PROCESS CONTROL AND INSTRUMENTATION

(SETK 3564 - 01)

SEMESTER 2 SESSION 2021/2022

REPORT CASE STUDY 2B

Lecturer’s Name : 1) Prof. Dr. Khairiyah Mohd. Yusof

2) Dr. Muhammad Afiq Zubir

Group number : 05 (Not Pi)

Group members
Name Matric number

Muhammad Danish Fahmi bin Azhar A19ET0142

Nor Husna binti Omar A19ET0178

Nurul Zahirah binti Muhammad Zakri A19ET0209

Sam Chua Chun Hong A19ET0220

Submission Date : 9th May 2022

Table of Content

1.0 Introduction 3
1.1 Problem Restatement 3
1.2 Problem Identification 3
2.0 Schematic Diagram 4
3.0 Assumptions 6
4.0 Mathematical Model 6
4.1 Overall Mass Balance, Energy Balance and Component Balance 6
5.0 Fluctuation Calculation and Simulation 10
5.1 Calculation for Input Flow Fluctuations 10
5.1.1 Response to positive fluctuation 16
5.1.2 Response to negative fluctuation 21
5.2 Calculation for Reactor Temperature Fluctuations 26
5.3 Calculation for Inlet Temperature Fluctuations 30
6.0 Overall Input-Output Model 36
7.0 Conclusion 37

2
1.0 Introduction

1.1 Problem Restatement

We are tasked to complete line tracing for the process of gas dehydration. During line
tracing, we are needed to identify the mechanical equipment, valves and identification, and all
control loop symbols and identification letters. All the information from P&ID should be
explained and the instruments should be listed in a table according to the categories. Meanwhile,
the possible type of instruments used to measure and manipulate the variables should be stated
with the price range. With the consideration of economical aspects and ability to maintain the
process's stability, the selection of the most suitable instrument should be justified.

1.2 Problem Identification

What do We Know What we Need to know Learning Issues

Process description of gas The operation constraints Line tracing

dehydration system

P&ID Control loop Terminologies in gas

dehydration

Control configuration Budget Type of instruments

The process variables Mechanical equipments

Process stability

Economically aspect when

selecting equipments

3
2.0 Schematic Diagram

Symbols / Abbreviation Definition

𝐶𝐴𝑖 Concentration of PO inlet

𝐶𝐵𝑖 Concentration of water inlet

𝐶𝑀𝑖 Concentration of methanol inlet

𝐶𝐶 Concentration of PG

T Final temperature of reactor

𝑇𝑖 Initial temperature of reactor

𝑇𝑐 Temperature of coolant (cooling water)

𝑇𝑅 Reference temperature

F Volumetric flow rate

4
 ρ Density of liquid in reactor

A Area of reactor

At Area of tube for coolant

h Height of reactor

t Time

k Reaction rate constant

V Volume of reactor

𝐶𝑝 Heat capacity of liquid in reactor

r Rate law

𝑚 Mass flow rate

Ĥ Enthalpy

Q Amount of heat transferred between the

coolant and liquid

ΔĤ𝑅 Heat of reaction

U Internal energy

H Enthalpy

K Kinetic energy

P Potential energy

E Activation energy

R Gas constant

5
3.0 Assumptions
1. Density of liquid, ρ is constant.
2. CSTR is an open system, so internal energy, U is equal to enthalpy, H.
3. Cross sectional area, A for reactor is constant.
4. Heat capacity of the liquid is constant.
5. Shaft work is negligible.
6. Kinetic and potential energy is neglected as it is too small compared to the heat of
reaction.
7. Heat loss to the surrounding is neglected.
8. No change in pressure throughout the process.
9. Content of CSTR is perfectly mixed where there is an equal composition throughout the
reactor.
10. First order reaction because water is in excess, rA = − kCA.

4.0 Mathematical Model

4.1 Overall Mass Balance, Energy Balance and Component Balance

Overall Mass Balance

𝑑ℎ
𝐴 𝑑𝑡
= 𝐹𝑖 − 𝐹

PO Balance
𝑑(𝐶𝐴𝐴ℎ)
𝑑𝑡
= 𝐹𝑖𝐶𝐴𝑖 − 𝐹𝐶𝐴 − 𝑘𝐶𝐴𝑉
𝑑𝐶𝐴 𝑑ℎ
𝐴ℎ 𝑑𝑡
+ 𝐴𝐶𝐴 𝑑𝑡
= 𝐹𝑖𝐶𝐴𝑖 − 𝐹𝐶𝐴 − 𝑘𝐶𝐴𝐴ℎ

If the volume is not constant,

𝑑𝐶𝐴
𝐴ℎ 𝑑𝑡
+ 𝐶𝐴(𝐹𝑖 − 𝐹) = 𝐹𝑖𝐶𝐴𝑖 − 𝐹𝐶𝐴 − 𝑘𝐶𝐴𝐴ℎ
𝑑𝐶𝐴
𝐴ℎ 𝑑𝑡
= 𝐹𝑖𝐶𝐴𝑖 − 𝐹𝐶𝐴 − 𝐶𝐴(𝐹𝑖 − 𝐹) − 𝑘𝐶𝐴𝐴ℎ
𝑑𝐶𝐴
𝐴ℎ 𝑑𝑡
= 𝐹𝑖𝐶𝐴𝑖 − 𝐹𝐶𝐴 − 𝐶𝐴𝐹𝑖 + 𝐶𝐴𝐹 − 𝑘𝐶𝐴𝐴ℎ

6
 𝑑𝐶𝐴 1
𝑑𝑡
= 𝐴ℎ
𝐹𝑖(𝐶𝐴𝑖 − 𝐶𝐴) − 𝑘𝐶𝐴
𝑑𝐶𝐴 1
𝑑𝑡
= 𝐴ℎ
𝐹𝑖(𝐶𝐴𝑖 − 𝐶𝐴) − 𝑘𝐶𝐴

If volume is constant,
𝑑𝐶𝐴
𝐴ℎ 𝑑𝑡
= 𝐹𝑖𝐶𝐴𝑖 − 𝐹𝐶𝐴 − 𝑘𝐶𝐴𝐴ℎ
𝑑𝐶𝐴 1 1
𝑑𝑡
= 𝐴ℎ
𝐹𝑖𝐶𝐴𝑖 − 𝐴ℎ
𝐹𝐶𝐴 − 𝑘𝐶𝐴

Water Balance
𝑑(𝐶𝐵𝐴ℎ)
𝑑𝑡
= 𝐹𝑖𝐶𝐵𝑖 − 𝐹𝐶𝐵 − 𝑘𝐶𝐴𝑉
𝑑𝐶𝐵 𝑑ℎ
𝐴ℎ 𝑑𝑡
+ 𝐴𝐶𝐵 𝑑𝑡
= 𝐹𝑖𝐶𝐵𝑖 − 𝐹𝐶𝐵 − 𝑘𝐶𝐴𝐴ℎ

If the volume is not constant,

𝑑𝐶𝐵
𝐴ℎ 𝑑𝑡
+ 𝐶𝐵(𝐹𝑖 − 𝐹) = 𝐹𝑖𝐶𝐵𝑖 − 𝐹𝐶𝐵 − 𝑘𝐶𝐴𝐴ℎ
𝑑𝐶𝐵
𝐴ℎ 𝑑𝑡
= 𝐹𝑖𝐶𝐵𝑖 − 𝐹𝐶𝐵 − 𝐶𝐵(𝐹𝑖 − 𝐹) − 𝑘𝐶𝐴𝐴ℎ
𝑑𝐶𝐵
𝐴ℎ 𝑑𝑡
= 𝐹𝑖𝐶𝐵𝑖 − 𝐹𝐶𝐵 − 𝐶𝐵𝐹𝑖 + 𝐶𝐵𝐹 − 𝑘𝐶𝐴𝐴ℎ
𝑑𝐶𝐵 1
𝑑𝑡
= 𝐴ℎ
𝐹𝑖(𝐶𝐵𝑖 − 𝐶𝐵) − 𝑘𝐶𝐴
𝑑𝐶𝐵 1
𝑑𝑡
= 𝐴ℎ
𝐹𝑖(𝐶𝐵𝑖 − 𝐶𝐵) − 𝑘𝐶𝐴

If volume is constant,
𝑑𝐶𝐵
𝐴ℎ 𝑑𝑡
= 𝐹𝑖𝐶𝐵𝑖 − 𝐹𝐶𝐵 − 𝑘𝐶𝐴𝐴ℎ
𝑑𝐶𝐵 1 1
𝑑𝑡
= 𝐴ℎ
𝐹𝑖𝐶𝐵𝑖 − 𝐴ℎ
𝐹𝐶𝐵 − 𝑘𝐶𝐴

7
PG Balance
𝑑(𝐶𝐶𝐴ℎ)
𝑑𝑡
= 𝐹𝑖𝐶𝐶𝑖 − 𝐹𝐶𝐶 + 𝑘𝐶𝐴𝑉
𝑑𝐶𝐶 𝑑ℎ
𝐴ℎ 𝑑𝑡
+ 𝐴𝐶𝐶 𝑑𝑡
=− 𝐹𝐶𝐶 + 𝑘𝐶𝐴𝐴ℎ

If the volume is not constant,

𝑑𝐶𝐶
𝐴ℎ 𝑑𝑡
+ 𝐶𝐶(𝐹𝑖 − 𝐹) =− 𝐹𝐶𝐶 + 𝑘𝐶𝐴𝐴ℎ
𝑑𝐶𝐶
𝐴ℎ 𝑑𝑡
=− 𝐹𝐶𝐶 − 𝐶𝐶(𝐹𝑖 − 𝐹) + 𝑘𝐶𝐴𝐴ℎ
𝑑𝐶𝐶
𝐴ℎ 𝑑𝑡
=− 𝐹𝐶𝐶 − 𝐶𝐶𝐹𝑖 + 𝐶𝐶𝐹 + 𝑘𝐶𝐴𝐴ℎ
𝑑𝐶𝐶 1
𝑑𝑡
=− 𝐴ℎ
𝐹𝑖𝐶𝐶 + 𝑘𝐶𝐴

