Control System Design for Continuous Stirred

Tank Reactor Using Matlab Simulink

by :
Ahmed Babiker Ahmed
Hashim Ahmed Edress
Khalid Osman Mohammed

A graduation project is submitted to electrical & electronic engineering

department in partial fulfillment of the requirements for the degree of
bachelor in electrical & electronic engineering

Department of Electrical & Electronic Engineering

College of Engineering & Technology

Nile Valley University

July 2016
Control System Design for Continuous Stirred
Tank Reactor Using Matlab Simulink

by :
Ahmed Babiker Ahmed
Hashim Ahmed Edress
Khalid Osman Mohammed

A graduation project is submitted to electrical & electronic engineering

department in partial fulfillment of the requirements for the degree of
bachelor in electrical & electronic engineering

Department of Electrical & Electronic Engineering

College of Engineering & Technology

Nile Valley University

July 2016
 DEDICATION

We wish to dedicate this research to our most

beloved mothers

and fathers whose love and support has been

essential in all stages of this research

We also dedicate our research to our

teachers and colleagues.

With best wishes

ii
 ACKNOWLEDGMENT

We would like to thank Allah who blessed us with

the courage for completion of this study.

We also grateful to our supervisor Abubakr

Rahmtallah Abdalla for his guides and continuous
following.

Special thanks to our families for care and support.

iii
 Abstract

The temperature of the continuous stirred tank reactor (CSTR) is controlled in three
configurations (feedback, feed forward and cascade). For each type of the control systems
the controllers used was tuned and its optimum parameters were calculated. For the
feedback control system in particular, the proportional integral derivative controller (PID)
was selected other than the proportional (P) and the proportional integral (PI) controllers.

Also for each configuration a stability analysis is made using (Bode, Nyquist and
root-locus) criterions.

A selection for recommended control design has been taken on the output response
of the systems as well as the stability for each system.

iv
 Table of contents
Dedication i
Acknowledgement ii
Abstract iii
Table of contents iv
List of tables vi
List of figures vii

Chapter One : Introduction

Introduction to Chemical Reactors
Heat cooling systems (Jackets)
Classification of chemical reactors models
Batch reactor model (batch)
Continuous stirred – tank reactor model (CSTR)
Reactor temperature control
Feedback control system
Feed forward control system
Cascade control system
PID control
Objectives

Chapter Two : Mathematical Model

Approach
Experimental approach
Theoretical approach
Why do we need the mathematical modeling for process control?
Classifying mathematical models
Linear vs. nonlinear
Deterministic vs. probabilistic (stochastic)
Static vs. dynamic
Lumped parameters vs. distributed parameters
Derivation mathematical model of continuous stirred tank reactor
(CSTR)
v
Temperature sensors
Final control elements

Chapter Three : Design of control system

Design of feedback control system
Controller tuning
Proportional controller
Proportional Integral controller
Proportional integral derivative controller
Comment
Design of feed forward control system
Distribute rejection
Set pointtracking
Design of cascade control system
Controlling tuning

Chapter Four : Stability analysis of the control system

Stability analysis of feedback control system
Bode criteria
Nyquist criteria
Root locus criteria
Stability analysis of cascade control system
Nyquist criteria
Root locus criteria
Stability analysis of feed forward control system

Chapter Five : Summary and Conclusion

Summary
Conclusion
References
Appendix

vi
 List of Tables
Table Page
Contents
No. No.
Zigler-Nichols tuning using the oscillation method

Routh criteria

Zigler Nicholas tuning using the second method

Routh-Hurwitz criteria

comparison between the output responses

vii
 List of Figures

Figure Page
Contents
No. No.
PID action (1)

PID action (2)

PID action (3)

