Tuning of PID Controllers For Unstable Continuous Stirred Tank Reactors
Tuning of PID Controllers For Unstable Continuous Stirred Tank Reactors
Tuning of PID Controllers For Unstable Continuous Stirred Tank Reactors
a
Department of Chemical Engineering, M.V.G.R. College of Engineering,
Vizianagaram, India
b
Department of Chemical Engineering, Andhra University College of Engineering (A) Visakha-
patnam, India
Abstract: Tuning Proportional Integral and Derivative (PID) controllers for unstable Second
Order Plus Time Delay systems with a Zero (SOPTDZ), based on internal model control (IMC)
and stability analysis (SA) principles is proposed. The controllers designed by the proposed
methods are used to control unstable jacketed Continuous Stirred Tank Reactors (CSTR), carry-
ing out irreversible first order reaction. The performance of proposed controllers is compared
with the synthesis method. Simulation results on nonlinear unstable continuous stirred tank re-
actors and transfer function models are presented to the show the efficiency of the proposed con-
trollers.
Keywords: Internal model control; stability analysis method; synthesis method; CSTR; PID
controller; Unstable systems; Second Order Plus Time Delay system with a
Zero (SOPTDZ).
1. Introduction
*
Corresponding author; e-mail: [email protected] Received 24 May 2011
2012 Chaoyang University of Technology, ISSN 1727-2394 Revised 2 July 2011
Accepted 29 September 2011
K p (1 + ps )
+
is G P ( s ) = (4) 0 = 0.5L (15)
( 1 s + 1)( 2 s 1)(1 + 0.5 Ls )
p 3
The IMC controller for this system is given 1 = (16)
+ ( 3 0.5 L ) 2
as, Q = [G P ( s )] 1 . f (5)
Where f is IMC filter. It consists of both 3
2 = +p (17)
numerator and denominator dynamics. The ( 3 0.5 L ) 2
order of the numerator is equal to the number is selected by trial and error procedure. If
of unstable poles of the process. The order of the value of is large, the response is slug-
denominator is selected in such a way to gish but robust and if it is small the response
make controller realizable (the controller nu- is fast but less robust.
merator order should be less than or equal to If time delay is small, the time delay is ap-
that of the order of denominator). Therefore proximated as e Ls = 1 Ls , the invertible
IMC filter for this transfer function model is part of the process transfer function of Eq (1)
+ K p (1 + ps) 1 +
is G P ( s ) = (18) Where, K c = (23)
( 1 s + 1)( 2 s 1) K p ( 2 L)
I = ( 1 + ) (24)
The IMC controller for the given transfer 1
function is given in Eq (5). Therefore, IMC D = (25)
s + 1 ( 1 + )
filter f is given by f = (19) f = p (26)
(s + 1) 2
Using Eq (18) and Eq (19) in Eq (5), IMC + (2 + L) 2
2
= (27)
controller is given by 2 L
( s + 1)( 2 s 1)(s + 1)
Q= 1 (20)
K P (1 + ps )(s + 1) 2 2.2. Stability analysis method
Substituting Eq (1) and Eq (20) in Eq (8),
the following transfer function model for the The process transfer function for unstable
controller is obtained. SOPTD with a negative zero is given by Eq
(1s +1)( 2 s 1)(s +1) (1). The transfer function of the controller is
Gc (s) = (21) given by
K p (1 + ps)[(s +1)2 (1 Ls)(s +1)] 1 1
Gc ( s ) = K c (1 + ' )(1 + D s )(
' '
Eq (21) is rearranged into PID controller ) (28)
I s s + 1
with a first order lag filter.
1 1 The combined transfer function model of the
Gc ( s ) = K c [1 + + D s] (22) process and the controller is given by
Is ( f s + 1)
K P (1 + ps )e Ls 1 1
K c (1 + ' )(1 + D s )(
' '
Gc ( s )G p ( s ) = ) (29)
( 1 s + 1)( 2 s 1) I s s + 1
3. Simulation results
Case study-1
In this section, proposed PID controller de-
signed by IMC method (IMC-PID controller) Consider a jacketed CSTR carrying first
and proposed PID controller designed by sta- order irreversible exothermic reaction. The
bility analysis method (SA-PID controller) are heat of reaction is removed by a coolant in the
applied to various CSTR transfer function jacket to maintain temperature of reaction.
models and non-linear models to show the The model equations of jacketed CSTR with-
efficiency of the proposed controllers. The out jacket dynamics [1] are,
performance of the proposed controllers is dC A F E
compared with PID controller designed by = (C Af C A ) K 0 exp( a )C A
dt V RT (38)
synthesis method [3] (SM-PID controller).
dT F H Ea UA
= (T f T ) + ( ) K 0 exp( )C A (T T j ) (39)
dt V C p RT VC p
The above non-linear model equations are linearised around the unstable operating point
CA=0.0644 lb.mol/ft3, T=560.770R and Tj=523.01220R. The values of the process parameters are
given Table 1
Figure1. Servo and regulatory response of jacketed CSTR (linear model) case study-1
The servo and regulatory performance of model for the servo and regulatory response is
the proposed controllers is better than given in Table 3.