If volume is constant,
𝑑𝐶𝐶
𝐴ℎ 𝑑𝑡
=− 𝐹𝐶𝐶 + 𝑘𝐶𝐴𝐴ℎ
𝑑𝐶𝐶 1
𝑑𝑡
=− 𝐴ℎ
𝐹𝐶𝐶 + 𝑘𝐶𝐴

Methanol Balance
𝑑(𝐶𝑀𝐴ℎ)
𝑑𝑡
= 𝐹𝑖𝐶𝑀𝑖 − 𝐹𝐶𝑀
𝑑𝐶𝑀 𝑑ℎ
𝐴ℎ 𝑑𝑡
+ 𝐴𝐶𝑀 𝑑𝑡
= 𝐹𝑖𝐶𝑀𝑖 − 𝐹𝐶𝑀

If the volume is not constant,

𝑑𝐶𝑀
𝐴ℎ 𝑑𝑡
+ 𝐶𝑀(𝐹𝑖 − 𝐹) = 𝐹𝑖𝐶𝑀𝑖 − 𝐹𝐶𝑀
𝑑𝐶𝑀
𝐴ℎ 𝑑𝑡
= 𝐹𝑖𝐶𝑀𝑖 − 𝐹𝐶𝑀 − 𝐶𝑀(𝐹𝑖 − 𝐹)
𝑑𝐶𝑀
𝐴ℎ 𝑑𝑡
= 𝐹𝑖𝐶𝑀𝑖 − 𝐹𝐶𝑀 − 𝐶𝑀𝐹𝑖 + 𝐶𝑀𝐹
𝑑𝐶𝑀 1
𝑑𝑡
= 𝐴ℎ
𝐹𝑖(𝐶𝑀𝑖 − 𝐶𝑀)

8
If volume is constant,
𝑑𝐶𝑀
𝐴ℎ 𝑑𝑡
= 𝐹𝑖𝐶𝑀𝑖 − 𝐹𝐶𝑀
𝑑𝐶𝑀 1 1
𝑑𝑡
= 𝐴ℎ
𝐹𝑖𝐶𝑀𝑖 − 𝐴ℎ
𝐹𝐶𝑀

Energy Balance for reactor

𝑑 (𝐻+𝑃+𝐾)
𝑑𝑡
= Σ 𝑚𝑖Ĥ𝑖 − Σ 𝑚Ĥ ± 𝑄 ± 𝑊𝑠 ± 𝑟𝑉ΔĤ𝑅
𝑑𝐻
𝑑𝑡
= ρ𝐹𝑖𝐶𝑝 (𝑇𝑖 − 𝑇𝑟𝑒𝑓) − ρ𝐹𝐶𝑝 (𝑇 − 𝑇𝑟𝑒𝑓) − 𝑈𝐴𝑡(𝑇𝑐 − 𝑇) + 𝑟𝑉ΔĤ𝑅
𝑑[ρ𝑉𝐶𝑝 (𝑇 − 𝑇𝑟𝑒𝑓)]
𝑑𝑡
= ρ𝐹𝑖𝐶𝑝 (𝑇𝑖 − 𝑇𝑟𝑒𝑓) − ρ𝐹𝐶𝑝 (𝑇 − 𝑇𝑟𝑒𝑓) − 𝑈𝐴𝑡(𝑇𝑐 − 𝑇) + 𝑟𝑉ΔĤ𝑅

Assume Tref =0
𝑑𝑇 𝑑𝑉
ρ𝑉𝐶𝑝 𝑑𝑡
+ ρ𝐶𝑝𝑇 𝑑𝑡
= ρ𝐹𝑖𝐶𝑝𝑇𝑖 − ρ𝐹𝐶𝑝𝑇 − 𝑈𝐴𝑡(𝑇𝑐 − 𝑇) + 𝑟𝑉ΔĤ𝑅

If the volume is not constant,

𝑑𝑇 𝑑ℎ
ρ𝑉𝐶𝑝 𝑑𝑡
+ ρ𝐶𝑝𝑇𝐴 𝑑𝑡
= ρ𝐹𝑖𝐶𝑝𝑇𝑖 − ρ𝐹𝐶𝑝𝑇 − 𝑈𝐴𝑡(𝑇𝑐 − 𝑇) + 𝑟𝑉ΔĤ𝑅
𝑑𝑇
ρ𝑉𝐶𝑝 𝑑𝑡
+ ρ𝐶𝑝𝑇(𝐹𝑖 − 𝐹) = ρ𝐹𝑖𝐶𝑝𝑇𝑖 − ρ𝐹𝐶𝑝𝑇 − 𝑈𝐴𝑡(𝑇𝑐 − 𝑇) + 𝑟𝑉ΔĤ𝑅
𝑑𝑇
ρ𝑉𝐶𝑝 𝑑𝑡
= ρ𝐹𝑖𝐶𝑝𝑇𝑖 − ρ𝐹𝐶𝑝𝑇 − ρ𝐶𝑝𝑇(𝐹𝑖 − 𝐹) − 𝑈𝐴𝑡(𝑇𝑐 − 𝑇) + 𝑟𝑉ΔĤ𝑅
𝑑𝑇
ρ𝑉𝐶𝑝 𝑑𝑡
= ρ𝐹𝑖𝐶𝑝𝑇𝑖 − ρ𝐹𝐶𝑝𝑇 − ρ𝐶𝑝𝑇𝐹𝑖 + ρ𝐶𝑝𝑇𝐹 − 𝑈𝐴𝑡(𝑇𝑐 − 𝑇) + 𝑟𝑉ΔĤ𝑅
𝑑𝑇
ρ𝑉𝐶𝑝 𝑑𝑡
= ρ𝐹𝑖𝐶𝑝𝑇𝑖 − ρ𝐶𝑝𝑇𝐹𝑖 − 𝑈𝐴𝑡 (𝑇𝑐 − 𝑇) + 𝑟𝑉ΔĤ𝑅

𝑑𝑇 𝐹𝑖(𝑇𝑖− 𝑇) 𝑈𝐴𝑡(𝑇𝑐 − 𝑇) 𝑘1𝐶𝐴ΔĤ𝑅

𝑑𝑡
= 𝐴ℎ
− ρℎ𝐴𝐶𝑝
+ ρ𝐶𝑝

If volume is constant,
𝑑𝑇
ρ𝑉𝐶𝑝 𝑑𝑡
= ρ𝐹𝑖𝐶𝑝𝑇𝑖 − ρ𝐹𝐶𝑝𝑇 − 𝑈𝐴𝑡(𝑇𝑐 − 𝑇) + 𝑟𝑉ΔĤ𝑅

𝑑𝑇 𝐹𝑖(𝑇𝑖− 𝑇) 𝑈𝐴𝑡(𝑇𝑐 − 𝑇) 𝑘1𝐶𝐴ΔĤ𝑅

𝑑𝑡
= 𝐴ℎ
− ρℎ𝐴𝐶𝑝
+ ρ𝐶𝑝

9
Energy Balance for cooling jacket
𝑑 (𝐻+𝑃+𝐾)
𝑑𝑡
= Σ 𝑚𝑖Ĥ𝑖 − Σ 𝑚Ĥ ± 𝑄 ± 𝑊𝑠
𝑑[ρ𝑊𝑉𝐶𝑝𝑊 (𝑇𝑐− 𝑇𝑟𝑒𝑓)]
𝑑𝑡
= ρ𝑊𝐹𝐶𝑖𝐶𝑝𝑊 (𝑇𝐶𝑖 − 𝑇𝑟𝑒𝑓) − ρ𝑊𝐹𝐶𝐶𝑝𝑊 (𝑇𝐶 − 𝑇𝑟𝑒𝑓) + 𝑈𝐴𝑡(𝑇𝑐 − 𝑇)

If volume is constant,
𝑑𝑇𝑐
ρ𝑊𝐴ℎ𝐶𝑝𝑊 𝑑𝑡
= ρ𝑊𝐹𝐶𝑖𝐶𝑝𝑊 (𝑇𝐶𝑖) − ρ𝑊𝐹𝐶𝐶𝑝𝑊 (𝑇𝐶) + 𝑈𝐴𝑡(𝑇𝑐 − 𝑇)
𝑑𝑇𝑐 𝐹𝐶𝑖𝑇𝐶𝑖 𝐹𝐶𝑇𝐶 𝑈𝐴𝑡 (𝑇𝑐 − 𝑇)
𝑑𝑡
= 𝐴ℎ
− 𝐴ℎ
+ ρ𝑊ℎ𝐴𝐶𝑝𝑊

5.0 Fluctuation Calculation and Simulation

5.1 Calculation for Input Flow Fluctuations

Input Flow Fluctuations affect Liquid Level

If volume is not constant,
𝑑ℎ 1 1
𝑑𝑡
= 𝐴
𝐹 − 𝐴
𝐹 (1)
𝑖

At steady state,
𝑑ℎ 1 1
𝑑𝑡
= 𝐴
𝐹𝑖 − 𝐴
𝐹 (2)

(1) - (2) :
𝑑ℎ' 1 1
𝑑𝑡
= 𝐴
𝐹' − 𝐴
𝐹'
𝑖

𝑑ℎ' 1 1
ℒ{ 𝑑𝑡
} = ℒ{ 𝐴 𝐹 ' − 𝐴
𝐹'}
𝑖

1 1
𝑠ℎ'(𝑠) − ℎ'(0) = 𝐴 𝐹 '(𝑠) − 𝐴
𝐹'(𝑠)
𝑖

1 1
𝑠ℎ'(𝑠) = 𝐴 𝐹 '(𝑠) − 𝐴
𝐹'(𝑠)
𝑖
1
ℎ'(𝑠) 𝐴
𝐹𝑖'(𝑠)
= 𝑠

10
Steady state gain,
1 ℎ
K= 𝐴
= 𝑉

3.06
= 10

= 0.306

Time constant,
𝒯=∞
∴ It is a first-order dynamic model.