CSTR with cooling jacket

typical thermocouple arrangement

conventional feedback control of CSTR

feedback control diagram

block diagram of feedback control using P controller

output response of the system using P controller

block diagram of feedback control using PI controller

output response of the system using PI controller

block diagram of feedback control using PID controller

output response of the system using PID controller

feed forward control of CSTR

block diagram of feed forward control of CSTR

modified block diagram of feed forward system

output response of feed forward system

cascade control of CSTR

block diagram of cascade control of CSTR

modified block diagram of cascade system

bode plot of the feedback system

Nyquist plot of the feedback system

root locus plot of the feedback system

Nyquist plot of the feedback system

viii
rood locus of the feedback system

cascade control of CSTR

block diagram of cascade control of CSTR

Bode plot of the cascade system

Nyquist plot of the cascade system

root locus plot of the cascade system

ix
 Chapter 1. Introduction

Introduction to chemical reactors

In chemical engineering ,chemical reactors are vessels designed to contain
chemical reactions. The design of a chemical reactor deals with multiple aspects of
chemical engineering.
Chemical reactions are either exothermic (release energy) or endothermic (require
energy input) and therefore require that energy either be removed or added to the reactor
for a constant temperature to be maintained. Exothermic reactions are the most interesting
systems to study because of potential safety problems (rapid increases in temperature,
sometimes called "ignition" behavior) and the possibility of exotic behavior such as
multiple steady-states (for the same value of the input variable there may be several
possible values of the output variable).

Heat Cooling Systems (Jackets)

Products within reactors usually liberate or absorb heat during processing. Even
the action of stirring stored liquids generates heat. In order to hold the reactor contents at
the desired temperature, heat has to be added or removed by a cooling jacket or cooling
pipe. Heating/cooling coils or external jackets are used for heating and cooling reactors.
Heat transfer fluid passes through the jacket or coils to add or remove heat.

Classification of chemical reactor models

There are two main basic models used to estimate the most important process
variables of different chemical reactors:
 Batch reactor model (batch)
 Continuous stirred-tank reactor model (CSTR)
Batch reactor model (batch)
The Batch reactor is the generic term for a type of vessel widely used in the
process industries. Its name is something of a misnomer since vessels of this type are used
for a variety of process operations such as solids dissolution, product mixing, chemical
reactions, batch distillation and liquid/liquid extraction. In some cases, they are not
referred to as reactors but have a name which reflects the role they perform (such as
crystallizer, or bio reactor).

1
 Continuous stirred-tank reactor model (CSTR)
In a CSTR, one or more fluid reagents are introduced into a tank reactor equipped
with an impeller (An impeller is a rotating component or a pump) while the reactor
effluent is removed, the impeller stirs the reagents to ensure proper mixing. Simply
dividing the volume of the tank by the average volumetric flow rate through the tank gives
the residence time.
At steady-state, the flow rate in must equal the mass flow rate out, otherwise the
tank will overflow or go empty (transient state). While the reactor is in a transient state the
model equation must be derived from the differential mass and energy balances.
All calculations performed with CSTRs assume perfect mixing.

Reactor temperature control

The amount of heat generated by a exothermic reactor increases as the
reaction temperature rises.
If the reactor is operated without temperature controller (in an open loop
configuration), an increase in the reaction temperature will also increase heat
removal, because of the increase in ( T) between process and coolant
temperature.
If an increase in a reaction temperature result in a greater increase in heat
generation than in heat removal, the process is said to display positive feedback; as such it
is considered to be (unstable in the open loop). The positive feedback of the open loop
process can be compensated by the negative feedback of a reactor temperature controller,
which will increase the heat removal rate as the temperature rises.
There are several types of control systems:

Feedback control system

The feedback control action measures the value of the output using the measuring
device, which sends the signal through the transmitter to the controller. The controller
compares this value with the desired value (set point) and supplies the deviation signal to
the final control element, which in turn changes the value of the manipulated variable.

Feed forward control system

Feed forward control is a strategy used to compensate for disturbances in a system
before they affect the controlled variable. A feed forward control system measures a
disturbance variable. Predicts its effect on the process, and applies corrective action.
However, this system has three major drawbacks:

2
  The model must be exact (including dynamics and nonlinearities).
 All instruments in the loop must be perfectly calibrated.
 Disturbances other than the feed forward variable are not controlled.
Cascade control system
A cascade control system is a multiple-loop system where the primary variable is
controlled by adjusting the set point of a related secondary variable controller. The
secondary variable then affects the primary variable through the process.
The primary objectives in cascade control is to divide an otherwise difficult to
control process, into two portions, whereby a secondary control loop is formed around a
major disturbances thus leaving only minor disturbances to be controlled by the primary
controller.
The advantages of cascade control are all somewhat interrelated. They include:
 Better control of the primary variable.
 Primary variable less affected by disturbances.
 Faster recovery from disturbances.
 Improve dynamic performance.
 Provide limits on the secondary variable.

