CH3050: Process Dynamics and Control

Introduction

Arun K. Tangirala
Department of Chemical Engineering
IIT Madras

Arun K. Tangirala (IIT Madras) CH3050: Process Dynamics and Control 1

Expected Learning Outcomes

Expected Outcomes
The learner will be able to
1 Provide a technical definition of control.
2 Give examples of control problems in different domains.
3 Describe the top five reasons for control.
4 Explain the hierarchy of process operations.

Arun K. Tangirala (IIT Madras) CH3050: Process Dynamics and Control 2

What is control?

Control is the act of maintaining (regulating) a process variable at a desired

value whenever it deviates (due to disturbances) or the act of forcing a process
variable to follow (track) a specified trajectory (due to set-point changes).

Arun K. Tangirala (IIT Madras) CH3050: Process Dynamics and Control 3

What is control?

Control is the act of maintaining (regulating) a process variable at a desired

value whenever it deviates (due to disturbances) or the act of forcing a process
variable to follow (track) a specified trajectory (due to set-point changes).

Common examples:

▶ Temperature control in air-conditioned enclosures

▶ Level control in flush-tank systems
▶ Blood pressure control in living beings

Arun K. Tangirala (IIT Madras) CH3050: Process Dynamics and Control 4

Example: Chemical Process Control
Fi

h
Fo

▶ Maintain liquid level by

manipulating inlet flow

Arun K. Tangirala (IIT Madras) CH3050: Process Dynamics and Control 5

Example: Chemical Process Control
Fin , CAf
Fi

F ,T
c c,in
A B

h CA, T
Qremoved
Fo , CA
Fo TC
T
c

▶ Maintain liquid level by ▶ Maintain reactor

manipulating inlet flow temperature by
manipulating coolant flow

Arun K. Tangirala (IIT Madras) CH3050: Process Dynamics and Control 6

Example: Chemical Process Control
Fin , CAf
Fi

Condenser
F ,T Top
c c,in
product
A B

h CA, T
Qremoved
Fo , CA Distillation
Fo TC
T
Feed Column
c

▶ Maintain liquid level by ▶ Maintain reactor Reboiler

manipulating inlet flow temperature by Bottom

product

manipulating coolant flow

▶ Maintain top and bottom
compositions by
▶ Several other processes: pressure and flow control,
manipulating flows
product quality control, etc.
Arun K. Tangirala (IIT Madras) CH3050: Process Dynamics and Control 7
Example: Cruise Control

Source: http://www.eurofot-ip.eu/en/intelligent_vehicle_systems/acc/

▶ Control speed by manipulating gas flow

Arun K. Tangirala (IIT Madras) CH3050: Process Dynamics and Control 8
Example: Cruise Control

Source: http://www.start-flying.com/new%20site/controlling aircraft.htm

Source: http://www.eurofot-ip.eu/en/intelligent_vehicle_systems/acc/
▶ Control rotations by manipulating
▶ Control speed by manipulating gas flow actuators
Arun K. Tangirala (IIT Madras) CH3050: Process Dynamics and Control 9
 of such inadequate glucose regulation tion) has to be inferred from these infrequent samples.
ncreased risk for retinopathy, nephropa- The results of a subsequent clinical trial (Zisser et al.,
pheral vascular disease (DCCT, 1993; Jo- 2005) demonstrated that a large fraction of the patients
Example: Control in Biomedical / Biophysical Systems
; Zisser at al., 2005). responded favorably to this type of control.

ock diagram for artificialf3-cell, illustrating the meal as the most common disturbance. G denotes the blood sugar
Gm is the output of the glucose sensor, and Gsp is the glucose set point.
Artificial β-cell for glucose regulation

Source: Seborg et al (2011). Process Dynamics and Control

▶ Artificially regulate glucose level in Type-I

Diabetes

Arun K. Tangirala (IIT Madras) CH3050: Process Dynamics and Control 10

 of such inadequate glucose regulation tion) has to be inferred from these infrequent samples.
ncreased risk for retinopathy, nephropa- The results of a subsequent clinical trial (Zisser et al.,
pheral vascular disease (DCCT, 1993; Jo- 2005) demonstrated that a large fraction of the patients
Example: Control in Biomedical / Biophysical Systems
; Zisser at al., 2005). responded favorably to this type of control.

Heat shock regulation in bacteria

ock diagram for artificialf3-cell, illustrating the meal as the most common disturbance. G denotes the blood sugar
Gm is the output of the glucose sensor, and Gsp is the glucose set point.
Artificial β-cell for glucose regulation

Source: Seborg et al (2011). Process Dynamics and Control

Source: Seborg et al (2011). Process Dynamics and Control

▶ Control protein (mis)folding by

▶ Artificially regulate glucose level in Type-I
manipulating production of heat shock
Diabetes
proteins
Arun K. Tangirala (IIT Madras) CH3050: Process Dynamics and Control 11
Why is control required?
▶ Safety: For the safe operation of a process, it may be required to keep several key
variables within limits.