If the volume is constant,

𝑑ℎ 1 1
𝑑𝑡
= 𝐴
𝐹 − 𝐴
𝐹=0
𝑖

𝐹𝑖 = 𝐹

∴ Thus, there is no response to the change.

Input Flow Fluctuations affect Temperature

If the volume is not constant,
𝑈𝐴𝑡(𝑇𝑐−𝑇) 𝑘𝐶𝐴(−ΔĤ𝑅)
𝑑𝑇 𝐹𝑖𝑇𝑖 𝐹𝑖𝑇
𝑑𝑡
= 𝐴ℎ
− 𝐴ℎ
− ρ𝐴ℎ𝐶𝑝
+ ρ𝐶𝑝

f(𝐹𝑖, 𝑇𝑖, T, h, 𝑇𝑐, 𝐶𝐴) = f(𝐹𝑖, 𝑇𝑖, 𝑇, ℎ, 𝑇𝐶, 𝑐𝐴) = 0

𝑑𝑇' δ𝑓 δ𝑓 δ𝑓 δ𝑓 δ𝑓 δ𝑓
𝑑𝑡
= | 𝐹𝑖'
δ𝐹𝑖 𝑠𝑠
+ | 𝑇𝑖'
δ𝑇𝑖 𝑠𝑠
+ | 𝑇'
δ𝑇 𝑠𝑠
+ | ℎ'
δℎ 𝑠𝑠
+ | 𝑇 '
δ𝑇𝐶 𝑠𝑠 𝐶
+ | 𝐶 '
δ𝐶𝐴 𝑠𝑠 𝐴

𝐸
𝑇𝑖−𝑇 𝐹𝑖 𝐹𝑖 𝑈𝐴𝑡 𝑘𝐶𝐴(−ΔĤ𝑅)
{ }
2
𝑑𝑇'
ℒ 𝑑𝑡
= ℒ{ 𝐹𝑖' + 𝑇𝑖' − 𝑇' + 𝑇' + 𝑅𝑇
ρ𝐶𝑝
𝑇'
𝐴ℎ 𝐴ℎ 𝐴ℎ ρ𝐴ℎ𝐶𝑝

𝐹𝑖'(𝑇𝑖−𝑇) 𝑈𝐴𝑡(𝑇𝑐−𝑇) 𝑈𝐴𝑡 𝑘(−ΔĤ𝑅)

− 2
ℎ' − 2
ℎ'− ρ𝐴ℎ𝐶𝑝
𝑇𝑐' + ρ𝐶𝑝
𝐶𝐴'}
𝐴ℎ ρ𝐴 ℎ 𝐶𝑝
𝐸
𝑇𝑖−𝑇 𝐹𝑖 𝐹𝑖 𝑈𝐴𝑡 2 𝑘𝐶𝐴(−ΔĤ𝑅)
𝑅𝑇
𝑠𝑇'(𝑠) − 𝑇'(0) = 𝐹𝑖'(𝑠) + 𝑇𝑖'(𝑠) − 𝑇'(𝑠) + 𝑇'(𝑠) + ρ𝐶𝑝
𝑇'(𝑠)
𝐴ℎ 𝐴ℎ 𝐴ℎ ρ𝐴ℎ𝐶𝑝

𝐹𝑖'(𝑇𝑖−𝑇) 𝑈𝐴𝑡(𝑇𝑐−𝑇) 𝑈𝐴𝑡 𝑘(−ΔĤ𝑅)

− ℎ'(𝑠) − ℎ'(𝑠) − 𝑇𝑐'(𝑠) + ρ𝐶𝑝
𝐶𝐴'(𝑠)
2 2 ρ𝐴ℎ𝐶𝑝
𝐴ℎ ρ𝐴 ℎ 𝐶𝑝

11
 𝐸
𝐹𝑖 𝑈𝐴𝑡 2 𝑘𝐶𝐴(−ΔĤ𝑅) 𝑇𝑖−𝑇 𝐹𝑖
𝑅𝑇
𝑠𝑇'(𝑠) + 𝑇'(𝑠) − 𝑇'(𝑠) − ρ𝐶𝑝
𝑇'(𝑠) = 𝐹𝑖'(𝑠) + 𝑇𝑖'(𝑠)
𝐴ℎ ρ𝐴ℎ𝐶𝑝 𝐴ℎ 𝐴ℎ

𝐹𝑖'(𝑇𝑖−𝑇) 𝑈𝐴𝑡(𝑇𝑐−𝑇) 𝑈𝐴𝑡 𝑘(−ΔĤ𝑅)

− ℎ'(𝑠) − ℎ'(𝑠) − 𝑇𝑐'(𝑠) + ρ𝐶𝑝
𝐶𝐴'(𝑠)
2 2 ρ𝐴ℎ𝐶𝑝
𝐴ℎ ρ𝐴 ℎ 𝐶𝑝

𝐸
𝐹𝑖ρ𝐶𝑝−𝑈𝐴𝑡− 2
𝑘𝐶𝐴(−ΔĤ𝑅)𝐴ℎ 𝑇𝑖−𝑇 𝐹𝑖 𝐹𝑖'(𝑇𝑖−𝑇)
𝑅𝑇
[𝑆 + ]𝑇'(𝑠) = 𝐹𝑖'(𝑠) + 𝑇𝑖'(𝑠)− ℎ'(𝑠)
ρ𝐴ℎ𝐶𝑝 𝐴ℎ 𝐴ℎ 2
𝐴ℎ

𝑈𝐴𝑡(𝑇𝑐−𝑇) 𝑈𝐴𝑡 𝑘(−ΔĤ𝑅)

− ℎ'(𝑠)− 𝑇𝑐'(𝑠) + ρ𝐶𝑝
𝐶𝐴'(𝑠)
2 ρ𝐴ℎ𝐶𝑝
ρ𝐴 ℎ 𝐶𝑝

𝑇𝑖−𝑇
𝑇'(𝑠) 𝐴ℎ
𝐺2(𝑠) = 𝐹𝑖'(𝑠)
= 𝐹𝑖ρ𝐶𝑝−𝑈𝐴𝑡−
𝐸
𝑘𝐶𝐴(−ΔĤ𝑅)𝐴ℎ
2
𝑅𝑇
𝑆+
ρ𝐴ℎ𝐶𝑝

(𝑇𝑖−𝑇)ρ𝐶𝑝
𝐸
𝐹𝑖ρ𝐶𝑝−𝑈𝐴𝑡− 𝑘𝐶𝐴(−ΔĤ𝑅)𝐴ℎ
𝑇'(𝑠) 2
𝐺2(𝑠) = 𝐹𝑖'(𝑠)
= ρ𝐴ℎ𝐶𝑝
𝑅𝑇

𝐸 𝑆+1
𝐹𝑖ρ𝐶𝑝−𝑈𝐴𝑡− 𝑘𝐶𝐴(−ΔĤ𝑅)𝐴ℎ
2
𝑅𝑇

Steady state gain,

(𝑇𝑖−𝑇) ρ𝐶𝑝
𝐾= 𝐸
𝐹𝑖ρ𝐶𝑝 −𝑈𝐴𝑡− 2
𝑘𝐶𝐴(−ΔĤ𝑅)𝐴ℎ
𝑅𝑇

(25−50) (955.2)(82.32)
K= 5
75300
12 − 8.314(323))
75300 358.3(0.003)
8(955.2)(82.32)−(3.6×10 )− 2 (16.96×10 𝑒 )( 7.8
)(84500−29.24(323−293))(3.2685)(2.601)
8.314(323)

𝐾 =− 11. 3460

Time constant,
ρ𝐴ℎ𝐶𝑝
𝒯= 𝐸
𝐹𝑖ρ𝐶𝑝 −𝑈𝐴𝑡− 2
𝑘𝐶𝐴(−ΔĤ𝑅)𝐴ℎ
𝑅𝑇

(955.2)(3.2685)(2.601)(82.32)
𝒯= 5
75300
12 − 8.314(323))
75300 358.3(0.003)
8(955.2)(82.32)−(3.6×10 )− 2 (16.96×10 𝑒 )( 7.8
)(84500−29.24(323−293))(3.2685)(2.601)
8.314(323)

𝒯 = 3. 8583 ℎ𝑜𝑢𝑟
∴ It is a first-order dynamic model.