PID Control
What is a PID control:
 Proportional + Integral + Derivative (PID).
 Popular in the industry.
 By 1989, more than 90% PID.
 Easy to implement.
 It is quite robust.
 Applies to mechanical systems.
Predominantly 2nd-order systems:
 Tuning algorithms not dependent on exact system model.
 Two popular tuning techniques.
 Step reaction curve experiment.
Closed-loop “cycling” experiment under proportional control around the nominal
operating point.

3
 Fig 1.1 PID action (1)

The PID action

∫ ̇

( ) ( ) ( ) ( )

( ) ( ) ( )

( )
( )
( )

Equivalently,

Let:

( ∫ ̇

( ) ( ) ( )

( )
( ) ) ( )
( )

4
 Fig 1. PID action ( )

Fig 1. PID action ( )

Objectives
There are some objectives need to be achieved in order to accomplish this project. These
objectives will act as a guide and will restrict the system to be implemented for certain situations.

 Design of control systems of CSTR.

 Tuning of the systems.
 Analysis of response and stability of the systems.
 Make an appropriate block diagram of the recommended configuration.

5
 Chapter 2. Mathematical model

Approach
To investigate how the behavior of a chemical process change with time under the
influence of changes in the external disturbances and manipulated variables and
consequently design an appropriate controller, we can use two different approaches.

Experimental approach
In this case the physical equipment of the chemical process is available to us.
Consequently , we change deliberately the values of various inputs (disturbances,
manipulated variables) and through appropriate measuring devices we observe.
How the outputs (temperature, pressure, concentration) of the chemical processes
changes with time. Such a procedure is time and effort consuming and it's usually quite
costly because a large number of such experiments must be performed.

Theoretical approach
It is quite often the case that we have to design the control system for a chemical
process before the process has been constructed. In such a case we cannot rely on the
experimental procedure, and we need a different represented of the chemical process in
order to study its dynamic behavior. This representation is usually given in terms of a set
of mathematical equations (differential, algebraic) whose solution yields the dynamic or
static behavior of the chemical process we examine.

Why do we need the mathematical modeling for process control?

Our goal is to develop a control system for chemical process which will guarantee
that the operational objective of our process is satisfied in the presence ever-changing
disturbances. Then, why do we need to develop a mathematical description for the process
we want to control?
In the experimental approach we noted that often the physical equipment of the
chemical process we want to control have not been constructed. Consequently, we cannot
experiment to determine how the process react to various inputs and therefore we cannot
design the appropriate control system. But even if the process equipment is available for
experimentation, the procedure is usually is very costly. Therefore, we need a simple
description of how the process reacts to various inputs, and this is what the mathematical
models can provide to the control designer.

6
 Often when engineers analyze a system to be controlled or optimized, they use a
mathematical model. In analysis, engineers can build a descriptive model of the system as
a hypothesis of how the system could work, or try to estimate how and unforeseeable even
could affect the system. Similarly, in control of a system, engineers can try out different
control approaches in simulations.
A mathematical model usually describes a system by a set of variables and a set of
equations that establish relationships between the variables. The values of the variables
can be practically anything; real or integer numbers, Boolean values or strings, for
example. The variables represent some properties of the system, for example, measured
system outputs often in the form of signals, timing data, counters, event occurrence
(yes/no). The actual model is the set of functions that describe the relations between the
different variables.

Classifying mathematical models

Mathematical models can be classified in several ways, some of which are
described below.

Linear vs. nonlinear

Mathematical models are usually composed by variables, which are abstractions of
quantities of interest in the described systems, and operators that act on these variables,
which can be algebraic operators, functions, differential operators, etc. If all the operators
in a mathematical model present linearity, the resulting mathematical model is defined as
linear. A model is considered to be nonlinear otherwise. In a mathematical programming
model, if the objective functions and constraints are represented entirely by linear
equations, then the model is regarded as a linear model. If one or more of the objectives
functions or constraints are represented with a nonlinear equation, then the model is
known as a nonlinear model.

