ABOUT THE AUTHOR
William L. Luyben received his B.S. in Chemical Engineering from the Penn-
sylvania State University where he was the valedictorian of the Class of 1955. He
worked for Exxon for five years at the Bayway Refinery and at the Abadan
Refinery (Iran) in plant. technical service and design of petroleum processing
units. After earning a Ph.D. in 1963 at the University of Delaware, Dr. Luyben
worked for the Engineering Department of DuPont in process dynamics and
control of chemical plants. In 1967 he joined Lehigh University where he is now
Professor of Chemical Engineering and Co-Director of the Process Modeling and
Control Center.
Professor Luyben has published over 100 technical papers and has
authored or coauthored four books. Professor Luyben has directed the theses of
over 30 graduate students. He is an active consultant for industry in the area of
process control and has an international reputation in the field of distillation
column control. He was the recipient of the Beckman Education Award in 1975
and the Instrumqntation Technology Award r.-., in 1969 from the Instrument Society
of America. f .,y<i ‘.,
Overall, he has devoted ove$? 3$,years to, his profession as a teacher,
researcher, author, and practicing en&eer: :.: ’ ! 1. I’
vii
This book is dedicated to
Robert L. Pigford and Page S. Buckley,
two authentic pioneers
in process modeling
and process control
CONTENTS
Preface Xxi
1 Introduction 1
1.1 Examples of the Role of Process Dynamics
and Control 1
1.2 Historical Background 6
1.3 Perspective 7
1.4 Motivation for Studying Process Control 8
1.5 General Concepts 8
1.6 Laws and Languages of Process Control 11
1.6.1 Process Control Laws 11
1.6.2 Languages of Process Control 12
Part I Mathematical Models of
Chemical Engineering Systems
2 Fundamentals 15
2.1 Intreduction 15
2.1.1 Uses of Mathematical Models 15
2.1.2 Scope of Coverage 16
2.1.3 Principles of Formulation 16
2.2 Fundamental Laws 17
2.2.1 Continuity Equations 17
2.2.2 Energy Equation 23
2.2.3 Equations of Motion 27
2.2.4 Transport Equations 31
2.2.5 Equations of State 32
2.2.6 Equilibrium 33
2.2.7 Chemical Kinetics 36
Problems 38
xi
I
Xii CONTENTS
3 Examples of Mathematical Models
of Chemical Engineering Systems 40
3.1 Introduction 40
3.2 Series of Isothermal, Constant-Holdup CSTRs 41
3.3 CSTRs With Variable Holdups 43
3.4 Two Heated Tanks 44
3.5 Gas-Phase, Pressurized CSTR 45
3.6 Nonisothermal CSTR 46
3.7 Single-Component Vaporizer 51
3.8 Multicomponent Flash Drum 54
3.9 Batch Reactor 57
3.10 Reactor With Mass Transfer 62
3.11 Ideal Binary Distillation Column 64
3.12 Multicomponent Nonideal Distillation Column 70
3.13 Batch Distillation With Holdup 72
3.14 pH Systems 74
3.14.1 Equilibrium-Constant Models 74
3.14.2 Titration-Curve Method 75
Problems 77
Part II Computer Simulation
4 Numerical Methods 89
4.1 Introduction 89
4.2 Computer Programming 90
4.3 Iterative Convergence Methods 91
4.3.1 Interval Halving 93
4.3.2 Newton-Raphson Method 96
4.3.3 False Position 100
4.3.4 Explicit Convergence Methods 101
4.35 Wegstein 103
4.3.6 Muller Method 103
4.4 Numerical Integration of Ordinary Differential Equations 105
4.4.1 Explicit Numerical Integration Algorithms 106
4.4.2 Implicit Methods 113
Problems 114
5 Simulation Examples 116
5.1 Gravity-Flow Tank 116
5.2 Three CSTRs in Series 119
5.3 Nonisothermal CSTR 124
5.4 Binary Distillation Column 129
5.5 Multicomponent Distillation Column 132
5.6 Variable Pressure Distillation 141
5.6.1 Approximate Variable-Pressure Model 141
5.6.2 Rigorous Variable-Pressure Model 142
.. .