12
If volume is constant,
𝑈𝐴𝑡(𝑇𝑐−𝑇) 𝑘𝐶𝐴(−ΔĤ𝑅)
𝑑𝑇 𝐹𝑖𝑇𝑖 𝐹𝑖𝑇
𝑑𝑡
= 𝐴ℎ
− 𝐴ℎ
− ρ𝐴ℎ𝐶𝑝
+ ρ𝐶𝑝

f(𝐹𝑖, 𝐹, 𝑇𝑖, T, 𝑇𝑐, 𝐶𝐴) = f(𝐹𝑖, 𝐹, 𝑇𝑖, 𝑇, 𝑇𝐶, 𝑐𝐴) = 0

𝑑𝑇' δ𝑓 δ𝑓 δ𝑓 δ𝑓 δ𝑓 δ𝑓
𝑑𝑡
= | 𝐹𝑖'
δ𝐹𝑖 𝑠𝑠
+ | 𝐹'
δ𝐹 𝑠𝑠
+ | 𝑇𝑖'
δ𝑇𝑖 𝑠𝑠
+ | 𝑇'
δ𝑇 𝑠𝑠
+ | 𝑇𝑐'
δ𝑇𝑐 𝑠𝑠
+ | 𝐶 '
δ𝐶𝐴 𝑠𝑠 𝐴

𝐸
𝑇𝑖 𝐹𝑖 𝑈𝐴𝑡 2 𝑘𝐶𝐴(−ΔĤ𝑅)
𝑑𝑇' 𝑇 𝐹 𝑅𝑇
ℒ{ 𝑑𝑡
} = ℒ{ 𝐴ℎ 𝐹𝑖'(𝑠) − 𝐴ℎ
𝐹'(𝑠) + 𝑇 '(𝑠) −
𝐴ℎ 𝑖 𝐴ℎ
𝑇'(𝑠) + ρ𝐴ℎ𝐶𝑝
𝑇'(𝑠) + ρ𝐶𝑝
𝑇'(𝑠)

𝑈𝐴𝑡 𝑘𝐶𝐴(−ΔĤ𝑅)
− 𝑇 '(𝑠) +
ρ𝐴ℎ𝐶𝑝 𝑐 ρ𝐶𝑝
𝐶𝐴'(𝑠)}
𝐸
𝑇𝑖 𝐹𝑖 𝑈𝐴𝑡 2 𝑘𝐶𝐴(−ΔĤ𝑅)
𝑇 𝐹 𝑅𝑇
𝑠𝑇'(𝑠) − 𝑇'(0) = 𝐹 '(𝑠) −
𝐴ℎ 𝑖 𝐴ℎ
𝐹'(𝑠) + 𝑇 '(𝑠) −
𝐴ℎ 𝑖 𝐴ℎ
𝑇'(𝑠) + ρ𝐴ℎ𝐶𝑝
𝑇'(𝑠) + ρ𝐶𝑝
𝑇'(𝑠)

𝑈𝐴𝑡 𝑘𝐶𝐴(−ΔĤ𝑅)
− 𝑇 '(𝑠) +
ρ𝐴ℎ𝐶𝑝 𝑐 ρ𝐶𝑝
𝐶𝐴'(𝑠)
𝐸
𝑈𝐴𝑡 2 𝑘𝐶𝐴(−ΔĤ𝑅) 𝑇𝑖 𝐹𝑖
𝐹 𝑅𝑇 𝑇
𝑠𝑇'(𝑠) + 𝐴ℎ
𝑇'(𝑠) − ρ𝐴ℎ𝐶𝑝
𝑇'(𝑠) − ρ𝐶𝑝
𝑇'(𝑠) = 𝐹 '(𝑠) −
𝐴ℎ 𝑖 𝐴ℎ
𝐹'(𝑠) + 𝐴ℎ
𝑇𝑖'(𝑠)

𝑈𝐴𝑡 𝑘𝐶𝐴(−ΔĤ𝑅)
− 𝑇 '(𝑠) +
ρ𝐴ℎ𝐶𝑝 𝑐 ρ𝐶𝑝
𝐶𝐴'(𝑠)
𝐸
𝐹ρ𝐶𝑝−𝑈𝐴𝑡− 𝑘𝐶𝐴(−ΔĤ𝑅)𝐴ℎ 𝑇𝑖 𝐹𝑖
𝑅𝑇
2
𝑇
[𝑆 + ρ𝐴ℎ𝐶𝑝
]𝑇'(𝑠) = 𝐴ℎ
𝐹𝑖'(𝑠) − 𝐴ℎ
𝐹'(𝑠) + 𝐴ℎ
𝑇𝑖'(𝑠)

𝑈𝐴𝑡 𝑘𝐶𝐴(−ΔĤ𝑅)
− 𝑇 '(𝑠) +
ρ𝐴ℎ𝐶𝑝 𝑐 ρ𝐶𝑝
𝐶𝐴'(𝑠)
𝑇𝑖
𝑇'(𝑠) 𝐴ℎ
𝐹𝑖'(𝑠)
= 𝐹ρ𝐶𝑝−𝑈𝐴𝑡−
𝐸
𝑘𝐶𝐴(−ΔĤ𝑅)𝐴ℎ
2
𝑅𝑇
𝑆+ ρ𝐴ℎ𝐶𝑝

𝑇𝑖 ρ𝐶𝑝
𝐸
𝐹ρ𝐶𝑝−𝑈𝐴𝑡− 𝑘𝐶𝐴(−ΔĤ𝑅)𝐴ℎ
𝑇'(𝑠) 2

𝐹𝑖'(𝑠)
= ρ𝐴ℎ𝐶𝑝
𝑅𝑇

𝐸 𝑆+1
𝐹ρ𝐶𝑝−𝑈𝐴𝑡− 𝑘𝐶𝐴(−ΔĤ𝑅)𝐴ℎ
2
𝑅𝑇

Steady state gain,

𝑇𝑖 ρ𝐶𝑝
𝐾= 𝐸
𝐹ρ𝐶𝑝−𝑈𝐴𝑡− 2
𝑘𝐶𝐴(−ΔĤ𝑅)𝐴ℎ
𝑅𝑇

13
 298 (955.2)(82.32)
𝐾= 5
75300
12 − 8.314(323))
75300 358.3(0.003)
7.8(955.2)(82.32)−(3.6×10 )− 2 (16.96×10 𝑒 )( 7.8
)(84500−29.24(323−293))(3.2685)(2.601)
8.314(323)

𝐾 = 148. 7455
Time constant,
ρ𝐴ℎ𝐶𝑝
𝒯= 𝐸
𝐹ρ𝐶𝑝−𝑈𝐴𝑡− 2
𝑘𝐶𝐴(−ΔĤ𝑅)𝐴ℎ
𝑅𝑇

(955.2)(3.268)(2.601)(82.32)
𝒯= 5
75300
12 − 8.314(323))
75300 358.3(0.003)
7.8(955.2)(82.32)−(3.6×10 )− 2 (16.96×10 𝑒 )( 7.8
)(84500−29.24(323−293))(3.2685)(2.601)
8.314(323)

𝒯 = 4. 2434 ℎ𝑜𝑢𝑟
∴ It is a first-order dynamic model.

Input Flow Fluctuations affect PG Concentration

If volume is not constant,
𝑑𝐶𝑐 𝐹𝑖𝐶𝐶
𝑑𝑡
=− 𝐴ℎ
+ 𝑘𝐶𝐴

f(𝐹𝑖, 𝐶𝐶, T, h, 𝐶𝐴) = f(𝐹𝑖, 𝐶𝐶, 𝑇, ℎ, 𝐶𝐴) = 0

𝑑𝐶𝐶' δ𝑓 δ𝑓 δ𝑓 δ𝑓 δ𝑓
𝑑𝑡
= | 𝐹𝑖'
δ𝐹𝑖 𝑠𝑠
+ | 𝐶 '
δ𝐶𝐶 𝑠𝑠 𝐶
+ | ℎ'
δℎ 𝑠𝑠
+ | 𝑇'
δ𝑇 𝑠𝑠
+ | 𝐶 '
δ𝐶𝐴 𝑠𝑠 𝐴

ℒ { } = ℒ ⎰⎱−
𝑑𝐶𝑐'
𝑑𝑡
𝐶𝐶
𝐴ℎ
𝐹𝑖' −
𝐹𝑖
𝐴ℎ
𝐶𝐶' −
𝐹𝑖 𝐶𝐶
𝐴ℎ
ℎ' +
𝑅𝑇
𝐸
2
𝑘𝐶𝐴𝑇' + 𝑘𝐶𝐴'
⎱
⎰
𝐶𝐶 𝐹𝑖 𝐹𝑖 𝐶𝐶 𝐸
𝑆𝐶𝐶'(𝑠) − 𝐶𝑐'(0) =− 𝐹𝑖'(𝑠) − 𝐶𝐶'(𝑠) − ℎ'(𝑠) + 2
𝑘𝐶𝐴𝑇'(𝑠) + 𝑘𝐶𝐴'(𝑠)
𝐴ℎ 𝐴ℎ 𝐴ℎ 𝑅𝑇

𝐹𝑖 𝐶𝐶 𝐹𝑖 𝐶𝐶 𝐸
𝑆𝐶𝐶'(𝑠) + 𝐶𝐶'(𝑠) =− 𝐹𝑖'(𝑠) − ℎ'(𝑠) + 2
𝑘𝐶𝐴𝑇'(𝑠) + 𝑘𝐶𝐴'(𝑠)
𝐴ℎ 𝐴ℎ 𝐴ℎ 𝑅𝑇

