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H2 H2
coal H2 N2
N2 powder N2
6 7
N2 H2
N2
NH 3
N2 coal coal
O2 powder powder gases
8 9 10 11 12
N2 N2
coal solids
powder diesel fuel liquids
in air N2
N2
14 CH 4 CH 4
13 H2S
ash
coal lumps
in air S 15
S H2 H2S
17 16
H2
Lets say we have agreed on which unit operations to use. The
next step is decide on the capacity of the process.
Why? Because we have to know how large reactors, distillation
columns, heat exchangers, pipes, etc. are going to be.
So comes the concept of operating (or design) conditions!
Each equipment is designed to operate at a certain set of
conditions.
Ex. Your boss wants a fuel production of 1 m3/min. You design
the equipment in such a way to handle this capacity and make
the pipe connections to maintain this production rate.
The important point is that most of the chemical processes is
continuous (like the one described here), so it seems that
unsteady balances are not required in design. Steady state
balances will be sufficient.
So where is automatic control in this picture?
Why, on earth, did we have to learn those differential equations
in Maths and Modeling Courses???
We, chemical engineers, would not have to deal with
differential equations (at least in the Undergraduate level), if it
werent for control. Modeling is a tool for process control.
So comes the why question again.
The design scheme without control, explained here, would
have worked if
1. Operating conditions would stay constant forever, and
2. All of our equipment were perfect, and process stayed at its
operating conditions.
So, to achieve (1), we use servo control; to achieve (2), we use
regulatory control.
What is process control?
To control a process means to affect the
behavior of the system in a desirable way.
Fjf 1.52 L / s
T
j 13.6 C
If process is to be operated at T = 14 oC, what should be Fjf?
fsolve('jacket_design', [5 -20], optimset('fsolve'), 14)
Fjf 2.6 L / s
T
j 18 .2 C
Tank Temperature vs. Jacket Fluid Flow Rate
2. Start-up of the Process (Unsteady State Simulation)
dT F f
T f T UA
T T j
dt V c pV
T (0) 23 C
dT j
T jf T j
F jf UA
T T j T (0)
dt Vj j c pjV j j 23 C
[t, x] = ode45('jacket_dynamic', 8000, [23 23]);
Assume that the initial volume
of the CSTR is equal to its
steady state value, and jacket
is full (note that if the CSTR
and/or jacket is empty,
additionally we need to
perform transient mass
balances)
If neither any variable in the process changes, nor my manager changes
his/her mind about the process, then this process will work fine without a
controller, as has been taught in other chemical engineering courses.
3. If there is a disturbance? (Unsteady State Simulation)
Ff suddenly increases to 2.3 L/s
So what should be done to bring T to 15 oC?
(The concept of feedback control)
F jf f (T ) F jf f (T )