Heat transfer system and feedback temperature controller design for safety process operation of phosphorous acid potassium salts production

Abstract

The phosphorous acid salts are widely used in the industry because of the effective treatment against various fungal diseases encountered in plants. The production process is exothermic and, with high temperatures around 94℃ achieved, significant risks were observed in terms of occupational health and safety. Therefore, the aim is to design a control system that will make this production process reliable for human health, economic and ecological damage. For this purpose, studies were carried out to determine the optimum operating mode, heat transfer system, and temperature controller design to prevent a sudden temperature rise. First, the overall heat transfer coefficient between the reactor and the jacket was determined as 51.0930 W/m2℃ and, the refrigerant was chosen as cooling water with 1.271 g/s flow rate which is relatively more economical and accessible. The model parameters of the system were determined with a detailed dynamic analysis by giving positive and negative step inputs to the cooling water flow rate and then obtaining model parameters through reaction curve and linear regression methods. By using the obtained model parameters theoretical P, PI and PID parameters were calculated by Cohen Coon and, Ziegler-Nichols approaches, and the success of controller parameters was tested, simulated with the MATLAB Simulink program and lastly, successful temperature control was achieved in the experimental system.

Keywords

• feedback temperature control
• model parameters
• neutralization
• phosphorous acid
• potassium salts

Supporting Institution

TUBITAK 2209-B Undergraduate Research Projects Industry-Oriented Support Program

Project Number

1139B412001078

Thanks

Authors would like to thank to TUBITAK 2209-B Undergraduate Research Projects Industry-Oriented Support Program.

References

1. 1. Rosival, L., Pesticides. Scandinavian Journal of Work, Environment and Health, 1985. 11(3): p. 189–197.
2. 2. Bates, J., Recommended approaches to the production and evaluation of data on pesticide residues in food. Pure and Applied Chemistry, 1982. 54(7): p. 1361–1449.
3. 3. Programme, U.N.E., List of Environmentally Dangerous Chemical Substances and Processes of Global Significance. IRPTC, 1986.
4. 4. Rani, L., K. Thapa, N. Kanojia, N. Sharma, S. Singh, A.S. Grewal, J. Kaushal, An extensive review on the consequences of chemical pesticides on human health and environment. Journal of Cleaner Production, 2021. 283: 124657.
5. 5. Akande, M. G., Health Risks Associated with the Consumption of Legumes Contaminated with Pesticides and Heavy Metals, 2021. [cited 2021 25 June]; Available from: https://www.intechopen.com/online-first/78185.
6. 6. Syafrudin, M., R.A. Kristanti, A. Yuniarto, T. Hadibarata, J. Rhee, W.A. Al-Onazi, A.M. Al-Mohaimeed, Pesticides in drinking water—a review. International Journal of Environmental Research and Public Health, 2021, 18(2): 468.
7. 7. Al-Maydama, H. M. A., and P.J. Gardner, The enthalpy of solution of phosphorous acid (H3PO3) in water. Thermochimica Acta, 1990, 161(1): p. 51–54.
8. 8. Ann, P. J., J.N. Tsai, I.L. Wong, T. Hsieh, T., & C.Y. Lin, A simple technique, concentration and application schedule for using neutralized phosphorous acid to control phytophthora diseases. Plant Pathology Bulletin, 2009, 18: p. 155–165.

