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Group No.
STUDENT ID 18024577
1q
MODULE CODE CHEE2022 Fundamentals of Process Control
MODULE CONVENOR Dr. Senthil Kumar Arumugasamy
ASSESSOR (if different from convenor) -
Coursework 1
CHEE2022 FPC FUNDAMENTALS OF PROCESS CONTROL
Submission
Write your answers on this handout. The hand out must be submitted via moodle
along with the HYSYS simulation file. Name the HYSYS file as 001234-
_StudentName.
Instruction:
Follow the instruction given in this handout, solve the modelling problem and answer
the questions. Save your work regularly
Question:
Benzene is produced by the hydrodealkylation of toluene at high temperature and
pressure according to the following reaction:
Heat the inlet feed to 250°C and increase the pressure to the operating pressure
of the reactor (X psia) before sending the stream to reactor.
The reactor can be approximated as a CONVERSION REACTOR, operated
isothermally at X°C and X psia, at a conversion of 65% (toluene is the limiting
reactant).
To separate the gas products from liquid products, connect the relevant outlet
stream from the reactor to a flash unit, which modelled as SEPARATOR.
Set the flash vessel temperature at X°C and pressure drop as 375 psi.
To separate toluene from benzene, send the relevant outlet stream from the flash
unit to a distillation column in which C 6H6 will be recovered. Use short cut
distillation model. Set the condenser and reboiler pressures as 20 psia and 25
psia respectively. Design the overhead condenser as a partial condenser. Select
benzene and toluene as light key and heavy key respectively and set their mole
fraction as 0.01. Set the external reflux ratio as 2 times the minimum reflux ratio.
Task 1: Solve the material and energy balances for the abovementioned process.
1. Give the molar flowrate and the mole fraction of the top and bottom streams from
the SEPARATOR and DISTILLATION COLUMN:
Argon 0.00013 0
Benzene 0.93 0.001
Toluene 0.001 0.99
[5 marks]
2. Consider a distillation column with the control valves shown in Fig 1. F is the feed
flow rate, Z is the feed composition, D is the distillate, B is the bottoms, R is the
reflux, xD is the measured mole fraction of the distillate, x B is the mole fraction of
bottoms and xDd is the desired mole fraction of the distillate. If x D the mole fraction
of the distillate is the controlled variable then identify the manipulated variable and
draw the (1) feedback control and (2) feedforward control for this process
mentioning all the basic components in these control strategies. Give a brief
description on your design. [15 marks]
Fig 1
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CHEE2022FPC Fundamentals of Process Control (Autumn 2018-19)
Feedback control
A
C
C
AT
C
Feedforward control
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CHEE2022FPC Fundamentals of Process Control (Autumn 2018-19)
A
C
C
AT
C
Since the mole fraction of the distillate is the controlled variable in the system, the manipulated
variable of the system is the flow rate of the distillate column. For the feedback control of the
distillation, the mole fraction of the distillate can be controlled by placing a feedback control
which includes a composition controller (AC) and composition analyzer (AT) between distillate
stream and at the reflux valve. If the desired mole fraction of the distillate stream is not
achieved, the measuring element which is the composition analyzer (AT) in the controller will
sense the difference and send a signal to the composition controller (AC) to control the reflux
valve to release the desired flow rate to the distillate stream. The desired mole fraction of the
distillate can be achieved according to the set point by measuring the mole composition of the
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CHEE2022FPC Fundamentals of Process Control (Autumn 2018-19)
For feedforward control, feedforward controller is placed between the feed stream and reflux
valve. The composition analyzer (AT) will measure the composition of the feed stream and
sends signal to the composition controller (AC) which then controls the reflux valve. Thus the
desired composition of the distillate is achieved according to the set point by measuring the
measuring the feed stream and controlling the reflux valve of the distillate. Feedforward takes
For flow control, P controller can be used if the aim is to just open or close the valve. However if
the flow rate of the system varies a lot then PI controller is the better controller to be used. This is
because PI controller will help to control the flow according to the set point that is desired however
P controller will never tune the varying flow exactly to the set point. The measured value will be
For pressure control, PID controller can be used to set the varying pressure to the set point. PI is
more suitable compared to PID controller because machines dealing with pressure will normally
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CHEE2022FPC Fundamentals of Process Control (Autumn 2018-19)
have noise. If PID controller is used, there will be more disturbance in the system because PID
controller are sensitive to sound and PID controller will amplify the sound.
For level control, PID controller can be used to adjust the level of a process since it has faster
response time to the disturbance. During the level control process, there is no noise so there will
be less disturbance. PID has fast warm up time which is suitable for level control.
For temperature control PID is the best controller because it provides more stable and accurate
control. PID can predict how the system’s temperature is going to behave. PID will rapidly react to
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CHEE2022FPC Fundamentals of Process Control (Autumn 2018-19)
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