Scribd Logo
Upload

Welcome to Scribd!

  • 61 views

    CHEN 4470 - Process Design Practice: Dr. Mario Richard Eden Department of Chemical Engineering Auburn University

    Uploaded by

    Rachele Piovanelli
    This document summarizes steps for conceptual plantwide control system design. It outlines a 9-step approach involving establishing control objectives and degrees of freedom, energy management, production rate setting, product quality control, recycle loop flow rate fixing, component balancing, unit control, and optimization. It provides an example applying these steps to an acyclic and cyclic process, identifying control valves to achieve objectives at each step. The summary highlights control structure selection approaches covered in the previous and current lectures.

    Copyright:

    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd

    CHEN 4470 - Process Design Practice: Dr. Mario Richard Eden Department of Chemical Engineering Auburn University

    Uploaded by

    Rachele Piovanelli
    61 views23 pages
    This document summarizes steps for conceptual plantwide control system design. It outlines a 9-step approach involving establishing control objectives and degrees of freedom, energy management, production rate setting, product quality control, recycle loop flow rate fixing, component balancing, unit control, and optimization. It provides an example applying these steps to an acyclic and cyclic process, identifying control valves to achieve objectives at each step. The summary highlights control structure selection approaches covered in the previous and current lectures.

    Original Description:

    6

    Original Title

    4470-Lecture-16-2013

    Copyright

    © © All Rights Reserved

    Available Formats

    PPT, PDF, TXT or read online from Scribd

    Did you find this document useful?

    Is this content inappropriate?

    This document summarizes steps for conceptual plantwide control system design. It outlines a 9-step approach involving establishing control objectives and degrees of freedom, energy management, production rate setting, product quality control, recycle loop flow rate fixing, component balancing, unit control, and optimization. It provides an example applying these steps to an acyclic and cyclic process, identifying control valves to achieve objectives at each step. The summary highlights control structure selection approaches covered in the previous and current lectures.

    Copyright:

    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    61 views23 pages

    CHEN 4470 - Process Design Practice: Dr. Mario Richard Eden Department of Chemical Engineering Auburn University

    Uploaded by

    Rachele Piovanelli
    This document summarizes steps for conceptual plantwide control system design. It outlines a 9-step approach involving establishing control objectives and degrees of freedom, energy management, production rate setting, product quality control, recycle loop flow rate fixing, component balancing, unit control, and optimization. It provides an example applying these steps to an acyclic and cyclic process, identifying control valves to achieve objectives at each step. The summary highlights control structure selection approaches covered in the previous and current lectures.

    Copyright:

    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    of 23

    Integration of Design & Control

    CHEN 4470 – Process Design Practice

    Dr. Mario Richard Eden


    Department of Chemical Engineering
    Auburn University

    Lecture No. 16 – Integration of Design and Control II


    March 7, 2013

    Contains Material Developed by Dr. Daniel R. Lewin, Technion, Israel


    Plantwide Control Design
    Luyben et al. (1999) suggest a method for the conceptual
    design of plant-wide control systems, which consists of the
    following steps:
    Step 1: Establish the control objectives.
    Step 2: Determine the control degrees of freedom.
    Simply stated – the number of control valves – with
    additions if necessary.
    Step 3: Establish the energy management system.
    Regulation of exothermic or endothermic reactors, and
    placement of controllers to attenuate temperature
    disturbances.
    Step 4: Set the production rate.
    Step 5: Control the product quality and handle safety,
    environmental, and operational constraints.
    Plantwide Control Design

    Step 6: Fix a flow rate in every recycle loop and control


    vapor and liquid inventories (vessel pressures and
    levels).
    Step 7: Check component balances. Establish control to
    prevent the accumulation of individual chemical species
    in the process.
    Step 8: Control the individual process units. Use
    remaining DOFs to improve local control, but only after
    resolving more important plant-wide issues.
    Step 9: Optimize economics and improve dynamic
    controllability. Add nice-to-have options with any
    remaining DOFs.
    Example 2: Acyclic Process

    Select V-7 for


    On-demand
    product flow

    Select V-1 for


    fixed feed

    Steps 1 & 2: Establish the control objectives and DOFs:


