Control and Monitoring of Chemical Batch Reactors (eBook)

Series Editors' Foreword 9
Preface 11
Acknowledgements 13
Contents 14
Introduction 17
Overview of the Main Topics 17
The Batch Reactor 18
The Case Study 19
Identification of Mathematical Models 20
Thermal Stability 20
Control of Batch Reactors 21
Fault Diagnosis for Chemical Batch Reactors 22
Applications to Non-ideal Reactors 23
Suggested Reading Paths 23
The Chemical Batch Reactor 24
Ideal Chemical Reactors 25
The Rate of Chemical Reactions 27
The Ideal Batch Reactor 30
Conservation of Mass 31
Conservation of Energy 35
Introducing the Case Study 37
Components 39
Reactions 40
A General Model for a Network of Nonchain Reactions 42
Measuring the Reactor Status 46
Measurements Quality 47
Online Measurements 47
Offline Measurements 50
Manipulating the Reactor Status 50
Conclusions 52
References 52
Identification of Kinetic Parameters 54
Bayesian Approach and Popper's Falsificationism 56
Experimental Data and Mathematical Models 58
Maximum Likelihood and Least Squares Criteria 60
Optimization for Models Linear in the Parameters 63
Optimization for Models Nonlinear in the Parameters 65
Steepest Descent Algorithm 65
Newton-Raphson Algorithm 66
Levenberg-Marquardt Algorithm 67
Implicit Models 68
Statistical Analysis of the Results 69
Case Study: Identification of Reduced Kinetic Models 71
Reduced Models 71
Generation of Data for Identification 73
Estimating the Kinetic Parameters 74
Estimating the Heats of Reaction 76
Validation of the Reduced Models 77
Conclusions 80
References 81
Thermal Stability 83
Runaway in Chemical Batch Reactors 84
Dimensionless Mathematical Model 85
Adiabatic Reactor 88
Isoperibolic Reactor 89
The Semenov Theory 90
Geometry-based Runaway Criteria 93
Sensitivity-based Runaway Criteria 96
Operation Limited by the Maximum Allowable Temperature 98
Case Study: Runaway Boundaries 99
Conclusions 101
References 101
Model-based Control 103
Control Strategies for Batch Reactors 105
PID Regulator 106
Model Predictive Control 107
Feedback Linearization 109
Input-Output Linearization 109
Generic Model Control 110
State-Space Model for Control Design 111
Estimation of the Heat Released by Reaction 113
Model-Based Nonlinear Observer 114
Model-Free Approaches 116
Approach Based on Universal Interpolators 116
A Classical Model-Free Approach 118
Adaptive Two-Loop Control Scheme 118
Case Study: Temperature Control 122
Simulation Model 123
Design of the Controller-Observer Scheme 124
Discussion of Results 125
Comparison with the PID Controller 127
Conclusions 130
References 131
Fault Diagnosis 135
Fault Diagnosis Strategies for Batch Reactors 136
Model-Free Approaches 137
Model-Based Approaches 138
Basic Principles of Model-Based Fault Diagnosis 139
Residual Generation 141
Decision Making System and Fault Isolation 142
Fault Diagnosis for Chemical Batch Reactors 143
Fault Characterization 143
Architecture of the Fault Diagnosis Scheme 145
Sensor Fault Diagnosis 147
Residuals Generation and Fault Isolation 149
Determination of the Healthy Signal 150
Voter procedure 150
Actuator and Process Fault Diagnosis 152
Fault Detection 152
Fault Isolation and Identification 154
Decoupling Sensor Faults from Process and Actuator Faults 157
Case Study: Fault Diagnosis 157
Simulation Results: Sensor Faults 158
Simulation Results: Process and Actuator Faults 162
Simulation Results: Sensor and Actuator Faults 166
Conclusions 169
References 169
Applications to Nonideal Reactors 173
Nonideal Batch Reactors 174
Nonideal Mixing 175
Multiphase Batch Reactors 179
Scaling-up the Information 180
Basic Ideas of Scale-up 180
The Scale-up of Real Batch Reactors 182
Suggestions and Conclusions 183
References 184
Appendix A Proofs 185
Proof of Theorem 5.1 185
Proof of Theorem 5.2 187
Proof of Theorem 5.3 188
Proof of Theorem 5.4 189
Proof of Theorem 6.1 190
Proof of Theorem 6.2 192
References 194
Index 195