Process Modeling Lecture 1
Process Modeling Lecture 1
Process Modeling
1
Outline of this lecture
• Introduction and outline of the course
• Need for process modeling
• Statistical and mechanistic models
• Rate laws and adjustable parameters
• Selection of variables
• Model application areas
Learning outcomes for this lecture
• Understand what is mathematical modeling and
how it is related to physical problems
• Recognize the need for modeling, estimate
necessary model complexity
• Understand how models are built from balances
and constitutive equations
• Understand the basis of rate laws and adjustable
parameters in them
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Teaching
• Lectures each Wednesday from 8.30-10
• Exercises Tuesday and Thursday 8.30-10 at the
computer class. Also exercises with pen and paper!
• There could be some small exercises during the
lectures (be prepared with pen, paper and a
calculator), and theory parts during the exercises.
One full lecture will be given on We 4.11. during
the exercise times.
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Teaching
• Teachers from various research groups:
– Prof. Ville Alopaeus, chemical engineering
(responsible teacher)
– Kaj Jakobsson, chemical engineering
– Olli Sorvari, chemical engineering
– Reetta Karinen, Yaseen Khan, industrial chemistry
Additional assistants / visitors may participate
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Workload estimate
work / h Grade weight / %
Pre-exam 15 15
Lectures 16
Home assignments 30 30
Computer exercises 40 15
Other independent study 30
Final exam 3 40
total 134 100
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Lecture schedule
2.11.2016 1. Introduction and course outline. Need for process modeling. Statistical
and mechanistic models. Rate laws and adjustable parameters
9.11.2016 3. Tubular reactors, CSTR:s. Static and dynamic models. Numerical tools
for initial value ODE:s. Stiff systems
16.11.2016 4. Partial differential equations. Unsteady heat and mass transfer. Finite
differences
3.11.2016 2. Pre-exam (45 min). Building of mechanistic models from balances and
rate laws
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Pre-exam
• 45 min, during the second exercise
10
Home assignments (tot. 30 h of work)
1. Reactor simulation, coding with Matlab m-files
2. Unsteady heat transfer example with finite
differences
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The idea of a (mathematical) model
1. Reality to mathematics
2. Mathematical solution
3. Interpreting the model outputs
4. Using the results in the real world
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Model building steps
• Build a sketch and define quantities
xin xout
xout = f(xin)
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Model building steps
2nd step: assume something related to spatial or
temporal variations.
xin xout
D
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L
Model building steps
• 3rd step: Assume Vapor phase (V) Dry catalyst (D)
VV hDW
TV
• Multiscale modeling
TI
Liquid phase (L) Wet catalyst (W)
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Box colors
• ”Black box” models:
– Empirical
– Process fundamentals are not necessary
– Based on observed input and output variables
– Purely mathematical (as an opposite to a physical
model) form where some parameters (coefficients)
are identified based on observed variables. These
coefficients typically have no physical meaning
– Often polynomials, could be neural networks etc.
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Box colors
”White box” models
dc dn
r or rV
dt dt
Ideally mixed
batch reactor
• What are these describing?
• Which one is based on conserved property
(extensive variables)
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Selection of variables
concentration is not a conserved
property (extensive variable), but
amount of moles is.
dn dcV
rV n=cV rV
dt dt
dc
This reduces to r
dV dc dt
c V rV only if volume does not change
dt dt
(or the first term is negligible)
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Balances and closures
Physically correct models (not black box) are based on
balances (material, energy, momentum etc...)
dn
Material balance rV
dt
Ideally mixed
batch reactor
dn
Material balance rV
dt
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Balances and closures
dn
Material balance rV
dt
2D # of variables N2
Then…
• Improve the model if it is not good enough
• Carry out sensitivity analysis
• Carry out optimization
• Test the model at extreme conditions (near the
applicability limits of the variables)
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Model application areas
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Model application areas
• Process design
– Feasibility analysis of novel designs
– Technical, economic, environmental assesment
– Effects of process parameter changes on
performance
– Optimization using structural and parametric
changes
– Analysing process interactions
– Waste minimization in design
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Model application areas
• Process control
– Examining regulatory control strategies
– Analysing dynamics for setpoint changes or
disturbances
– Optimal control strategies for batch operations
– Optimal control for multi-product operations
– Optimal startup and shutdown policies
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Model application areas
• Trouble-shooting
– Identifying likely causes for quality problems
– Identifying likely causes for process deviations
• Process safety
– Detection of hazardous operating regimes
– Estimation of accidental release events
– Estimation of effects from release scenarios
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Model application areas
• Operator training
– Startup and shutdown for normal operations
– Emergency response training
– Routine operations training
• Environmental impact
– Quantifying emission rates for a specific design
– Dispersion predictions for air and water releases
– Characterizing social and economic impact
– Estimating acute accident effects (fire, explosion) 39
Summary
• Reality → Mathematical model → Model solution →
Interpretation → Application to reality
• Different box colors exist
• Carefully think about:
– Variables (state) needed in the model
– Independent variables (dimensions) as the model easily
gets too complicated
– Balance equations that the model is based on
– Rate laws and other necessary relations to close the model
• Mathematical models are needed in many parts of
Chemical Engineering 40
George E.P. Box:
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