Arun K. Tangirala (IIT Madras) CH3050: Process Dynamics and Control 12

Why is control required?
▶ Safety: For the safe operation of a process, it may be required to keep several key
variables within limits.
▶ Performance: Necessary to satisfy various performance specifications (e.g., missile
to follow a desired trajectory, temperature to reach set-point in the quickest time)

Arun K. Tangirala (IIT Madras) CH3050: Process Dynamics and Control 13

Why is control required?
▶ Safety: For the safe operation of a process, it may be required to keep several key
variables within limits.
▶ Performance: Necessary to satisfy various performance specifications (e.g., missile
to follow a desired trajectory, temperature to reach set-point in the quickest time)
▶ Quality control: Required to meet product specifications (e.g., cement fineness,
molecular weight of a polymer)

Arun K. Tangirala (IIT Madras) CH3050: Process Dynamics and Control 14

Why is control required?
▶ Safety: For the safe operation of a process, it may be required to keep several key
variables within limits.
▶ Performance: Necessary to satisfy various performance specifications (e.g., missile
to follow a desired trajectory, temperature to reach set-point in the quickest time)
▶ Quality control: Required to meet product specifications (e.g., cement fineness,
molecular weight of a polymer)
▶ Environmental regulations: Ensure levels of toxic elements or pollutants are
within acceptable limits.

Arun K. Tangirala (IIT Madras) CH3050: Process Dynamics and Control 15

Why is control required?
▶ Safety: For the safe operation of a process, it may be required to keep several key
variables within limits.
▶ Performance: Necessary to satisfy various performance specifications (e.g., missile
to follow a desired trajectory, temperature to reach set-point in the quickest time)
▶ Quality control: Required to meet product specifications (e.g., cement fineness,
molecular weight of a polymer)
▶ Environmental regulations: Ensure levels of toxic elements or pollutants are
within acceptable limits.
▶ Economics: Meet productivity and cost requirements.

Arun K. Tangirala (IIT Madras) CH3050: Process Dynamics and Control 16

Why is control required?
▶ Safety: For the safe operation of a process, it may be required to keep several key
variables within limits.
▶ Performance: Necessary to satisfy various performance specifications (e.g., missile
to follow a desired trajectory, temperature to reach set-point in the quickest time)
▶ Quality control: Required to meet product specifications (e.g., cement fineness,
molecular weight of a polymer)
▶ Environmental regulations: Ensure levels of toxic elements or pollutants are
within acceptable limits.
▶ Economics: Meet productivity and cost requirements.
▶ Constraints: Maintain certain key variables within specified bounds.
Arun K. Tangirala (IIT Madras) CH3050: Process Dynamics and Control 17
Plant operations hierarchy
Planning &
Scheduling

Real-time Process
Optimization Monitoring

Multivariable &
▶ Control, measurement and actuation
Constraint Control
are fundamental to process operations
Regulatory ▶ The higher layers are concerned with
Control
supervision and decision-making tasks.
Measurement /
Actuation

Process

Arun K. Tangirala (IIT Madras) CH3050: Process Dynamics and Control 18

Opening doors to PSE
Process Systems Engineering (PSE)
PSE is the scientific discipline of integrating scales and components describing the behaviour
of a physico-chemical-biological system, via mathematical modelling, data analytics, design,
optimisation and control.

Arun K. Tangirala (IIT Madras) CH3050: Process Dynamics and Control 19

Course Learning and Evaluation components

As

Legend:
Q3 20%
As: Assignments
15
% Q1: Quiz 1
Q2 15%
Overall
35% ES
Q2: Quiz 2
Performance
(Grade) Q3: Quiz 3
15
% ES: End Semester
Q1 CP: Class Participation

CP

Arun K. Tangirala (IIT Madras) CH3050: Process Dynamics and Control 20

Bibliography

Bequette, B. W. (1998). Process Dynamics: Modeling, Analysis and Simulation. Upper Saddle River,
NJ, USA: Prentice Hall.
Dorf, R. C. and R. H. Bishop (2010). Modern Control Systems. 12th edition. Upper Saddle River, NJ,
USA: Prentice Hall.
Ogunnaike, B. A. and W. H. Ray (1994). Process Dynamics, Modeling, and Control. Oxford University
Press.
Seborg, D. E., T. F. Edgar, D. A. Mellichamp, and F. Doyle (2011). Process Dynamics and Control. 3rd
edition. New York, USA: John Wiley & Sons, Inc.
Stephanopoulos, G. (1984). Chemical Process Control: An Introduction to Theory and Practice. Upper
Saddle River, NJ, USA: Prentice Hall.

Arun K. Tangirala (IIT Madras) CH3050: Process Dynamics and Control 21