Batch Control

This document discusses batch process control systems. It describes how batch control systems involve sequencing different process steps and controlling processes during each batch run. Additionally, batch control uses measurements from previous batch runs through run-to-run control to improve the current batch. Finally, batch production management involves planning and scheduling to optimize production of multiple products using the same equipment.

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Batch Control

Uploaded by

Ganesh Kumar V

Available Formats

Download as PPT, PDF, TXT or read online on Scribd

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Batch Process Control

1. Introduction
2. Sequential and logic control
3. Control during the batch
4. Run-to-run control
5. Batch production management

Introduction
Batch operation is very common in the specialty
chemical, pharmaceutical and materials
processing industries
Multiproduct batch plants produce a range of
similar products using the same equipment
Batch control is particularly difficult because
there is no steady-state operating point and
processes operate over a wide range of conditions
Batch process control systems involve sequencing
of different process steps and control during the
batch
Run-to-run control uses experience from previous
batch runs to improve the current run
Batch plant scheduling and planning are used to
manage the production of different products
Batch Distillation Example
Batch Control Systems
Sequencing and logic sequencing of control
steps according to a predefined recipe
Control during the batch tracking of
predetermined setpoint trajectories
Run-to-run control end-of-batch measurements
are used to improve control of next batch
Batch production management planning of
production needs and scheduling of product
campaigns
Sequential and Logic Control
Control of batch unit operations
involves the proper sequencing and
execution of specific steps
Sequential logic can be represented
in several ways, such as information
flow diagrams
Information flow diagrams can be
translated into digital logic diagrams
to be executed by programmable
logic controllers (PLCs)
PLCs can execute sequencing
operations are well as standard PID
control algorithms
PLCs are the key control hardware
used in batch plants
Batch Sequence Control Example
Control During the Batch
Execution of sequenced operations often
involves feedback control of specified
outputs
Batch control is challenging because there is
no steady-state operating point and processes
operate over a wide range of conditions
Tracking of predetermined setpoint
trajectories is often required
Process nonlinearities and model
inaccuracies become more pronounced when
processes are operated over large regimes
Some product properties affected during a
batch are irreversible once off target

Batch Reactor Control
PI Control of Batch Reactors
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Rapid Thermal Processing
Rapid Thermal Processing (RTP) is semiconductor
manufacturing process in which silicon wafers are
heated to very high temperatures (~1,200C) on a
timescale of seconds.
During cooling temperatures must be reduced slowly
so the wafer does not break due to thermal shock.
Rapid heating and cooling rates are attained with high
intensity lamps or lasers.
A key challenge in RTP is accurate measurement and
control of the wafer temperature during a batch cycle.
High temperature ramp rates prevent the wafer from
coming to thermal equilibrium with the process
chamber where temperature is more easily measured.
Gain Scheduled PID Control
PID controllers usually provide satisfactory control
near the steady-state operating point where the
controller was designed
If the process is highly nonlinear and/or operates over
a large regime a single set of PID tuning parameter
may be inadequate
RTP processes operate over a very wide range of
temperatures and exhibit strong nonlinear behavior
Gain scheduling is a simple method to adapt PID
controllers to nonlinear processes
Gain scheduling is implemented by adjusting the
controller gain according to the current operating point
IMC PI tuning example
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Comparison of PID Controllers
Standard PID Controller Gain Scheduled PID Controller
Run-to-Run Control
Product quality measurements are usually
collected only at the end of each batch run.
Run-to-run control uses quality
measurements from previous runs to
adjust conditions of the current run.
Semiconductor manufacturing
Controlled variable: film thickness
Manipulated variable: heating rate
Polymer manufacturing
Controlled variable: molecular weight
Manipulated variable: chain transfer agent
addition rate
Batch Production Management
Many batch plants produce multiple
products for multiple customers
Specialty polymers plant: ~25 products for
~100 customers
Planning procedures to optimally order
the raw materials, manufacturer the
products, and ship the products to
customers
Scheduling procedures to optimally
implement the manufacturing plan by
scheduling the use of available equipment
Batch Scheduling and Planning
DETERMINE

What
Product amounts: lot sizes, batch sizes

When
Timing of specific operations, run lengths

Where
Sites, units, equipment items

How
Resource types and amounts
GIVEN

Product requirements
Time horizon, demands, starting and ending
inventories

Operational steps
Precedence order, resource utilization

Production facilities
Types, capacities

Resource limitations
Types, amounts, rates
Multiproduct Batch Plant Example
Batch Plant Scheduling Example
Integrated Batch Control Systems