Clyde - Botha 1643191609 A
Clyde - Botha 1643191609 A
Clyde - Botha 1643191609 A
CE 560 / MT 580
Process control
Lecture 02
Introduction to process control
C. Botha (Mr.)
Contacts: Chemical Engineering Department
Email: [email protected]
Alt. Email: [email protected]
January, 2021
Classification of process variables
o Disturbances: Input variables whose values are not as a result of adjustment by a control
mechanism or a human operator.
o Equally, the output variables can further be classified into measured and unmeasured
variables.
o Measured output variables: If values of such variables are known by directly measuring
them.
o Unmeasured output variables: If their values cannot be known by directly measuring them.
o However, the measured and unmeasured variables in some cases can be input variables.
cA,i, Ti , Fi
Reactants
Thermocouple Tc,o, Fc
Controller
A B cA, T, F
Coolant
Tc,i , Fc Products
o Heat produced by the reaction is removed by the coolant circulating around the reactor
jacket.
o At steady-state, the coolant flow-rate is just enough to remove all the heat generated by
the reaction and so keep the temperature T at a desired value, which is, the control
objective.
o Product flow-rate F can be regarded as both a manipulated (input) and output variable.
o Suppose that the control objective is to maintain the volume of the reaction mixture at a
constant value.
o Then, a control valve may be installed in the effluent (product) stream and its flow-rate
controlled.
o Furthermore, suppose that the inlet stream to the CSTR comes from some upstream unit
which we have no control of;
o For the output variables, CA, T, F, Tc,o, and V (volume of reaction mixture) are measured
output variables.
o For instance, thermocouple (T, Tc,o), flowmeter (F) and differential pressure (dp) cell (V).
Classification of process variables: Example 2
o However, such instruments are usually expensive and unreliable (i.e. break down).
o Hence, CA and/or CB may be difficult to determine, that is, becomes unmeasured outputs.
o In some cases, measuring instruments may be in a laboratory that is located some distance
from the plant.
o Because of the time lag between sampling and obtaining results, measurents may not be
useful for control purposes.
Classification of process variables: Example 2
Water addition
(Flow-rate)
New feed-rate
· level
Mill load · Density
· Flow-rate
Pump speed · Density
· Pressure
o The purpose of milling is to reduce ore particle size to a point where economic liberation of
the valuable mineral may be possible.
o The following are the control objectives when implementing instrumentation and control
schemes for the grinding circuit.
1) To maintain particle size in the product stream for a specified maximum throughput.
o The following are the main input variables that can affect control of grinding circuit:
o Water addition.
Classification of process variables: Example 2
o Among the input variables listed above the following are the disturbances:
o Feed composition, mineralization may affect hardness and grindability in the crushers.
o This in turn will affect feed rate, ore particle size and distribution in the feed.
Classification of process variables: Example 2
o Small fluctuations in the disturbances (ore hardness) can be smoothed out by blending
ore from different parts of the mine.
o Furthermore, ore storage, provided that no segregation occurs in the bins, can be used
to smooth out the new feed rate.
o Increase in feed size or hardness produces a coarser mill product provided that the feed
rate is not reduced.
o Likewise, a decrease in feed size and ore hardness may allow an increase in mill
throughput.
Classification of process variables: Example 2
o Therefore, circulating load depends on the feed rate and cannot be used as a
manipulated variable.
o Hence, product size and/or distribution from the milling circuit may change due to
increased mill circulating load.