DESIGN AND VALIDATION OF AN IOT-INTEGRATED AUTOMATED DISTILLATION SYSTEM WITH PID TEMPERATURE CONTROL

By Nguyen Anh Vu, Nguyen Thanh Doan, Nguyen Phuong Tra
DOI: 10.37550/tdmu.EJS/2026.01.702

This paper presents the design, implementation, and empirical evaluation of a sophisticated automated alcohol distillation system. The system integrates modern control theory with Internet of Things (IoT) technology to overcome the limitations of traditional manual distillation, which often suffers from inconsistent product quality, high labor dependency, and significant safety risks. The core of the system employs a REX-C100 PID temperature controller for precise thermal regulation, an ESP8266 microcontroller for IoT connectivity, and an array of sensors including a K-type thermocouple and an MQ-3 alcohol concentration sensor for comprehensive process monitoring and safety. A detailed mathematical model of the distillation process and an enhanced PID control algorithm with feedforward compensation are provided. Experimental results demonstrate a 50% reduction in processing time, an increase in process efficiency from 60% to 90%, and a remarkable improvement in product quality consistency from 70% to 95%, all while maintaining a temperature control accuracy of ±1°C. The system successfully enables remote monitoring and control via the Blynk IoT platform, establishing a robust framework for intelligent, safe, and efficient distillation applicable to both small-scale and industrial production