SM-PID controller. The performance com-
parison in terms ISE, IAE and ITAE for linear
The simulation of non-linear model equa- servo response (change in reactor temperature
tions [Eq (38) and Eq (39)] of the jacketed 560.77 to 5630 R) is shown in Figure2.
CSTR with the proposed IMC-PID controller,
SA-PID controller and SM-PID controller for
The regulatory response of jacketed CSTR change in ratio F/V from 4 to 4.2 hr-1 are
for the change in feed temperature from shown in Figure 3, Figure 4, Figure 5, and
519.67 to 5230 R, change in feed concentra- Figure 6 respectively.
tion from 0.132 to 0.134 lb.mol/ft3, change in
jacket temperature from 524.67 to 5200 R and
Figure 5. Regulatory problem of jacketed CSTR Figure 6. Regulatory problem of jacketed CSTR for
for change in jacket temperature(Tj=524.67 change in feed rate to volume of reactor
to 5200 R) for non-linear model in case study-1 (F/V=4 to 4.2 min-1) for non-linearmodel in
case study-1
The performance of these three controllers
for nonlinear models in terms of ISE, IAE and Case study-2
ITAE for both servo and regulatory problems
is given in Table 4. The performance of pro- Consider a jacketed CSTR carrying first
posed controllers is superior to the SM-PID order irreversible exothermic reaction. The
controller. The robustness of the IMC-PID model equations of jacketed CSTR without
controller, SA-PID controller and SM-PID jacket dynamics [7] are given by
controller is studied for the model uncertain- dC A F E
ties considering 20% perturbation in pa- = (C A0 C A ) K 0 C A exp( a )
dt V RT (41)
rameters such as H, K0, and U considering
one parameter at a time. The performance is
reported in terms of ISE, IAE and ITAE val-
ues in Table 5.
Table 5. Performance comparison under model uncertainty for non-linear model in case study-1
dT F (H ) K 0 C A E UA
= (T0 T ) + exp( a ) + (T j T ) (42)
dt V C p RT VC p
The above non-linear model equations are The values of the parameters are given in Ta-
linearised around unstable operating point CA ble 6.
=3.734 Kmol/m3, T=3440 K and Tj=317.40 K.
The transfer function relating the reactor for linear model for the servo and regulatory
temperature to the jacket temperature along problem is given Table 3.
with a measurement time delay of one second The simulation of non-linear model equa-
is given by tions [Eq (41), Eq (42)] of jacketed CSTR
T ( s) 0.0004706s + 6.143 10 7 with IMC-PID controller, SA-PID controller
= 2 7
e 1s (43) and SM-PID controller for servo problem
T j ( s) s 0.0004483s 4.055 10
(change in reactor temperature from 344 to
The IMC-PID controller, SA-PID controller, 3460 K) is shown in Figure 9. The regulatory
and SM-PID controller parameters are shown response of jacketed CSTR for change in feed
in Table 2. The servo and regulatory response temperature from 300 to 3050 K is shown in
of IMC-PID controller, SA-PID controller and Figure 10. The regulatory response of jack-
SM-PID controller for linear model are shown eted CSTR for change in initial concentration
in Figure 7 and Figure 8 respectively.The from 7.5 to 7.7 kmol/m3, change in jacket
performance of the proposed controllers is temperature from 317.4 to 3190 K and change
better than the SM-PID controller for both in F/V from 0.00065 to 0.0007 s-1 is also
servo and regulatory problem. The perform- studied.
