Hitesh Dholakiya

Thursday, March 01, 2012

Benefits of Cascade Control Logic

Isolating the controller for a key process variable from a

problem element Responding faster to certain disturbances Providing more consistent performance over a range of process conditions

Jacketed Reactor with Simple feedback

Thursday, March 01, 2012

Simple Feedback
Figure

2.1 presents the simple feedback control configuration. The measured value of the reactor temperature is the PV input to the reactor temperature controller; the output of the reactor temperature controller is the cooling water valve opening. The simple feedback control configuration requires only one measurement device, one controller, and one control valve. The advantages of the simple feedback configuration are : The simplest possible control configuration The fewest process measurements (one) However, its performance is inferior to the cascade configurations in several respects.

Measurement Parameters
Reactor temperature - Control of reactor temperature is of utmost

importance. Sometimes more than one reactor temperature transmitter is installed. Jacket outlet temperature/cooling water return temperature The temperature - transmitter is installed on the outlet of the jacket, but within the recirculation loop. The cooling water return temperature is the same as the jacket outlet temperature. Jacket inlet temperature - The transmitter is installed at the inlet to the jacket. Being within the recirculation loop, this temperature is not the same as the cooling water supply temperature. Cooling water flow - Especially in batch reactors, this measurement can be challenging. Many batch reactors experience a large change in the heat removal rate between the early and late stages of the batch. A turndown ratio of 50 or more is often necessary.

Process
Rise in the temp suggest recirculation flow is slow.

At steady state this must be equal :

Heat librated by reactor Heat transferred to jacket

Heat removed from jacket by cooling water

Heat librated by reactor

The heat librated by reactor is
Q FH F
Where

o Q = Heat released by reaction (Btu/hr)

o F = Reactor Feed rate (lb/hr) o H F = heat released by reaction per unit of feed (Btu/lb)

Heat transferred to jacket

The heat transferred to jacket from reactor is
Q UA(T T j )
Where

o U = Heat transfer Coefficient (Btu/hr-ft^2-F)

o A= Heat transfer area(ft^2) o T= Reactor temperature (F) o Tj= Jacket temperature (F)

Heat Removed From jacket

The heat removed from jacket by cooling water is
Q WC p (T j Tcws )
Where

o W = Cooling water flow (lb/hr)

o Cp = Cooling water heat capacity (Btu/lb-F) o Tcws = Cooling water supply temperature (F) o Tj= Jacket temperature (F)

Jacketed Reactor temperature to flow cascade

Thursday, March 01, 2012

Temperature to Flow control

This control mechanism is basically working on two control

element
Reactor Temperature Cooling water flow

Jacketed Reactor temperature to temperature cascade

Thursday, March 01, 2012

Temperature to Temperature control

This control mechanism is basically working on two control

element
Reactor Temperature Jacket temperature

Block diagram of temperature to temperature cascade

Thursday, March 01, 2012

Temperature to Temperature control

Inner and outer loop

Reactor temperature is out-loop

Jacket temperature is inner-loop Master and Slave control Reactor temperature controller provides master control Jacket temperature controller provides slave control Primary and secondary Reactor temperature is primary importance to control logic

Jacket temperature is secondary importance to control logic

Disturbance associated with Cooling media

Disturbance associated with cooling media basically are

Cooling Temperature Supply Pressure