Deterministic vs. probabilistic (stochastic)

A deterministic model is one in which every set of variable states is uniquely
determined by parameters in the model and by sets of previous states of these variables.
Therefore, deterministic models perform the same way for a given set of initial conditions.
Conversely, in a stochastic model, randomness is present, and variable states are not
described by unique values, but rather by probability distributions.

7
 Static vs. dynamic
A static model does not account for the element of time, while a dynamic model
does. Dynamic models typically are represented with difference equations or differential
equations.

Lumped parameters vs. distributed parameters

If the model is homogeneous (consistent state throughout the entire system) the
parameters are lumped. If the model is heterogeneous (varying state within the system),
then the parameters are distributed. Distributed parameters are typically represented with
partial differential equations.

Derivation mathematical model of continuous stirred tank reactor

(CSTR)

Fig 2.1 CSTR with cooling jacket

A+B R
Input energy – output energy + heat provided by steam = rate of change of energy

( )

( )

Dividing the above equation by (mf Cp)

8
 ( )

But

Also put

( )

Let

( )

Taking Laplace transform of the above equation

( ) ( ) ( )

( ) ( ) ( )
( ) ( )

The coefficient of Ms(s) represents the process transfer function (Gp) also the
coefficient of Tf(s) represents the load transfer function (Gd).
For our process we have found that

And also for the load variable:

Thus, the transfer function of the process becomes

( )

Also, the transfer function of the load variable is:

( )

9
 Temperature sensors
The most common are the thermocouples, resistance bulb thermometers and
thermistors. All provide measurements in terms of electrical signals .The temperature
sensing elements is always inside the thermo-well figure (2.2).

Figure 2.2 typical thermocouple arrangement

We assume that the major resistance to heat transfer is located outside the
thermowell casing. In such a case we have a single capacity with resistance and it is
modeled by a first order system.

After Laplace transform of the above equation

( ) ( ) ( )

Thus, the transfer function of the temperature sensor:

( )
( )
( ) ( )

For our process we find that

So the transfer function is

( )

Final control elements

These are the hardware components of the control loops that implement the control
action. They receive the output of the controller (actuating signal) and adjusts accordingly

11
the value of the manipulated variable. We have chosen the final control element (valve) to
have a first-order response.

( )

For the valve used we take that

The transfer function becomes

11
 Chapter 3. Design of control system

Design of feedback control system

Consider the temperature control system for the continuous stirred tank reactor of
figure

Figure 3.1 conventional feedback control of CSTR

The temperature T is the controlled output, while the inlet temperature Tf, mf, is
the load and the coolant is the manipulated variable.
The transfer functions for each component of the feedback loop as illustrated in
Chapter 2 are
The process transfer function=

( )

The load transfer function =

( )

The valve transfer function =

( )

The measuring element transfer function =

( )

12
 The feedback control action measures the value of the output (temperature)using
the temperature measuring device (thermo-couple), then compares this value with the
desired value (set point) and supplies the deviation signal to the valve which in turn
changes the value f the manipulated variable (coolant). The block diagram of this control
action is shown in figure (3.2) below:

Figure feedback control diagram

Controller tuning
One of the traditional ways to design controller parameters was to use empirical
tuning rules based on measurements made on the real plant. We suggest that it is
preferable for the controller designer to employ model-based techniques. And one of best
techniques is Ziegler-Nichols method.
This criteria depends on setting the plant under proportional controller and calculating
the ultimate gain (ku) and the ultimate period (Pu) which leads to continuous oscillation.
Then we adjust the controller parameters according to the table developing by
Ziegler-Nichols shown below:

Table 3.1 Zigler-Nichols tuning using the oscillation method

Kc Ti Td
P 0.5Ku
PI 0.45Ku Pu/1.2
PID 0.6Ku Pu/2 Pu/8

13
 We will use Routh criteria to calculate the ultimate gain and period from the
characteristics equation of the feedback configuration.
The transfer functions of the feedback control loop:

( ) ( )
( ) ( )

( )
( )( )

( )
( )( )( )
( ) ( )
( ) ( )( )( )
( ) ( )
( ) ( ) ( )
Then the characteristic equation is:
( ) ( )

For our system and from chapter two we found that:

Then the characteristic equation becomes:

Table Routh criteria

S
S 50.3 kc
S A A
S B B

Where
( )( ) ( )( )

( )( )

14
 In order for the system to be critically stable (continuous oscillation) the first
elements in this third row (A ) must be equal to zero.