     Maintain a constant production rate
     Achieve constant composition in the liquid effluent from flash drum
     Keep the conversion of the plant at its highest permissible value.
    Example 2: Acyclic Process

    Step 3: Establish energy management system:


     Need to control reactor temperature: Use V-2
     Need to control reactor feed temperature: Use V-3
    Example 2: Acyclic Process

    Step 4: Set the production rate:


     For on-demand product: Use V-7
    Example 2: Acyclic Process

    Step 5: Control product quality, and meet safety, environmental, and


    operational constraints:
     To regulate V-100 pressure: Use V-5
     To regulate V-100 temperature: Use V-6
    Example 2: Acyclic Process

    Step 6: Fix recycle flow rates and vapor and liquid inventories :
     Need to control vapor inventory in V-100: Use V-5 (already installed)
     Need to control liquid inventory in V-100: Use V-4
     Need to control liquid inventory in R-100: Use V-1
    Example 2: Acyclic Process

    Step 7: Check component balances N/A: Neither A or B can build up

    Step 8: Control the individual process units N/A: All control valves in use

    Step 9: Optimization
     Install composition controller, cascaded with TC of reactor
    Example 2: Acyclic Process

    Select V-1 for


    fixed feed

    Differences: Only step 6 is different


     The liquid levels in R-100 and V-100 are now controlled in the
    direction of the process flow, where before they were controlled in
    the reverse direction.
    Example 2: Acyclic Process
    Example 3: Cyclic Process

    This control structure for fixed feed has an inherent problem.


    Can you see what it is?
    Example 3: Cyclic Process

    F0
    D

    F0 + B

    Combined molar feed to the CSTR: F0  B


    Molar material balance around the flash vessel: F0  B  D  B
    Overall molar material balance: F0  D
    Example 3: Cyclic Process

    Molar balance on CSTR:

    1 dnA
      kxActotal  1  xA  F0  B   kxActotalVR Substitute: ctotalVR  nT
    VR dt

    1  xA  F0  B   kxActotalVR  1  xA  F0  B   kxAnT

    xA F0  knT   F0
    Rearranging: B 
    1  xA

    Balance on A for perfect separation: F0  kxAnT F02


    B
    knT  F0
    Example 3: Cyclic Process

    e.g., suppose knT = 200:

    F02 F0 B
    B
    knT  F0 50 16.7
    75 45
    “Snowball” effect 100 100
    125 208
    150 450

    A more general result uses the dimensionless, Damköhler


    number: Da = knT/F0 giving:
    F0
    B  “Snowball” effect for Da 1
    Da  1
    Example 3: Cyclic Process

    Steps 1 & 2: Establish the control objectives and DOFs:


     Maintain the production rate at a specified level
     Keep the conversion of the plant at its highest permissible value.
    Example 3: Cyclic Process

    Step 3: Establish energy management system:


     Need to control reactor temperature: Use V-2
    Example 3: Cyclic Process

    Step 4: Set the production rate:


     For on-demand product: Use V-1
    Example 3: Cyclic Process

    Step 5: Control product quality, and meet safety, environmental, and


    operational constraints:
     To regulate V-100 pressure: Use V-4
     To regulate V-100 temperature: Use V-5
    Example 3: Cyclic Process

    Step 6: Fix recycle flow rates and vapor and liquid inventories :
     Need to control recycle flow rate: Use V-6
     Need to control vapor inventory in V-100: Use V-4 (already installed)
     Need to control liquid inventory in V-100: Use V-3
     Need to control liquid inventory in R-100: Cascade to FC on V-1
    Example 3: Cyclic Process

    Step 7, 8 and 9: Improvements


     Install composition controller, cascaded with TC of reactor
    Summary

    Part I: Previous Lecture


     Provided motivation for handling flowsheet
    controllability and resiliency as an integral part of
    the design process

     Outlined qualitative approach for unit by unit


    control structure selection

    Part II – This Lecture


     Outlined a qualitative approach for plantwide
    control structure selection
    Other Business

    • Next Lecture – March 19


    – Equipment sizing and pinch analysis

    • Q&A Session with Consultant – March 21


    – Bob Kline will participate via videoconference
    – Questions can be sent to Bob and/or me ahead of time

    You might also like