Process Dynamics

Process dynamics
A plant is dynamic and this provides the key reason
for process control.
Only with an understanding of transient behavior of
physical systems can engineers design processes
that perform well in the dynamic world.
The field of process control encompasses the basic
principles most useful such as chemical reactors,
heat exchangers, and mass transfer equipment.

Process dynamics
Plant engineers must consider the dynamic operation
of all equipment because the plant will never operate
at steady state.
Engineers charged w/ operating plants must ensure
that the proper response is made to the ever-occurring
disturbances so that operation is safe and profitable.
Therefore, the engineer must understand the dynamic
behavior of a physical system in order to design the
equipment, select operating conditions and implement
automation technique properly.

Process Dynamics
FACTORS THAT AFFECTS OPERATION OF PLANTS:
Effect of process design: a key aspect of
automation is designing & building equipment that
can easily be controlled.
Effect of automation method: the design and
implementation of an automation system requires
knowledge of the dynamic behavior of the system.

Process dynamics
Consider a CSTR w/ Cooling:
The reactor can be influenced by adjusting the
opening of the valve of the coolant and the outlet
concentration is measured by an analyzer located
downstream from the reactor outlet.
The delay in the measurement of the outlet
concentration will reduce the effectiveness of the
control system (effect of process design)
A very aggressive method for adjusting the coolant
flow can also cause a large overshoot or oscillations
in trying to return the concentration back to its
desired value. (effect of the automation

Process dynamics
Knowledge of and understanding dynamic behavior
required for process control is formalized in
mathematical models.
Modeling plays a central role in the theory and
practice of process control
It is said to be the key element in the successful
application of process control.

Basic question addressed in modeling

1. Which variables can be influenced?
2. Over what range can the variables be altered?
3. How effectively can the control system maintain the
process at the desired conditions?
4. How sensitive are the results?

1. Which variables can be influenced?

Process control inherently involves some manipulated
variables which can be adjusted and some controlled
variables which are affected by the adjustments.
These variables can be identified properly by analysis
of the process through modeling.
Analysis of degrees of freedom, cause-effect
relationships.

2. Over what range can the variables be

altered?
The acceptable range of process variables such as
temperature and pressure, and the limited range of
the manipulated variables place bounds on the
effects of adjustments.
The range of possible values is termed as the
operating window and models can be used to
determine the bounds or frame on this window
quantitatively.

3. How effectively can the control system

maintain the process at the desired conditions?
a. Sign and magnitude of response nearly
constant sign and magnitude
It is essential that the sign does not change & it is
best if the magnitude does not vary greatly
b. Speed of response the speed must be known to
determine the manipulations that can be entered.
If the magnitudes are too aggressive, the system can
oscillate & may even become unstable.
This may occur when there is a long delay between
the adjusted variable and measurements

3. How effectively can the control system

maintain the process at the desired conditions?
c. Shape of the response

4. How sensitive are the results?

Process control systems are applied in industrial
scale plants that change operations often
The process will then experience variation in
operating conditions and equipment performance.
This variation affects the dynamic behavior of the
process which must be considered in process control.
The analysis of the possible variation in the system
and sensitivity of the dynamic behavior to the
variability begins in the modeling procedure.

4. How sensitive are the results?

Conclusion: The dynamic features most favorable
to good control include
Nearly constant sign and magnitude
Fast response
Minimum delay
Insensitivity to process changes

Some Models Used In Process Control

Mathematical Models system of equations whose
solution, given specific input data, is representations
of the response of the process to a corresponding set
of points.
Fundamental and Empirical Models based on
such principles as material and energy conservation.
Steady State and Dynamic Models (Unsteady
State)
Lumped and Distributed Models
Lumped Models are valid for systems in which the
properties do not depend on the position within the
system

Approaches in the design of a

controller
Experimental Approach
Applicable if physical equipment of the chemical process is
available.
Done by changing the values of various inputs (disturbances,
manipulated variables) and then through the use of
appropriate measuring devices, the output variables
(temperature, pressure, flowrates, concentration, etc.) are
observed and measured.
The changes in the process are recorded with time and
subsequent analyses follows.
Such a procedure is time and effort consuming and it is
usually quite costly because a large number of such
experiments must be performed.

Approaches in the design of a

controller
Theoretical Approach
Control system is designed for a chemical process before the
construction of the process.
This case does not rely on experimental procedure but there is
a need for a different representation of the chemical process
in order to study its dynamic behavior.
This representation is given in terms of a set of mathematical
equations (differential & algebraic) where solution yields the
dynamic or static behavior of the chemical process under
study.