𝐹𝑖 𝐶𝐶 𝐹𝑖 𝐶𝐶 𝐸
[𝑆 + ]𝐶𝐶'(𝑠) =− 𝐹𝑖'(𝑠) − ℎ'(𝑠) + 2
𝑘𝐶𝐴𝑇'(𝑠) + 𝑘𝐶𝐴'(𝑠)
𝐴ℎ 𝐴ℎ 𝐴ℎ 𝑅𝑇
𝐶𝐶
𝐶𝐶'(𝑠) −
𝐴ℎ
𝐺3(𝑠) = 𝐹𝑖'(𝑠)
= 𝐹𝑖
𝑆+
𝐴ℎ

𝐶𝐶
𝐶𝐶'(𝑠) −
𝐹𝑖
𝐺3(𝑠) = 𝐹𝑖'(𝑠)
= 𝐴ℎ
𝑆+1
𝐹𝑖

14
Steady state gain,
𝐶𝐶
𝐾 =−
𝐹𝑖

358.3 (0.069)
− 7.8
𝐾= 8

𝐾 =0.3962

Time Constant,
𝐴ℎ
𝒯=
𝐹𝑖

3.2685(2.601)
𝒯= 8

𝒯 = 1. 0627 ℎ𝑜𝑢𝑟
∴ It is a first-order dynamic model.

If volume is constant,
𝑑𝐶𝑐 𝐹𝑖𝐶𝐶
𝑑𝑡
=− 𝐴ℎ
+ 𝑘𝐶𝐴

f(𝐹𝑖, 𝐶𝐶, T, 𝐶𝐴) = f(𝐹𝑖, 𝐶𝐶, 𝑇, 𝐶𝐴) = 0

𝑑𝐶𝐶' δ𝑓 δ𝑓 δ𝑓 δ𝑓
𝑑𝑡
= | 𝐹𝑖'
δ𝐹𝑖 𝑠𝑠
+ | 𝐶 '
δ𝐶𝐶 𝑠𝑠 𝐶
+ | 𝑇'
δ𝑇 𝑠𝑠
+ | 𝐶 '
δ𝐶𝐴 𝑠𝑠 𝐴

ℒ { }
𝑑𝐶𝑐'
𝑑𝑡
⎰
= ℒ −
⎱
𝐶𝐶
𝐴ℎ
𝐹𝑖' −
𝐹𝑖
𝐴ℎ
𝐶𝐶' +
𝑅𝑇
𝐸
2
𝑘𝐶𝐴𝑇' + 𝑘𝐶𝐴'
⎱
⎰
𝐶𝐶 𝐹𝑖 𝐸
𝑆𝐶𝐶'(𝑠) − 𝐶𝑐'(0) =− 𝐴ℎ
𝐹𝑖'(𝑠) − 𝐴ℎ
𝐶𝐶'(𝑠) + 2
𝑘𝐶𝐴𝑇'(𝑠) + 𝑘𝐶𝐴'(𝑠)
𝑅𝑇

𝐹𝑖 𝐶𝐶 𝐸
𝑆𝐶𝐶'(𝑠) + 𝐶 '(𝑠) =−
𝐴ℎ 𝐶 𝐴ℎ
𝐹𝑖'(𝑠) + 2
𝑘𝐶𝐴𝑇'(𝑠) + 𝑘𝐶𝐴'(𝑠)
𝑅𝑇

𝐹𝑖 𝐶𝐶 𝐸
[𝑆 + 𝐴ℎ
]𝐶𝐶'(𝑠) =− 𝐴ℎ
𝐹𝑖'(𝑠) + 2
𝑘𝐶𝐴𝑇'(𝑠) + 𝑘𝐶𝐴'(𝑠)
𝑅𝑇
𝐶
𝐶𝐶'(𝑠) − 𝐴ℎ𝐶
𝐺3(𝑠) = 𝐹𝑖'(𝑠)
= 𝐹
𝑆+ 𝐴ℎ𝑖

𝐶𝐶
𝐶𝐶'(𝑠) −
𝐹𝑖
𝐺3(𝑠) = 𝐹𝑖'(𝑠)
= 𝐴ℎ
𝑆+1
𝐹𝑖

15
Steady state gain,
𝐶𝐶
𝐾 =−
𝐹𝑖

358.3 (0.069)
− 7.8
𝐾= 8

𝐾 =0.3962

Time Constant,
𝐴ℎ
𝒯=
𝐹𝑖

3.2685(2.601)
𝒯= 8

𝒯 = 1. 0627 ℎ𝑜𝑢𝑟
∴ It is a first-order dynamic model.

5.1.1 Response to positive fluctuation

Input Flow Fluctuations affect Liquid Level

If the volume is not constant, when +5% fluctuation in input flow:

0.05 (8) 0.4

𝐹𝑖'(𝑠) = 𝑠
= 𝑠

(0.306) 0.4 0.1224

ℎ'(𝑠) = 2 = 2
𝑠 𝑠

ℎ'(𝑡) = 0. 1224𝑡

16
 ℎ'(𝑡) = ℎ(𝑡) − ℎ(𝑡)
ℎ(𝑡) = 0. 1224𝑡 + 3. 06 (0. 85)
ℎ(𝑡) = 0. 1224𝑡 + 2. 601
ℎ(3. 75ℎ𝑟𝑠) = 𝑉 = 3. 06𝑚
∴ For +5% fluctuation in input flow rate there is a possibility
for the overflowing of liquid at 3.75 hrs.

Input Flow Fluctuations affect The Temperature

If the volume is not constant, when +5% fluctuation in input flow:

0.05 (8) 0.4

𝐹𝑖'(𝑠) = 𝑠
= 𝑠

−11.3460 0.4 −4.5384

𝑇'(𝑠) = (3.8583)𝑠 + 1
( 𝑠
) = (3.8583𝑠 + 1)(𝑠)

−1
ℒ {𝑇'(𝑠)} = ℒ
−1
{ −4.5384
(3.8583𝑠+1)(𝑠) }
𝑡
− 3.8583
𝑇'(𝑡) =− 4. 5384[1 − 𝑒 ]
𝑇' = T - 𝑇
𝑡
− 3.8583
𝑇(𝑡) =− 4. 5384[1 − 𝑒 ] +𝑇
𝑡
− 3.8583
𝑇(𝑡) =− 4. 5384[1 − 𝑒 ] + 50

17
 The critical limit: T(t)=55℃
𝑡
− 3.8583
55 = − 4. 5384[1 − 𝑒 ] + 50
𝑡 = -2.8658 hours
∴ For +5% fluctuation in temperature, the reaction already run away
and the critical limit was violated.

If the volume is constant, when +5% fluctuation in input flow:

0.05 (8) 0.4

𝐹𝑖'(𝑠) = 𝑠
= 𝑠

148.7455 0.4
𝑇'(𝑠) = (𝑠+1)
( 𝑠
)
59.4982
𝑇'(𝑠) = (4.2434𝑠+1)(𝑠)

−1
ℒ {𝑇'(𝑠)} = ℒ
−1
{ 59.4982
(4.2434𝑠+1)(𝑠) }
𝑡
− 4.2434
𝑇'(𝑡) = 59. 4982[1 − 𝑒 ]
𝑇' = 𝑇 − 𝑇
𝑡
− 4.2434
𝑇(𝑡) = 59. 4982[1 − 𝑒 ] +𝑇
𝑡
− 4.2434
𝑇(𝑡) = 59. 4982[1 − 𝑒 ] + 50

18
 The critical limit: T(t)=55℃
𝑡
− 4.2434
55 = 59. 4982[1 − 𝑒 ] + 50
𝑡 = 0.3725 hours
∴ For +5% fluctuation in temperature, the reaction must be taken in 0.3725 hours before it run
away and before the critical limit is violated.

Input Flow Fluctuations affect PG Concentration

If the volume is not constant, when +5% fluctuation in input flow:

0.05 (8) 0.4

𝐹𝑖'(𝑠) = 𝑠
= 𝑠

−0.3962 0.4
𝐶𝑐'(𝑠) = 1.0627 (𝑠+1)
( 𝑠
)
−0.1585
𝐶𝑐'(𝑠) = 1.0627 (𝑠+1)(𝑠)

ℒ {𝐶𝑐'(𝑠)} = ℒ−1{ 1.0627

−1
(𝑠+1)(𝑠) }
−0.1585

𝑡
− 1.0627
𝐶𝑐'(𝑡) =− 0. 1585[1 − 𝑒 ]

𝐶𝑐' = 𝐶𝑐 − 𝐶𝑐
𝑡
− 1.0627
𝐶𝑐'(𝑡) =− 0. 1585[1 − 𝑒 ] + 𝐶𝑐
𝑡
− 1.0627 358.3(0.069)
𝐶𝑐'(𝑡) =− 0. 1585[1 − 𝑒 ]+ 7.8
𝑡
− 1.0627
𝐶𝑐'(𝑡) =− 0. 1585[1 − 𝑒 ] + 3. 1696

19
If the volume is constant, when +5% fluctuation in input flow:

0.05 (8) 0.4

𝐹𝑖'(𝑠) = 𝑠
= 𝑠

−0.3962 0.4
𝐶𝑐'(𝑠) = 1.0627 (𝑠+1)
( 𝑠
)
−0.1585
𝐶𝑐'(𝑠) = 1.0627 (𝑠+1)(𝑠)