9. 9. Förster, H., J. Adaskaveg, D.H. Kim, M., Stanghellini, Effect of Phosphite on Tomato and Pepper Plants and on Susceptibility of Pepper to Phytophthora Root and Crown Rot in Hydroponic Culture. Plant disease, 1998, 82(10): p. 1165–1170.
10. 10. Macintire, W. H., S.H. Winterberg, L.J., Hardin, A.J. Sterges, L.B. Clements, Fertilizer evaluation of certain phosphorus, phosphorous, and phosphoric materials by means of pot cultures. Agronomy journal, 1950. 42: p. 543-549.
11. 11. Conrath, U., G.J.M. Beckers, V. Flors, P. García-Agustín, G. Jakab, F. Mauch, B. Mauch-Mani, Priming: getting ready for battle. Molecular plant-microbe interactions : MPMI, 2006. 19(10): p. 1062–1071.
12. 12. Conrath, U., Molecular aspects of defence priming. Trends in plant science, 2011. 16(10): p. 524–531.
13. 13. Luna, E., T.J.A. Bruce, M.R. Roberts, V. Flors, & J. Ton, Next-generation systemic acquired resistance. Plant physiology, 2012. 158(2): p. 844–853.
14. 14. Hunt, M. D., J.A. Ryals, D. Reinhardt, Systemic acquired resistance signal transduction. Critical Reviews in Plant Sciences, 1996. 15(5–6): p. 583–606.
15. 15. Neuenschwander, U., K. Lawton, J. Ryals, Plant microbe interactions. 1996, New York: Chapman and Hall. Systemic acquired resistance, p. 81–106.
16. 16. Ryals, J. A., U.H. Neuenschwander, M.G. Willits, A. Molina, H.Y. Steiner, M.D. Hunt, Systemic Acquired Resistance. The Plant cell, 1996. 8(10): p. 1809–1819.
17. 17. Klessig, D. F., H.W. Choi, D.A. Dempsey, Systemic acquired resistance and salicylic acid: past, present, and future. Molecular plant-microbe interactions, 2018. 31(9): p. 871–888.
18. 18. Bellows, T. S., Foliar, Flower, and Fruit Pathogens In: Handbook of Biological Control. 1999, San Diego: Academic Press, p. 841-852.
19. 19. Chaudhry, M. Q., Phosphine resistance. Pesticide Outlook, 2000. 11(3): p. 88–91.
20. 20. Hashimoto, S., K. Fujiwara, K. Fuwa, Determination of phosphate ion by gas chromatography with the phosphine generation technique. Analytical Chemistry, 1985. 57(7): p. 1305–1309.
21. 21. Lee, K., & I.S. Han, Evaluation of Thermal Hazard in Neutralization Process of Pigment Plant by Multimax Reactor System. Journal of the Korean Society of Safety, 2008. 23(6): p. 91-99.
22. 22. Garrett, K. K., Potential Antidotes to Phosphine Poisoning. University of Pittsburgh. In Graduate School of Public Health, 2021, University of Pittsburgh: USA. p. 159.
23. 23. Yurkevich, V., PI/PID Control for Nonlinear Systems via Singular Perturbation Technique In: Advaces in PID Control. 2011, Rijeka: InTech, p. 113–142.
24. 24. A.Iyswariya, N. Nimitha, A. Veronica & S. Ranganathan, Design of PI Controller using First Order Plus Time Delay Model for Process Control. International Journal of Advanced Research in Electronics and Communication Engineering, 2015. 4(3): p. 687–691.
25. 25. Ziegler J.G., Optimum settings for automatic controllers. Transactions of the ASME, 1942. 64(11): p. 759–768.
26. 26. Li, Y., K. H. Ang, G.C.Y. Chong, PID control system analysis and design. IEEE Control Systems Magazine, 2006. 26(1): p. 32–41.
27. 27. Khosravi, A., A. Chatraei, G. Shahgholian, S.M. Kargar, System identification using NARX and centrifugal compressor control through the intelligent, active method—Case study: K‐250 centrifugal compressor. Asian Journal of Control, 2022. p. 1–20.
28. 28. Huang, J., & W.J. Hugh, On a nonlinear multivariable servomechanism problem. Automatica, 1990. 26(6): p. 963–972.
29. 29. Isidori, A. and C.I. Byrnes, Output regulation of nonlinear systems. IEEE transactions on Automatic Control, 1990. 35(2): p. 131–140.
30. 30. Gamasu, R. and V.R. B. Jasti, Robust cohen-coon PID controller for flexibility of double link manipulator. International Journal of Control and Automation, 2014. 7(1): p. 357–368.
31. 31. Khalil, H. K., Universal integral controllers for minimum-phase nonlinear systems. IEEE Transactions on automatic control, 2000. 45(3): p. 490–494.
32. 32. Mahmoud, N. A. and H.K. Khalil, Asymptotic regulation of minimum phase nonlinear systems using output feedback. IEEE Transactions on Automatic Control, 1996. 41(10): p. 1402–1412.
33. 33. Foley, M. W., R.H. Julien, B.R.A. Copeland, A comparison of PID controller tuning methods. The Canadian Journal of Chemical Engineering, 2005. 83(4): p. 712–722.
34. 34. Rivera, D. E., M. Morari and S. Skogestad, Internal model control: PID controller design. Industrial & engineering chemistry process design and development, 1986. 25(1): p. 252–265.
35. 35. Seborg, D. E., T.F. Edgar, D.A. Mellichamp, H. Wiley, N.J. Hoboken, Process Dynamics and Control, 2nd Edition, 2008. 54(11): p. 3026.
36. 36. Dunn, W., Introduction to instrumentation, sensors, and process control. 2005, Boston: Artech House, Inc.