ChEn 4601 - Process Control - Fall 2015

Project
Assigned: Monday, November 23
Due: Wednesday, December 16 (submit by 12:00 at 151 AmH)
Consider a continuous stirred-tank reactor where
takes place:
A
B
2A

the following series/parallel reaction scheme

B
C
D

Assuming constant volume and temperature, the mass balances for A and B have the form:
dx1
= k1 x1 k3 x21 + (cA0 x1 )u
dt
dx2
= k1 x1 k2 x2 x2 u
dt
where x1 , x2 represent the concentrations of A, B respectively, k1 = 50h1 , k2 = 100h1 and
k3 = 10l/(gmol.h) are the reaction rate constants for the three reactions, cA0 = 10gmol/l is the
inlet concentration of A, and u is the dilution rate (flowrate/volume). The objective is to control
x2 by manipulating u. A feedback control system is installed for this purpose, for which the
dynamics of the final control element can be neglected. The measuring device is modeled as a
pure time delay of 1min. The output variable can then be thought of as the delayed variable x2 .
Specific Questions
1. (5 pts.) Given a nominal steady-state value of u, us = 34.28h1 , obtain the steady-state values for
x1 and x2 , x1s and x2s .
2. (5 pts.) Linearize the process model equations around the nominal steady-state conditions, to obtain
an approximate linear model of the process expressed in terms of the deviation variables:
Xi = xi xis , i = 1, 2 and U = u us . Obtain the process transfer function. Is the process
stable or unstable? Is it minimum- or non-minimum-phase? Justify your answers.
3. (20 pts.) Starting from the nominal steady state, impose a step decrease in the value of u from
u = 34.28 to u = 25, and obtain (and plot) the response of the output variable on the basis
of the nonlinear process model. From this process reaction curve, obtain estimates of the
gain and integral time constant for a P and a PI controller, using the Cohen-Coon tuning
rules. In addition, obtain estimates of the controller settings using the Ziegler-Nichols tuning
rules.

4. (20 pts.) Implement the P and PI controllers that you derived in 3) on the nonlinear process model
and provide plots of the manipulated input and controlled output responses, for a change
in the set-point from x2s to 1. Discuss the nature of the responses and the performance of
the various controllers.
5. (20 pts.) Based on the transfer function of the process that you found in 2), synthesize a feedback controller that will give nearly ISE-optimal response for step changes in the set-point. Provide
the transfer function of the controller and the closed-loop response for the controlled output
as predicted by the theory. For the same change in the set-point as in 4), provide some
representative plots of this predicted response, for different values of the controller tuning
parameter(s). Your plots should clearly establish how the different values of the controller
tuning parameter(s) affect the optimality of the response. What would limit achieving the
exact ISE-optimal response in practice? Repeat for a larger step in the set point.
6. (30 pts.) Implement the controller that you derived in 5) on the nonlinear process model, for the
same changes in the set-point as in 4). Provide plots of the resulting manipulated input
and controlled output responses for different values of the tuning parameter(s) (use the
same ones that you used in 5) to have a meaningful comparison). Explain how your plots
document the practical limitations in achieving an ISE-optimal response. Compare the
output responses with those obtained in 5) and justify any discrepancies. Also, compare
the output responses with those obtained in 4) and discuss the relative effectiveness of the
various control methods that you tried.
Requirements and Report Format
You can work on groups of up to 3 persons on the project (smaller groups or even independent
submissions are also fine). You must turn in a neatly written, clear and concise report (preferably
typed).
Your report should include the following parts:
Title page. Please make sure you include your names and the sections in which you are
registered.
Main body. Address the questions posed previously. For each question, include the analytical
calculations and all necessary plots with a brief explanation of what they represent. Interpret
and discuss your results adequately.
Appendices. Include listings of representative programs that you used to generate your
results.
Note that no late submissions will be accepted. If you have any questions regarding the project,
please contact Professor Daoutidis.