ℒ {𝐶𝑐'(𝑠)} = ℒ−1{ 1.0627

−1
(𝑠+1)(𝑠) }
−0.1585

𝑡
− 1.0627
𝐶𝑐'(𝑡) =− 0. 1585[1 − 𝑒 ]

𝐶𝑐' = 𝐶𝑐 − 𝐶𝑐
𝑡
− 1.0627
𝐶𝑐'(𝑡) =− 0. 1585[1 − 𝑒 ] + 𝐶𝑐
𝑡
− 1.0627 358.3(0.069)
𝐶𝑐'(𝑡) =− 0. 1585[1 − 𝑒 ]+ 7.8
𝑡
− 1.0627
𝐶𝑐'(𝑡) =− 0. 1585[1 − 𝑒 ] + 3. 1696

20
5.1.2 Response to negative fluctuation

Input Flow Fluctuations affect Liquid Level

If the volume is not constant, when +5% fluctuation in input flow:

−0.05 (8) −0.4

𝐹𝑖'(𝑠) = 𝑠
= 𝑠

(−0.306) 0.4 −0.1224

ℎ'(𝑠) = 2 = 2
𝑠 𝑠

ℎ'(𝑡) = − 0. 1224𝑡
ℎ'(𝑡) = ℎ(𝑡) − ℎ(𝑡)
ℎ(𝑡) = − 0. 1224𝑡 + 3. 06 (0. 85)
ℎ(𝑡) = − 0. 1224𝑡 + 2. 601
ℎ(21. 25ℎ𝑟) = 𝑉 = 0 𝑚
∴ For -5% fluctuation, there is a possibility for the reactor to run dry at 21.25 hrs.

21
Input Flow Fluctuations affect The Temperature
If the volume is not constant, when -5% fluctuation in input flow:

−0.05 (8) −0.4

𝐹𝑖'(𝑠) = 𝑠
= 𝑠

−11.3460 −0.4
𝑇'(𝑠) = 3.8583 (𝑠+1)
( 𝑠
)
4.5384
𝑇'(𝑠) = 3.8583 (𝑠+1)(𝑠)

−1
ℒ {𝑇'(𝑠)} = ℒ
−1
{ 4.5384
3.8583 (𝑠+1)(𝑠) }
𝑡
− 3.8583
𝑇'(𝑡) = 4. 5384[1 − 𝑒 ]
𝑇' = 𝑇 − 𝑇
𝑡
− 3.8583
𝑇(𝑡) = 4. 5384[1 − 𝑒 ] +𝑇
𝑡
− 3.8583
𝑇(𝑡) = 4. 5384[1 − 𝑒 ] + 50
The critical limit: T(t)=55℃
𝑡
− 3.8583
55 = 4. 5384[1 − 𝑒 ] + 50
𝑡 ≥ 15 hours
∴ For -5% fluctuation, in 15 hours, the critical limit was already violated and the reaction
ran away. Thus, it is very difficult or impossible to control.

22
If the volume is constant, when -5% fluctuation in input flow:

−0.05 (8) −0.4

𝐹𝑖'(𝑠) = 𝑠
= 𝑠

148.7455 −0.4
𝑇'(𝑠) = 4.2434 (𝑠+1)
( 𝑠
)
−59.4982
𝑇'(𝑠) = 4.2434 (𝑠+1)(𝑠)

−1
ℒ {𝑇'(𝑠)} = ℒ
−1
{ −59.4982
4.2434 (𝑠+1)(𝑠) }
𝑡
− 4.2434
𝑇'(𝑡) =− 59. 4982[1 − 𝑒 ]
𝑇' = 𝑇 − 𝑇
𝑡
− 4.2434
𝑇(𝑡) =− 59. 4982[1 − 𝑒 ] +𝑇
𝑡
− 4.2434
𝑇(𝑡) =− 59. 4982[1 − 𝑒 ] + 50
The critical limit: T(t)=55℃
𝑡
− 4.2434
55 =− 59. 4982[1 − 𝑒 ] + 50
𝑡 = -0.3424 hours
∴ For -5% fluctuation, the reaction already run away and the critical limit was violated.

23
Input Flow Fluctuations affect PG Concentration
If the volume is not constant, when -5% fluctuation in input flow:

−0.05 (8) −0.4

𝐹𝑖'(𝑠) = 𝑠
= 𝑠

−0.3962 −0.4
𝐶𝑐'(𝑠) = 1.0627 (𝑠+1)
( 𝑠
)
0.1585
𝐶𝑐'(𝑠) = 1.0627 (𝑠+1)(𝑠)

ℒ {𝐶𝑐'(𝑠)} = ℒ−1{ 1.06270.1585

−1
(𝑠+1)(𝑠) }
𝑡
− 1.0627
𝐶𝑐'(𝑡) = 0. 1585[1 − 𝑒 ]

𝐶𝑐' = 𝐶𝑐 − 𝐶𝑐
𝑡
− 1.0627
𝐶𝑐'(𝑡) = 0. 1585[1 − 𝑒 ] + 𝐶𝑐
𝑡
− 1.0627 358.3(0.069)
𝐶𝑐'(𝑡) = 0. 1585[1 − 𝑒 ]+ 7.8
𝑡
− 1.0627
𝐶𝑐'(𝑡) = 0. 1585[1 − 𝑒 ] + 3. 1696

24
If the volume is constant, when -5% fluctuation in input flow:

−0.05 (8) −0.4

𝐹𝑖'(𝑠) = 𝑠
= 𝑠

−0.3962 −0.4
𝐶𝑐'(𝑠) = 1.0627 (𝑠+1)
( 𝑠
)
0.1585
𝐶𝑐'(𝑠) = 1.0627 (𝑠+1)(𝑠)

ℒ {𝐶𝑐'(𝑠)} = ℒ−1{ 1.0627

−1
(𝑠+1)(𝑠) }
−0.1585

𝑡
− 1.0627
𝐶𝑐'(𝑡) =− 0. 1585[1 − 𝑒 ]

𝐶𝑐' = 𝐶𝑐 − 𝐶𝑐
𝑡
− 1.0627
𝐶𝑐(𝑡) = 0. 1585[1 − 𝑒 ] + 𝐶𝑐
𝑡
− 1.0627 358.3(0.069)
𝐶𝑐(𝑡) = 0. 1585[1 − 𝑒 ]+ 7.8
𝑡
− 1.0627
𝐶𝑐(𝑡) = 0. 1585[1 − 𝑒 ] + 3. 1696

25
5.2 Calculation for Reactor Temperature Fluctuations

Temperature of Reactor affect PG Concentration

If volume is not constant,
𝐹𝑖 𝐶𝐶 𝐹𝑖 𝐶𝐶 𝐸
[𝑆 + ]𝐶𝐶'(𝑠) =− 𝐹𝑖'(𝑠) − ℎ'(𝑠) + 2
𝑘𝐶𝐴𝑇'(𝑠) + 𝑘𝐶𝐴'(𝑠)
𝐴ℎ 𝐴ℎ 𝐴ℎ 𝑅𝑇
𝐸
𝐶𝐶'(𝑠) 2
𝑘𝐶𝐴
𝑅𝑇
𝐺4(𝑠) = 𝑇'(𝑠)
= 𝐹𝑖
𝑆+
𝐴ℎ

𝐸 𝐴ℎ
𝐶𝐶'(𝑠) 2
𝑘𝐶𝐴( )
𝑅𝑇 𝐹𝑖
𝐺4(𝑠) = 𝑇'(𝑠)
= 𝐴ℎ
𝑆+1
𝐹𝑖

Steady state gain:

𝐸 𝐴ℎ
𝐾= 2
𝑘𝐶𝐴( )
𝑅𝑇 𝐹𝑖

75300
75300 12 − 8.314(323) 358.3×0.003 3.2685×2.601
𝐾= 2 (16. 96 × 10 )(𝑒 )( 7.8
)( 8
)
8.314(323)

𝐾 = 0. 1432

Time constant:
𝐴ℎ
𝒯=
𝐹𝑖

3.2685(2.601)
𝒯= 8

𝒯 = 1. 0627 ℎ𝑜𝑢𝑟
∴ It is a first-order dynamic model.