Thus:

To find he ultimate period, we must first calculate the ultimate frequency ωu:
From the second row we have:
( )
( )

Table Zigler Nicholas tuning using the second method

Kc Ti Td

P
PI
PID
We want to select from the three controllers above

Proportional controller

Figure 3.3 block diagram of feedback control using P controller

15
 The output of the closed loop using P controller due to step change in the set point is
recorded and graphed using MATLAB and illustrated below
Amplitude

t
Figure 3.4 output response of the system using P controller

From the output response of the system we notice that

The offset = Yidle – Y steady state -
The maximum deviation =
The system response time = 5 sec

Proportional Integral controller

Figure 3.5 block diagram of feedback control using PI controller

Again the output of the closed loop using PI controller due to step change in the set
point is recorded and graphed using MATLAP and illustrate below

16
Amplitude

t
Figure 3.6 output response of the system using PI controller

From the output response of the system we notice that

The offset = Yidle – Ysteady state = 0 at steady state
The maximum deviation =
The system response time = sec

3.1.4 Proportional integral derivative controller

Figure 3.7 block diagram of feedback control using PID controller

Also the output of the closed loop using PID controller due to step change in the
set point is recorded and graphed using MALTAB, and illustrate in figure (3.8).

17
Amplitude

t
Figure 3.8 output response of the system using PID controller

Form the output response of the system we notice that

The offset = Yidle – Y steady state = 0 at steady state
The maximum deviation =
The system response time = sec

Comment
The proportional controller alone accelerates the response of the controller process
(response time = 510 sec), but it produces a considerable offset (0.7).
The proportional integral controller completely eliminates the offset, this
elimination of the offset usually comes at the expense of higher maximum deviation
(maximum deviation = 0.7), it also produces sluggish long oscillation response (response
time = 770 sec).
The proportional integral derivative controller produces a fast response time
(response time = ), and completely eliminating the offset. Thus the proportional
integral derivative controller is recommended.
The above result is acceptable, because; we have two rather slow processes: a heat
transfer between the reacting mixture and the temperature sensor, and heat transfer form
coolant water to the reacting mixture. We expert, therefore, that the overall response will
be rather sluggish and a PI controller will make it even more. Consequently, for such
system a PID controller would be the most appropriate, because it can allow high gains for
faster response without any offset.

18
3.2 Design of feed forward control system
A feed forward control system uses a different approach than the conventional
feedback control system. It measures the temperature of the inlet reactants and adjusts
appropriately the coolant amount. Figure (3.9) shows the feed forward control
configuration. Thus it measures the disturbance directly and then it anticipates the effect it
will have on the process output.
Subsequently, it changes the manipulated variable by such an amount as to
eliminate completely the impact of the disturbance on process output.

Figure 3.9 feed forward control of CSTR

The feed forward loop measures the disturbance directly and then it anticipate the
effect it will have on the process output. Subsequently , it changes the manipulated
variable by such an amount as to eliminate completely the impact of the disturbance on the
process output, the block diagram of this control action is shown in figure below

Figure 3.10 block diagram of feed forward control of CSTR

19
 In feed forward system the feedforward controller cannot be a conventional
feedback controller (P,PI, and PID). Instead, it should be viewed as a special purpose
computing machine. This is the reason it is sometimes referred to as a feedforward
computer.
Now we have to determine the transfer function of the controller and the set point.
Referred to (Gc,Gsp) respectively.
We can easily show that:
( ) ( ) ( ) ( ) ( )

The design transfer function Gc and Gsp can now be identified by the following two
requirements

Distribute rejection
The controller should be capable of completely eliminating the impact of a
disturbance change on the process output. This implies that the coefficient of d(s) should
be zero:

Or

Set pointtracking
The control mechanism should be capable of making the process output track
exactly any change in the set point (i.e. (s) = Ysp(s)).
( ) ( )
( )

The implies that the coefficient of Ysp(S) should be equal to 1:

or

( )

And finally,

After substituting the values of Gm,Gd,Gp,Gf, we have

21
 ( )

And
( )( )( )
( )( )
( )

We notice that the controller transfer function can be arranged to the form of PID
controller as
( )( )

( )

The controller transfer function is represented as a derivative followed by a PID

controller.
After substituting the values of each component, Figure (3.10) becomes

Figure 3.11 modified block diagram of feed forward system

The output of the feed forward control system due to step change in the load
variable is recorded and graphed using MALTAB, and illustrated in figure (3.12) below

21
Amplitude

t
Figure 3.12 output response of feed forward system

Design of cascade control system

In a cascade control configuration shown in figure (3.13), we have one
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.