 Modelling involves or makes use of the following:

Conservation of energy, mass and momentum
Chemical engineering science such as thermodynamics,
kinetics, transport phenomena, etc.
Modelling is a task that requires creativity and problem
solving skills.

Uses of models
Improve understanding of the process
- aids in computer simulation where it allows valuable information in
the system even before the plant is constructed.
Train Plant Operating Personnel
- by interfacing a process simulator to standard process control
equipment, a realistic training environment is created.
Develop a new control strategy for a new process
- a dynamic model can help identify the process variables that should
be controlled and those that should be manipulated.
Optimize process operating conditions
- it can be advantageous to Recalculate the optimum operating
conditions periodically in order to maximize profit or minimize cost

Classification of models
1. Theoretical models- develop using principles of chemistry, physics,
and biology
2. Empirical Models- obtained by fitting experimental data
3. Semi-Empirical Models combination of the two
Advantages of Semi-Empirical models
a. they incorporate theoretical knowledge
b. they can extrapolate over a wider range of operating
conditions
than empirical models
c. they require less development effort than theoretical models

Modelling procedure
1. Define Goals: goal statement
Judging the type of model needed to solve an engineering
problem is the most demanding aspect of modeling. This
judgment is summarized in the goal statement.
Goal statement must be specific concerning the type of
information needed.
1. specific design decisions
2. numerical values maybe specified (limits/constraints)
3. functional relationships relationships with other
variables / parameters
4. required accuracy accuracy of the model and the effects
of estimated inaccuracy on the results

Modelling procedure
2. Prepare Information
Sketch the process and identify the system (block diagrams
can be used)
Identify the variables of interest, and define boundaries of the
system for the balance will be formulated
State assumptions and data when necessary
e.g. well stirred tank, continuously stirred tank
assumptions in relation to the physical system
data regarding the physicochemical system (heat capacities,
reaction rates, densities, etc.)
external variables / input to the system must be defined
External variables also referred to as forcing
variables/function (could be introduced by a person or by a

Modelling procedure
3. Formulate the Model: equations are based on two fundamental
principles
A. Conservation balances overall and component balance, energy,
mass and momentum
Mass: Accumulation = Mass in Mass out + Generation
B. Constitutive equations - depend on the physical variables of
interest
Heat Transfer: Q = h A T
Chemical Reaction Rate: rA = koe-E/RT
Fluid Flow: F = Cv (P/)0.5
Equation of State: PV = nRT (ideal gas equation)
Phase Equilibrium: yi = ki xi

Modelling procedure
C. Rationalize (combine equations and collect terms)
How many equations are appropriate
D. Check degrees of freedom, DOF: DOF = NV NE
NV = number of variables , NE = number of independent equations
DOF = 0; system is exactly specified, solution to model can proceed
DOF < 0; system is overspecified, no solution to the model exists
DOF > 0; system underspecified, an infinite number of solutions to
the model exists.
E. Transform the equation into dimensionless form

Modelling procedure
4. Determine the Solution to the Model:
Analytical Solution most preferred solution
Can be used to calculate specific numerical values
Used to determine important functional relationships among
design and operating variables and system behavior
Give insight into the sensitivity of the result to changes in data.
Disadvantage: assumptions are usually made to be able to
obtain analytical solution.
Approximation is frequently used, linearization of non-linear
terms

Modeling procedure
Numerical Method:
In some cases, the approximations necessary to make
analytical solutions possible introduce unacceptable errors into
the results.
Numerical solutions are never exact but the error introduced
can usually be made quite small, often less than the errors
associated with the assumptions and data in the model.

Modeling procedure
5. Results Analysis:
A. Check results for correctness evaluate whether the
answer is correct or at least to the extent that it satisfies the
formulation.
Check if the result satisfies initial and final conditions,
obeys bounds such as adiabatic reaction temperature,
contains negligible errors associated with numerical
calculations,
obey semi-quantitative expectations such as the sign of
the output change

Modeling procedure
B. Interpret results
Plot solution
Check for characteristic behavior such as oscillations or
extrema
Relate results to data and assumptions
Evaluate sensitivity
Answer what if questions

Modeling procedure
6. Validation:
Involves determining whether the results of steps 1 to 5 truly
represent the physical process with the required fidelity for
the specified range of conditions.
Does the model represent the data well enough that the
engineering task can be performed using the model?
Select key variables for validation
Compare with experimental results
Compare with results from more complex model