If the reactor temperature is 45℃,

45−50 −5
𝑇'(𝑠) = 𝑠
= 𝑠

0.1432 −5
𝐶𝑐'(𝑠) = 1.0627(𝑠+1)
( 𝑠
)
−0.716
𝐶𝑐'(𝑠) = 1.0627(𝑠+1)(𝑠)

ℒ
−1
{𝐶𝑐'(𝑠)} = ℒ−1{ 1.0627(𝑠+1)(𝑠)
−0.716
}

26
 𝑡
− 1.0627
𝐶𝑐'(𝑡) =− 0. 716[1 − 𝑒 ]

𝐶𝑐' = 𝐶𝑐 − 𝐶𝑐
𝑡
− 1.0627
𝐶𝑐(𝑡) =− 0. 716[1 − 𝑒 ] + 𝐶𝑐
𝑡
− 1.0627 358.3(0.069)
𝐶𝑐(𝑡) =− 0. 716[1 − 𝑒 ]+ 7.8
𝑡
− 1.0627
𝐶𝑐(𝑡) =− 0. 716[1 − 𝑒 ] + 3. 1696

If the reactor temperature is 55℃,

55−50 5
𝑇'(𝑠) = 𝑠
= 𝑠

0.1432 5
𝐶𝑐'(𝑠) = 1.0627(𝑠+1)
(𝑠)
0.716
𝐶𝑐'(𝑠) = 1.0627(𝑠+1)(𝑠)

ℒ {𝐶𝑐'(𝑠)} = ℒ−1{ 1.0627(𝑠+1)(𝑠)

−1 0.716
}
𝑡
− 1.0627
𝐶𝑐'(𝑡) = 0. 716[1 − 𝑒 ]

𝐶𝑐' = 𝐶𝑐 − 𝐶𝑐
𝑡
− 1.0627
𝐶𝑐(𝑡) = 0. 716[1 − 𝑒 ] + 𝐶𝑐
𝑡
− 1.0627 358.3(0.069)
𝐶𝑐(𝑡) = 0. 716[1 − 𝑒 ]+ 7.8
𝑡
− 1.0627
𝐶𝑐(𝑡) = 0. 716[1 − 𝑒 ] + 3. 1696

If the volume is constant,

𝑑𝐶𝑐 𝐹𝐶𝐶
𝑑𝑡
= − 𝐴ℎ
+ 𝑘𝐶𝐴

f(𝐹, 𝐶𝐶, T, 𝐶𝐴) = f(𝐹, 𝐶𝐶, 𝑇, 𝐶𝐴) = 0

𝑑𝐶𝐶' δ𝑓 δ𝑓 δ𝑓 δ𝑓
𝑑𝑡
= | 𝐹'
δ𝐹 𝑠𝑠
+ | 𝐶 '
δ𝐶𝐶 𝑠𝑠 𝐶
+ | 𝑇'
δ𝑇 𝑠𝑠
+ | 𝐶 '
δ𝐶𝐴 𝑠𝑠 𝐴

27
 ℒ { }
𝑑𝐶𝑐'
𝑑𝑡
⎰
= ℒ −
⎱
𝐶𝐶
𝐴ℎ
𝐹' −
𝐹𝑖
𝐶 '+
𝐴ℎ 𝐶
𝑅𝑇
𝐸
2
𝑘𝐶𝐴𝑇' + 𝑘𝐶𝐴'
⎱
⎰
𝐶𝐶 𝐹𝑖 𝐸
𝑆𝐶𝐶'(𝑠) − 𝐶𝑐'(0) =− 𝐴ℎ
𝐹'(𝑠) − 𝐴ℎ
𝐶𝐶'(𝑠) + 2
𝑘𝐶𝐴𝑇'(𝑠) + 𝑘𝐶𝐴'(𝑠)
𝑅𝑇

𝐹𝑖 𝐶𝐶 𝐸
𝑆𝐶𝐶'(𝑠) + 𝐶 '(𝑠) =−
𝐴ℎ 𝐶 𝐴ℎ
𝐹𝑖'(𝑠) + 2
𝑘𝐶𝐴𝑇'(𝑠) + 𝑘𝐶𝐴'(𝑠)
𝑅𝑇

𝐹𝑖 𝐶𝐶 𝐸
[𝑆 + 𝐴ℎ
]𝐶𝐶'(𝑠) =− 𝐴ℎ
𝐹𝑖'(𝑠) + 2
𝑘𝐶𝐴𝑇'(𝑠) + 𝑘𝐶𝐴'(𝑠)
𝑅𝑇
𝐸
𝐶𝐶'(𝑠) 2
𝑘𝐶𝐴
𝑅𝑇
𝑇'(𝑠)
= 𝐹
𝑆+ 𝐴ℎ

𝐸 𝐴ℎ
𝐶𝐶'(𝑠) 2
𝑘𝐶𝐴( )
𝑅𝑇 𝐹

𝑇'(𝑠)
= 𝐴ℎ
𝑆+1
𝐹

Steady state gain,

𝐸 𝐴ℎ
𝐾= 2
𝑘𝐶𝐴( )
𝑅𝑇 𝐹

75300
75300 12 − 8.314(323) 358.3×0.003 3.2685×2.601
𝐾= 2 (16. 96 × 10 )(𝑒 )( 7.8
)( 7.8
)
8.314(323)

𝐾 = 0. 1468

Time constant,
𝐴ℎ
𝒯=
𝐹

3.2685(2.601)
𝒯= 7.8

𝒯 = 1. 0899 ℎ𝑜𝑢𝑟
∴ It is a first-order dynamic model.

If the reactor temperature is 45℃,

45−50 −5
𝑇'(𝑠) = 𝑠
= 𝑠

0.1468 −5
𝐶𝑐'(𝑠) = 1.0899(𝑠+1)
( 𝑠
)
−0.734
𝐶𝑐'(𝑠) = 1.0899(𝑠+1)(𝑠)

28
 ℒ
−1
{𝐶𝑐'(𝑠)} = ℒ−1{ 1.0899(𝑠+1)(𝑠)
−0.734
}
𝑡
− 1.0899
𝐶𝑐'(𝑡) =− 0. 734[1 − 𝑒 ]

𝐶𝑐' = 𝐶𝑐 − 𝐶𝑐
𝑡
− 1.0899
𝐶𝑐(𝑡) =− 0. 734[1 − 𝑒 ] + 𝐶𝑐
𝑡
− 1.0899 358.3(0.069)
𝐶𝑐(𝑡) =− 0. 734[1 − 𝑒 ]+ 7.8
𝑡
− 1.0899
𝐶𝑐(𝑡) =− 0. 734[1 − 𝑒 ] + 3. 1696

If the reactor temperature is 55℃,

55−50 5
𝑇'(𝑠) = 𝑠
= 𝑠

0.1468 5
𝐶𝑐'(𝑠) = 1.0899(𝑠+1)
(𝑠)
0.734
𝐶𝑐'(𝑠) = 1.0899(𝑠+1)(𝑠)

ℒ
−1
{𝐶𝑐'(𝑠)} = ℒ−1{ 1.0899(𝑠+1)(𝑠)
0.734
}
𝑡
− 1.0899
𝐶𝑐'(𝑡) = 0. 734[1 − 𝑒 ]

𝐶𝑐' = 𝐶𝑐 − 𝐶𝑐
𝑡
− 1.0899
𝐶𝑐(𝑡) = 0. 734[1 − 𝑒 ] + 𝐶𝑐
𝑡
− 1.0899 358.3(0.069)
𝐶𝑐(𝑡) = 0. 734[1 − 𝑒 ]+ 7.8
𝑡
− 1.0899
𝐶𝑐(𝑡) = 0. 734[1 − 𝑒 ] + 3. 1696

29
5.3 Calculation for Inlet Temperature Fluctuations

Inlet Temperature affect Temperature Reactor

If volume is not constant,
𝐸
𝐹𝑖ρ𝐶𝑝−𝑈𝐴𝑡− 2
𝑘𝐶𝐴(−ΔĤ𝑅)𝐴ℎ 𝑇𝑖−𝑇 𝐹𝑖 𝐹𝑖'(𝑇𝑖−𝑇)
𝑅𝑇
[𝑆 + ]𝑇'(𝑠) = 𝐹𝑖'(𝑠) + 𝑇𝑖'(𝑠)− ℎ'(𝑠)
ρ𝐴ℎ𝐶𝑝 𝐴ℎ 𝐴ℎ 2
𝐴ℎ

𝑈𝐴𝑡(𝑇𝑐−𝑇) 𝑈𝐴𝑡 𝑘(−ΔĤ𝑅)

− ℎ'(𝑠)− 𝑇𝑐'(𝑠) + ρ𝐶𝑝
𝐶𝐴'(𝑠)
2 ρ𝐴ℎ𝐶𝑝
ρ𝐴 ℎ 𝐶𝑝

𝐹𝑖
𝑇'(𝑠) 𝐴ℎ
𝐺5(𝑠) = 𝑇𝑖'(𝑠)
= 𝐹𝑖ρ𝐶𝑝−𝑈𝐴𝑡−
𝐸
𝑘𝐶𝐴(−ΔĤ𝑅)𝐴ℎ
2
𝑅𝑇
𝑆+
ρ𝐴ℎ𝐶𝑝

𝐹𝑖ρ𝐶𝑝
𝐸
𝐹𝑖ρ𝐶𝑝−𝑈𝐴𝑡− 𝑘𝐶𝐴(−ΔĤ𝑅)𝐴ℎ
𝑇'(𝑠) 2
𝐺5(𝑠) = 𝑇𝑖'(𝑠)
= ρ𝐴ℎ𝐶𝑝
𝑅𝑇

𝐸 𝑆+1
𝐹𝑖ρ𝐶𝑝−𝑈𝐴𝑡− 𝑘𝐶𝐴(−ΔĤ𝑅)𝐴ℎ
2
𝑅𝑇

Steady state gain,

𝐹𝑖ρ𝐶𝑝
𝐾= 𝐸
𝐹𝑖ρ𝐶𝑝 −𝑈𝐴𝑡− 2
𝑘𝐶𝐴(−ΔĤ𝑅)𝐴ℎ
𝑅𝑇

8 (955.2)(82.32)
K= 5
75300
12 − 8.314(323))
75300 358.3(0.003)
8(955.2)(82.32)−(3.6×10 )− 2 (16.96×10 𝑒 )( 7.8
)(84500−29.24(323−293))(3.2685)(2.601)
8.314(323)

𝐾 = 3. 6307

Time constant,
ρ𝐴ℎ𝐶𝑝
𝒯= 𝐸
𝐹𝑖ρ𝐶𝑝 −𝑈𝐴𝑡− 2
𝑘𝐶𝐴(−ΔĤ𝑅)𝐴ℎ
𝑅𝑇

(955.2)(3.2685)(2.601)(82.32)
𝒯= 5
75300
12 − 8.314(323))
75300 358.3(0.003)
8(955.2)(82.32)−(3.6×10 )− 2 (16.96×10 𝑒 )( 7.8
)(84500−29.24(323−293))(3.2685)(2.601)
8.314(323)

𝒯 = 3. 8583 ℎ𝑜𝑢𝑟
∴ It is a first-order dynamic model.