ance comparison in terms ISE, IAE and ITAE
Figure 7. Servo response of jacketed CSTR Figure 8. Regulatory response of jacketed CSTR
for linear model in case study-2 for linear model in case study-2
Figure 9. Servo response of jacketed CSTR Figure 10. Regulatory problem of jacketed CSTR
(T=344 to 3460 K) for non-linear for change in feed temperature
model in case study-2 (Tf=300 to 3050 K) for non-linear model
in case study-2
Change in Change in
Change in Change in feed Change in
feed tem- jacket tem-
temperature concentration F/V
Performance Controller perature perature
Servo prob-
Regulatory problem
lem
-5
IMC-PID 10.9761 5.1421 10 3.1342 10-9 2.8393 10-6 2.297 10-5
ISE SA-PID 11.573 7.3194 10-5 4.688 10-9 4.0415 10-6 3.268 10-5
SM-PID 10.8417 8.1778 10-5 6.0684 10-9 4.5156 10-6 3.649 10-5
IMC-PID 7.6701 0.0165 3.53 10-4 0.0039 0.0108
IAE SA-PID 7.4008 0.0195 4.356 10-4 0.0046 0.0127
-4
SM-PID 8.2196 0.0213 5.082 10 0.0050 0.0146
IMC-PID 23.2699 0.0831 0.0080 0.0196 0.0481
ITAE SA-PID 19.4397 0.0921 0.0099 0.0217 0.0517
SM-PID 25.8931 0.0878 0.0115 0.0207 0.0727
Table 8. Performance under model uncertainty for non-linear model in case study-2
ISE SA-PID 11.482 11.66 12.039 8.273 11.482 11.665 10.959 12.535
IAE SA-PID 7.355 7.447 7.632 6.096 7.354 7.448 7.385 8.342
ITAE SA-PID 19.311 19.57 20.109 24.433 19.261 19.604 20.976 25.054
The performance of the proposed control- turbed parameters. The proposed IMC-PID,
lers for nonlinear models in terms of ISE, IAE, SA-PID and SM-PID controllers are robust
and ITAE for both servo and regulatory prob- under model uncertainty considering one pa-
lems is given in Table 7. For both servo and rameter at a time.
regulatory problem, IMC-PID controller and
SA-PID controller gives better response Case study-3
compared to SM-PID controller. The robust-
ness of the IMC-PID controller, SA-PID con- Consider a constant volume jacketed CSTR
troller and SM-PID controller is studied for carrying first order irreversible exothermic
the model uncertainties considering 20% reaction. The model equations of jacketed
perturbation in parameters such as H, Ea, CSTR without jacket dynamics [8] are given
K0, and U considering one parameter at a time. dC q E
The performance is reported in terms of ISE, by A = (C A0 C A ) K 0 C A exp( a ) (44)
dt V RT
IAE and ITAE values in Table 8. The control-
lers are designed based on nominal model pa-
rameters and applied to the process with per-
dT q (H ) K 0 C A E UA
= (T0 T ) + exp( a ) + (T j T ) (45)
dt V C p RT VC p
The above non-linear model equations are K. The values of the parameters are given in
linearised around unstable operating point CA Table 9.
=0.4758mol/l, T=312.73160 K and Tj=300.00
The transfer function relating the reactor compared to the proposed controllers. For
temperature to the jacket temperature along regulatory problem, proposed controllers per-
with a measurement time delay of 0.06 min is form better than SM-PID controller. The per-
given by formance comparison in terms ISE, IAE and
T (s) 2.092 s + 2.198 0.06 s ITAE for linear model for the servo and regu-
= 2 e (46)
T j ( s ) s 0.4939 s 1.6 latory problem is given Table 3. The simula-
tion of non-linear model equations [Eq (44),
The IMC-PID controller, SA-PID controller,
Eq (45)] of jacketed CSTR with IMC-PID
and SM-PID controller parameters are shown
controller, SA-PID controller and SM-PID
in Table 2. The servo and regulatory response
controller for servo problem (change in reac-
of IMC-PID controller, SA-PID controller and
tor temperature from 312.73 to 3140 K) is
SM-PID controller for linear model are shown
shown in Figure 12.
in Figure 11. The servo performance of
SM-PID controller shows a large overshoot
Figure 11. Servo and regulatory response of Figure 12. Servo response of jacketed CSTR
jacketed CSTR for linear model in (T=312.73 to 3140 K) for non-linear model
case study-3 in case study-3
The regulatory response of jacketed CSTR for change in feed concentration from 0.4758 to
0.6 mol/l is shown in Figure 13. The regulatory response of jacketed CSTR for change in jacket
temperature from 300 to 2900K, change in coolant flow rate from 100 to 110 l/min, and change
in feed temperature from 350 to 3400 K is also studied.
Figure 13. Regulatory response of jacketed CSTR for change in feed concentration
(CAf=0.4758 to 0.6 mol/l) for non-linear model in case study-3
The performance of the proposed control- overshoot (refer to Figure 11 and Figure 12).
lers for nonlinear models in terms of ISE, IAE, The controllers designed by proposed meth-
and ITAE for both servo and regulatory prob- ods give less overshoot for servo response.
lems is given in Table 10. For servo problem,
PID controller designed by synthesis method
gives best performance in terms of ISE, IAE
and ITAE. However, the response shows large
Table 11. Performance under model uncertainty for non-linear model in case study-3