CONTENTS xlu
5.7 Batch Reactor 150
5.8 Ternary Batch Distillation With Holdup 157
Problems 162
Part III Time-Domain Dynamics and Control
6 Time-Domain Dynamics 167
6.1 Classification and Dethtition 167
6.2 Linearization and Perturbation Variables 171
6.2.1 Linearization 171
6.2.2 Perturbation Variables 175
6.3 Responses of Simple Linear Systems 177
6.3.1 First-Order Linear Ordinary Differential Equation 177
6.3.2 Second-Order Linear ODES With Constant Coefficients 182
6.3.3 Nth-Order Linear ODES With Constant Coefficients 192
6.4 Steadystate Techniques 195
Problems 198
7 Corkentional Control Systems and Hardware 205
7.1 Control Instrumentation 205
7.1.1 Sensors 207
7.1.2 Transmitters 211
7.1.3 Control Valves 213
7.1.4 Analog and Digital Controllers 222
7.1.5 Computing and Logic Devices 226
7.2 Performance of Feedback Controllers 226
7.2.1 Specifications for Closedloop Response 226
7.2.2 Load Performance 227
7.3 Controller Tuning 231
7.3.1 Rules of Thumb 231
7.3.2 On-Line Trial and Error 234
7.3.3 Ziegler-Nichols Method 235
Problems 238
8 Advanced Control Systems 253
8.1 Ratio Control 253
8.2 Cascade Control 255
8.3 Computed Variable Control 257
8.4 Override Control 259
8.4.1 Basic System 259
8.4.2 Reset Windup 261
8.5 Nonlinear and Adaptive Control 262
8.5.1 Nonlinear Control 262
8.5.2 Adaptive Control 263
8.6 Valve-Position Control 263
8.7 Feedfonvard Control Concepts 265
Xiv CONTENTS
8.8 Control System Design Concepts 268
8.8.1 General Guidelines 268
8.8.2 Trade-Offs Between Steadystate Design and Control 273
8.8.3 Plant-Wide Control 274
8.9 Dynamic Matrix Control 281
8.9.1 Review of Least Squares 281
8.9.2 Step-Response Models 284
8.9.3 DMC Algorithm 287
Problems 288
Part IV Laplace-Domain Dynamics and Control
9 Laplace-Domain Dynamics 303
9.1 Laplace-Transformation Fundamentals 303
9.1.1 Definition 303
9.1.2 Linearity Property 304
9.2 Laplace Transformation of Important Functions 304
9.2.1 Step Function 304
9.2.2 Ramp 305
9.2.3 Sine 306
9.2.4 Exponential 306
9.2.5 Exponential Multiplied By Time 307
9.2.6 Impulse (Dirac Delta Function 6,,,) 307
9.3 Inversion of Laplace Transforms 308
9.4 Transfer Functions 311
9.4.1 Multiplication by a Constant 312
9.4.2 Differentiation With Respect To Time 312
9.4.3 Integration 314
9 . 4 . 4 Deadtime 315
9.5 Examples 316
9.6 Properties of Transfer Functions 325
9.6.1 Physical Realizability 325
9.6.2 Poles and Zeros 326
9.6.3 Steadystate Gains 327
9.7 Transfer Functions for Feedback Controllers 329
Problems 331
10 Laplace-Domain Analysis of Conventional
Feedback Control Systems 339
10.1 Openloop and Closedloop Systems 340
10.1.1 Openloop Characteristic Equation 340
10.1.2 Closedloop Characteristic Equation and Closedloop
Transfer Function 341
10.2 Stability 345
10.2.1 Routh Stability Criterion 346
10.2.2 Direct Substitution For Stability Limit 348