30
when +5% fluctuation in inlet temperature,

0.05 (25) 1.25

𝑇𝑖'(𝑠) = 𝑠
= 𝑠

3.6307 1.25 4.5384

𝑇'(𝑠) = (3.8583)𝑠 + 1
( 𝑠
) = (3.8583𝑠 + 1)(𝑠)

−1
ℒ {𝑇'(𝑠)} = ℒ
−1
{ 4.5384
(3.8583𝑠+1)(𝑠) }
𝑡
− 3.8583
𝑇'(𝑡) = 4. 5384[1 − 𝑒 ]
𝑇' = T - 𝑇
𝑡
− 3.8583
𝑇(𝑡) = 4. 5384[1 − 𝑒 ] +𝑇
𝑡
− 3.8583
𝑇(𝑡) = 4. 5384[1 − 𝑒 ] + 50

31
when -5% fluctuation in inlet temperature,

−0.05 (25) −1.25

𝑇𝑖'(𝑠) = 𝑠
= 𝑠

3.6307 −1.25 −4.5384

𝑇'(𝑠) = (3.8583)𝑠 + 1
( 𝑠
) = (3.8583𝑠 + 1)(𝑠)

−1
ℒ {𝑇'(𝑠)} = ℒ
−1
{ −4.5384
(3.8583𝑠+1)(𝑠) }
𝑡
− 3.8583
𝑇'(𝑡) =− 4. 5384[1 − 𝑒 ]
𝑇' = T - 𝑇
𝑡
− 3.8583
𝑇(𝑡) =− 4. 5384[1 − 𝑒 ] +𝑇
𝑡
− 3.8583
𝑇(𝑡) =− 4. 5384[1 − 𝑒 ] + 50

If volume is constant,
𝐸
𝐹ρ𝐶𝑝−𝑈𝐴𝑡− 𝑘𝐶𝐴(−ΔĤ𝑅)𝐴ℎ 𝑇𝑖 𝐹𝑖
𝑅𝑇
2
𝑇
[𝑆 + ρ𝐴ℎ𝐶𝑝
]𝑇'(𝑠) = 𝐹 '(𝑠) −
𝐴ℎ 𝑖 𝐴ℎ
𝐹'(𝑠) + 𝐴ℎ
𝑇𝑖'(𝑠)

𝑈𝐴𝑡 𝑘𝐶𝐴(−ΔĤ𝑅)
− ρ𝐴ℎ𝐶𝑝
𝑇𝑐'(𝑠) + ρ𝐶𝑝
𝐶𝐴'(𝑠)
𝐹𝑖
𝑇'(𝑠) 𝐴ℎ
𝑇𝑖'(𝑠)
= 𝐹ρ𝐶𝑝−𝑈𝐴𝑡−
𝐸
𝑘𝐶𝐴(−ΔĤ𝑅)𝐴ℎ
2
𝑅𝑇
𝑆+ ρ𝐴ℎ𝐶𝑝

𝐹𝑖ρ𝐶𝑝
𝐸
𝐹ρ𝐶𝑝−𝑈𝐴𝑡− 𝑘𝐶𝐴(−ΔĤ𝑅)𝐴ℎ
𝑇'(𝑠) 2

𝑇𝑖'(𝑠)
= ρ𝐴ℎ𝐶𝑝
𝑅𝑇

𝐸 𝑆+1
𝐹ρ𝐶𝑝−𝑈𝐴𝑡− 𝑘𝐶𝐴(−ΔĤ𝑅)𝐴ℎ
2
𝑅𝑇

32
Steady state gain,
𝐹𝑖 ρ𝐶𝑝
𝐾= 𝐸
𝐹ρ𝐶𝑝−𝑈𝐴𝑡− 2
𝑘𝐶𝐴(−ΔĤ𝑅)𝐴ℎ
𝑅𝑇

(8)(955.2)(82.32)
𝐾= 5
75300
12 − 8.314(323))
75300 358.3(0.003)
7.8(955.2)(82.32)−(3.6×10 )− 2 (16.96×10 𝑒 )( 7.8
)(84500−29.24(323−293))(3.2685)(2.601)
8.314(323)

𝐾 = 3.9932

Time constant,
ρ𝐴ℎ𝐶𝑝
𝒯= 𝐸
𝐹ρ𝐶𝑝−𝑈𝐴𝑡− 2
𝑘𝐶𝐴(−ΔĤ𝑅)𝐴ℎ
𝑅𝑇

(955.2)(3.268)(2.601)(82.32)
𝒯= 5
75300
12 − 8.314(323))
75300 358.3(0.003)
7.8(955.2)(82.32)−(3.6×10 )− 2 (16.96×10 𝑒 )( 7.8
)(84500−29.24(323−293))(3.2685)(2.601)
8.314(323)

𝒯 = 4. 2434 ℎ𝑜𝑢𝑟
∴ It is a first-order dynamic model.

33
when +5% fluctuation in inlet temperature:

0.05 (25) 1.25

𝑇𝑖'(𝑠) = 𝑠
= 𝑠

3.9932 1.25
𝑇'(𝑠) = (𝑠+1)
( 𝑠
)
4.9915
𝑇'(𝑠) = (4.2434𝑠+1)(𝑠)

−1
ℒ {𝑇'(𝑠)} = ℒ
−1
{ 4.9915
(4.2434𝑠+1)(𝑠) }
𝑡
− 4.2434
𝑇'(𝑡) = 4. 9915[1 − 𝑒 ]
𝑇' = 𝑇 − 𝑇
𝑡
− 4.2434
𝑇(𝑡) = 4. 9915[1 − 𝑒 ] +𝑇
𝑡
− 4.2434
𝑇(𝑡) = 4. 9915[1 − 𝑒 ] + 50

34
when -5% fluctuation in input flow:

−0.05 (25) −1.25

𝑇𝑖'(𝑠) = 𝑠
= 𝑠

3.9932 −1.25
𝑇'(𝑠) = (𝑠+1)
( 𝑠
)
−4.9915
𝑇'(𝑠) = (4.2434𝑠+1)(𝑠)

−1
ℒ {𝑇'(𝑠)} = ℒ
−1
{ −4.9915
4.2434 (𝑠+1)(𝑠) }
𝑡
− 4.2434
𝑇'(𝑡) =− 4. 9915[1 − 𝑒 ]
𝑇' = 𝑇 − 𝑇
𝑡
− 4.2434
𝑇(𝑡) =− 4. 9915[1 − 𝑒 ] +𝑇
𝑡
− 4.2434
𝑇(𝑡) =− 4. 9915[1 − 𝑒 ] + 50

35
Inlet Temperature affect PG Concentration

From calculation for reactor temperature affects PG concentration in section 5.4, when the
reactor temperature increases, concentration of PG increases. Thus, reactor temperature (T) is
proportional to concentration of PG (Cc).
𝑇∝ 𝐶𝑐

From calculation for inlet temperature (Ti) affects temperature reactor(T), when inlet temperature
increased, temperature reactor increased. Thus, inlet temperature is proportional to temperature
of the reactor.
𝑇𝑖∝ 𝑇

Therefore, we can assume that inlet temperature is proportional to concentration of PG which

indicates that when inlet temperature increases, the concentration of PG also increases.

𝑇𝑖∝ 𝐶𝑐

6.0 Overall Input-Output Model

36
7.0 Conclusion

After developing dynamic mathematical models in Case Study 2A, we are able to
transform them into input-output models to estimate the behavior of the system's output in
response to changes in its setpoint or inputs for control and operational purposes. Thus, we
do linearization and Laplace transform to make it in the standard transfer function form as
shown below:

where C(S) is output, R(S) is input, K is steady state gain and T is time constant.

From the calculation that we have done, the value of steady state gain and time constant
summarized in table below:

Steady state gain, K Time constant, 𝒯

Fluctuation Volume Volume is Volume is Volume is

is not constant not constant constant
constant

Liquid Level 0.306 - ∞ -

Input Flow
Temperature -11.3460 148.7455 3.8583 4.2434

PG 0.3962 0.3962 1.0627 1.0627

Concentration

Temperature PG 0.1432 0.1468 1.0627 1.0899

of Reactor Concentration

Inlet Reactor 3.6307 3.9932 3.8583 4.2434

Temperature Temperature

To sum up, all the models are the first order model and first order dynamic behavior. The
fluctuation in reactant flow rate that affects the reactor performance in terms of liquid level,
temperature and PG concentration can be observed from the simulation. Moreover, the

37
fluctuation of reactor temperature can be analyzed when the temperature is 55℃ and 45℃
while the fluctuation of inlet temperature that affects reactor temperature can be analyzed
through calculation and simulation. The fluctuation can be observed from the plot in section
5.0. The input-output model clearly exhibits that the fluctuation of input flow rate could
affect the liquid level, temperature and PG concentration, the fluctuation of temperature of
reactor could affect the PG concentration and the fluctuation of inlet temperature could affect
the reactor temperature.

38