter [6]. conservation:
Energy balance around the jacket:
Location of roots
Here, system stability is governed by the location of the + ……. (1)
roots of the characteristic equation. The system is stable if
all the roots lie on the left –hand plane of the s-plane. The Energy balance around the reactor:
system is unstable if any of the roots lie on the right –hand
portion of the s-plane. The system is critically stable if the + ….(2)
roots lie along the imaginary axis of the s-plane [5].
The P-Controller transfer function:
II. MATERIALS AND METHODS = ………. (3)
Transmitter:
A jacketed CSTR with exothermic reaction was chosen to The simplest form of the T.F. of a transmitter is a first
study cascade control. Transfer functions of cascade control order lag:
loop elements were derived using the mathematical model
(theoretical approach). Then the block diagram loops were = ………. (4)
constructed with time constants and gains obtained from
literature. From literature [3] the following transfer functions for the
cascade control loop are obtained (Fig. 2 and Fig. 3):
Ultimate gains for secondary and primary loops were = …………….…. (5)
calculated using different stability determination methods, = ………………. (6)
these are: direct substitution method, Root-locus and bode
methods. Z-N tuning method was used to determine the = ….………. (7)
optimum settings of ultimate gains and to calculate the
controller adjustable parameters ( . = ………. (8)
Stability investigation was made using Routh and Roots
location method. Finally, the offset was determined for a
= ………. (9)
step change of magnitude 5% in the set point. = ………. (10)
III. RESULTS AND DISCUSSION = 0.2 ………. (11)
The Mathematical Modeling of a CSTR: = 0.5 ………. (12

Figure 2: Block diagram of cascade loop

Journal of Applied and Industrial Sciences, 2013, 1 (4): 16-23, ISSN: 2328-4595 (PRINT), ISSN: 2328-4609 (ONLINE) 19

Figure 3: Block diagram of the reduced cascade loop

The open-loop transfer function of the secondary loop: used to calculate . If there is no crossover frequency for
OLTF = ……..…. (13) the secondary control loop (system is unconditionally
The open-loop transfers function of the primary control stable), therefore large values for the gain can be used,
loop: which produces a very fast closed-loop response, to
OLTF = …. (14) compensate for any change in the disturbance arising
within the secondary process. Once the value of has
The characteristic equation of the primary control loop:
0.05 + 12.65 + 37.6 S +25 + 60 =0 …….….(15) been selected, the crossover frequency for the overall open-
loop transfer function can be calculated. Then the value of
the primary controller gain ( can be selected using Z-
Ultimate gains results:
Two cases appear when determining the ultimate gain for the N.
secondary loop ( . If the loop is unstable, the value of Here the secondary loop was unconditionally stable, hence
is taken to calculate (Table 2).
can be found directly, tuned with Z-N method and

Table 2
Ultimate gain results
Cascade loop

Secondary loop Overall loop

Direct sub. method Stable system No cross-over 157 27.4

Root Locus method Stable system No cross-over 155 27.1

Bode method Stable system No cross-over 167.4 28.2

average ---- ---- 159.8 27.56

Journal of Applied and Industrial Sciences, 2013, 1 (4): 16-23, ISSN: 2328-4595 (PRINT), ISSN: 2328-4609 (ONLINE) 20

Using MATLAB, Root locus and Bode plots (Figs. 4, 5, 6) are deduced for the secondary and primary loops:

Root Locus
1.5

0.5
Imaginary Axis

-0.5

-1

-1.5
-40 -35 -30 -25 -20 -15 -10 -5 0 5
Real A xis

Figure 4: Root-locus plot for the secondary loop

Bode Diagram
-10

-20
Magnitude (dB)

-30

-40

-50

-60
0
Phase (deg)

-45

-90
-1 0 1 2 3
10 10 10 10 10
Frequency (rad/sec)
Figure 5: Bode plot for the secondary loop
Journal of Applied and Industrial Sciences, 2013, 1 (4): 16-23, ISSN: 2328-4595 (PRINT), ISSN: 2328-4609 (ONLINE) 21

Root Locus

40

30

System: sys
20
Gain: 155
Pole: 0.116 + 27.1i
10 Damping: -0.00428
Imaginary Ax is

Overshoot (%): 101

Frequency (rad/sec): 27.1
0

-10

-20

-30

-40

-50
-40 -30 -20 -10 0 10 20 30 40
Real Axis
Figure 6: Root-locus plot for the reduced primary loop
Journal of Applied and Industrial Sciences, 2013, 1 (4): 16-23, ISSN: 2328-4595 (PRINT), ISSN: 2328-4609 (ONLINE) 22

Bode Diagram
50

0
Magnitude (dB)

-50

-100

-150

-200
0
Phase (deg)

-90

-180
System: sys
Frequency (rad/sec): 28.2
-270 Phase (deg): -180
-2 -1 0 1 2 3 4
10 10 10 10 10 10 10
Frequency (rad/sec)
Figure 7: Bode plot for the reduced primary loop
Journal of Applied and Industrial Sciences, 2013, 1 (4): 16-23, ISSN: 2328-4595 (PRINT), ISSN: 2328-4609 (ONLINE) 23

Tuning using Z-N method: fastest response ( is large without affecting the
= 159.8, = 0.2278 stability).

Nomenclature:
P 79.9 - - CSTR: Continuous Stirred Tank reactor
: Reactor temp.
PI 71.9 -
: Initial reactor temp.
: Jacket temp.
PID 95.88
: Initial jacket temp.
Stability investigation: : Time constant ( )
The Characteristic equation of the reduced primary loop:
0.05 + 12.65 + 37.6 S +25 + 60* =0 : Constant
0.05 + 12.65 + 37.6 S +9613 =0
: Controller gain
Using roots location method, the roots are:
>> roots ([0.05 12.65 37.6 9613]) : Primary controller gain
The values of the roots are: : Secondary controller gain
1.0e+002 *
-2.5153 : Ultimate gain of the primary loop
-0.0073 + 0.1956i : Ultimate gain
-0.0073 - 0.1956i
All of the roots lie on the LHP (left hand plane), therefore : Ultimate gain of the secondary loop
the system is stable. : Ultimate period
Offset due to a step change in the set point: : Cross-over frequency
: Integral time.
= --
: Derivative time.
= Z-N: Ziegler-Nichols method
= 0.05
Acknowledgment
Offset = = 0.049 The authors are indebted to the administration of Karary
University, faculty of graduate studies and research for their
help and support.
IV. CONCLUSIONS
The first step in the cascade control of a CSTR should be the REFERENCES
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and the root-locus, Bode plots are deduced, It has been [2]. Thoma M.,(2007). “Selected topics in Dynamics and Control
shown that the secondary loop is unconditionally stable for of Chemical and Biological Process” , Springer Science media,
all values of the controller gain, while the primary loop is Germany. pp, 5-6.
[3].Carlos A. (2006). “ Principles and practice of Automatic
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Process Control” , John Wiely and sons Inc, Asia. Pp, 310-315.
gain which gives a close-loop stable reactor ( <159.8). [4]. Gasmelseed, G.A. (2012). “Advanced control for graduate
After tuning with Z-N method and investigation of the students”, G-town, Khartoum. pp, 142,174,183.
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the system was found to be stable.
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