Figure 3.13 cascade control of CSTR

22
 We have a process consisting of two parts:
Process I (primary) has as its output the variable we want to control.
Process II (secondary) has an output that we are not interested in controlling but
which effects the output we want to control.
For the CSTR system process I is the reaction in the tank and the controller output
is the temperature T. 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 a zero order transfer function.
The block diagram of this control action is shown in figure (3.14) below

Figure 3.14 block diagram of cascade control of CSTR

Controlling tuning
We are again going to use Ziegler-Nicols to find the parameters of the proportional
controller in the secondary loop.
After some modifications in the secondary loop in block diagram of figure (3.14),
it becomes

Figure 3.15 modified block diagram of cascade system

23
 The transfer function
( ) ( )
( ) ( )

( )
( )
( )( )

( )
( )
( )( )( )

( ) ( )( )
( ) ( )( )( ) ( )

( ) ( )( )
( ) ( ) ( ) ( )

From the above transfer function, the characteristic equation is

( ) ( ) ( )

After we finish our analysis development for mathematical equation now start
analysis the system using Routh-Hurwitz criteria
Table Routh-Hurwitz criteria
S 0.023Kc
S 401.76+124Kc 1+1.61 Kc
S A 0.023Kc
S B
S 0.023Kc

Where

( )( )
( )
(

In order for the system to be critically stable (continuous oscillation) the first
element in the fourth row (B ) must be equal to zero.
( )( )
( )
(

24
And that leads Kc to have the following values:

From the above value of Kc we see that Routh criteria failed to specify the ultimate
gain because all values of Kc have a negative real parts.
To determine the proportional controller parameter we simulate the system for
different values of Kc using MATlAB we find that

25
 Chapter 4. Stability analysis of the control system

A very important characteristic of transient performance of a system is its stability.

A system was considered a stable if, after it had been disturbed by an input change, it's
output returns to the initial state of reset state of reset.
It is required for the control system to keep the output within specified limits and to
have always y(t) r (t), here y (t) is the controlled variable and r(t) is its corresponding
desired value.
There are several methods to check whether a system is stable or not, we are going to
check the stability of our systems with the following methods
Nyquist stability criterion:
It states that if the open –loop Nyquist plot of a feedback system encircles the point.
(-1,0) as the frequency takes any value from (- ), the closed-loop
response is unstable.
 Root locus criterion
This criterion of stability does not require calculations of the actual values of the
roots of the characteristics equation, it only requires that we know if any root is to the right
of the imaginary axis (i.e., have positive real parts) that leads to unstable system.
 Bode criterion
4.1 Stability analysis of feedback control system
To analyze the stability of the system we should have its transfer function:
from figure (3.7):

( ) ( )
( ) ( )

( )
( )
( )( )

( )
( )
( )( )( )

( ) ( )( )
( ) ( )( )( ) ( )

26
After substituting the values of the above parameters:
( )
( )

4.1.1 Bode criteria

The Bode plot of the feedback transfer function is graphed using MALTAB and
shown below

Figure 4.1 bode plot of the feedback system

Nyquist criteria
The Nyquist plot of the feedback transfer function is graphed using MALTAB and
shown in figure (4.2)

27
 Figure 4.2 Nyquist plot of the feedback system
Since the Nyquist plot of a feedback system does not encircles the point (-1.0),
thus the system is stable according to Nyquist criterion.
4.1.3 Root locus criteria
Root locus plot of the feedback transfer function is graphed using MALTAB and
shown figure (4.3) below

Figure 4.3 root locus plot of the feedback system

The feedback system cannot go unstable, since the roots of the characteristic
equation cannot have positive real parts (i.e., root locus plot does not cross the imaginary
axis).
4.2. Stability analysis of cascade control system
We recall that from section (3.3.1) that the transfer function of the cascade control
system was:

( ) ( )( )
( ) ( ) ( ) ( )

28
The transfer function becomes:
( )
( )

Nyquist criteria

Figure 4.4 Nyquist plot of the feedback system

Also the Nyquist plot of a cascade system does not encircle the point (-1,0), therefore,
the system is stable in sense of Nyquist criteria.

Root locus criteria

Root locus plot of the cascade transfer function is graphed using MALTAB and shown
in figure (4.5)

Figure 4.5 rood locus of the feedback system

29
 A gain, the cascade system cannot go unstable, since the roots of the characteristics
equations cannot have positive real parts (i.e., root locus plot does not cross the imaginary
axis).

Stability analysis of feed forward control system

The above criterions used to investigate the stability of the systems cannot be
applied for feed forward control system because it is not a closed - loop system.
Generally the feed forward system does not introduce instability in the system
response because it measures the disturbance and takes control action to eliminate it
impact on the process output. This is clearly seen from the output response of figure

31
 Chapter 5. Summary and Conclusion

Summary
The mathematical model of the CSTR
 The transfer function of the CSTR:
0.503 1
Gp  , Gd 
12.4S  1 12.4S  1
 The transfer function of the final control element (valve)
10
Gf 
30S  1
 The transfer function of the measuring element
10
Gm 
10S  1
The tuned controllers of the CSTR
 Feedback controller
0.0045
Gc  0.122   0.82S
S
 Feed forward controller
0.02
Gc  S (0.8   6S )
S
 Cascade controller
Master controller (Gc) = 0.122+

Slave controller Gc = 27
. Recommended design configuration
 The physical diagram

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 Figure 5.1 cascade control of CSTR

 The block diagram

Figure 5.2 block diagram of cascade control of CSTR

Stability analysis of the recommended system

 Bode plot:

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 Figure 5.3 Bode plot of the cascade system

 Nyquist plot

Figure 5.4 Nyquist plot of the cascade system

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 Root locus plot

Figure 5.5 root locus plot of the cascade system

Conclusion
From preceding chapters, we designed three control systems for our CSTR. The
stability for each design has been investigated with the aid of some criterions.
We studied in this research the behavior and control method s for CSTR by using
deferent feedback controllers (P,PI,PID) , the comparison between three controllers was
investigated and we found that the PID controller has the best response.
In this chapter we are going to select the most appropriate design for our CSTR.
Our selection is based on the output response as well as the stability of each system.
The three control systems (feedback, feed forward and cascade) which are
designed before are considered to be stable according to (Bode, Nyquist and Root- locus)
criterion. Therefore the selection of the recommended system is going to be restricted to
the output response of the system.
The comparison between the output responses of the systems is shown in table

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 Table comparison between the output responses

The characteristic Feedback system

Feed forward system
features P PI PID

The offset

Response time (sec)

Maximum deviation

From table (5.1) it is seen that the feedback control system produces a long response
time with a considerable oscillation.

Although the feed forward control has a faster response time compared to the
feedback control system, it produces a considerable offset a large overshoot.

35
References:

Smith, R.M (2005) Chemical Process: Design and Integration, John Wiley & Sons,
chichester.

2. Houfar , F: Salah shoor, K. (2008). Adaptive control of CSTR using Feedback

Linearization Based on Grey – Box Modeling , proceeding of FEEE International confe.

3. Adaptive control systems : techniques and applications by V.V. chalam : 34 –

4. Srinivas Palanki , Soimitri Kolavennu , (2003). Simulation of control of CSTR process

int. J. Engng Ed. Vol. 19 No 3, PP 398

36
Appendix

Symbol Meaning

mf Input mass kg

tf Feed temperature k

T Out temperature k

m Output mass kg

A Inlet concentration of acetic an hydride

Hc Outlet temperature of coolant (kj/kg)

Hs Inlet temperature of coolant (kj/kg)

Ms Mass of fluid

B Water

R Out put

Cp Specific heat (kj/kg.k)

Kp Proportional gain

Ki Integral gain

Kd Derivative gain

Kc Critical gain

Gc(s) Transfer function of controller

Gd(s)s Transfer function of disturbance (load)

G Gain coefficient

Ts Setting time

tp Peak time

Td Delay time

ωn Angular frequency

ωu Ultimate frequency

V Valve

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C Controller

P Process

M Measuring element

S Laplace variable

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