Dynamics and Control of Chemical Reactors and Distillation Columns (eBook)

Front Cover 1
Dynamics and Control of Chemical Reactors and Distillation Columns 4
Copyright Page 5
Table of Contents 8
CHAPTER 1. DISTILLATION CONTROL SYSTEM STRUCTURES 12
INTRODUCTION 12
CHOICE OF CONTROLLED VARIABLES 12
CHOICE OF CONTROL VARIABLES 14
EXTERNAL DECOUPLING 15
ASPECTS ON HOLISTIC MULTIVARIABLE CONTROL 15
NUMBER AND LOCATION OF SENSORS 15
DISCUSSION 16
REFERENCES 16
CHAPTER 2. FIXED BED REACTOR DYNAMICS AND CONTROL - A REVIEW 22
1. INTRODUCTION 22
2. FIXED-BED REACTOR CONFIGURATIONS 23
3. PACKED BED REACTOR MODELS AND BEHAVIOR 24
4. PROCESS IDENTIFICATION 26
5. PROCESS CONTROL DESIGN 27
6. OPTIMIZING CONTROL 32
7. CONCLUSIONS 32
NOTATION 32
REFERENCES 33
CHAPTER 3. DEVELOPMENTS IN DISTILLATION EQUIPMENT AND SYSTEM DESIGN – IMPLICATIONS FOR DYNAMICS AND CONTROL 36
INTRODUCTION 36
TRENDS IN COLUMN INTERNALS 36
TRENDS IN DISTILLATION SYSTEM DESIGN 37
CONCLUSION 38
REFERENCES 38
CHAPTER 4. CONTROL OF POLYMERIZATION REACTORS 42
INTRODUCTION 42
MATHEMATICAL MODELS 42
OPEN-LOOP OPTIMAL POLICIES 43
ON-LINE MEASUREMENTS AND STATE ESTIMATION 43
FEEDBACK CONTROL 43
SUMMARY 45
REFERENCES 45
CHAPTER 5. DIAGNOSING AND PREVENTING TRAY DAMAGE IN DISTILLATION COLUMNS 48
INTRODUCTION 48
CAUSES OF TRAY DAMAGE - SURVEY OF COLUMN TRAY DAMAGE INCIDENTS 48
COLUMN TRAY DESIGN 49
DIAGNOSING COLUMN TRAY DAMAGE 50
GENERAL APPROACH TO TROUBLESHOOTING 51
PREVENTING COLUMN TRAY DAMAGE 51
CONCLUSIONS 53
ACKNOWLEDGMENTS 53
REFERENCES 53
CHAPTER 6. A DISTILLATION PLANT WITH AN INDIRECT HEAT PUMP FOR EXPERIMENTAL STUDIES OF OPERATION FORM, DYNAMICS AND CONTROL 54
INTRODUCTION 54
PROCESS EQUIPMENT 55
BASIC INSTRUMENTATION 56
DATA EQUIPMENT 57
SECURITY CONSIDERATIONS 58
EXPERIMENTAL EXPERIENCE 58
ACKNOWLEDGEMENTS 59
REFERENCES 59
CHAPTER 7. MULTIVARIABLE CONTROL OF INDUSTRIAL FRACTIONATORS 60
INTRODUCTION 60
DNA CONTROLLER DESIGN 61
THE DECOUPLING ALGORITHM 61
PROCESS CHARACTERISTICS AND CONTROL STRATEGY 62
PROCESS DESCRIPTION 62
CHOICE OF MANIPULATABLE VARIABLES AND CONTROLLED VARIABLES 63
RESULTS 63
CONCLUSIONS 64
REFERENCES 64
CHAPTER 8. OPTIMAL OPERATION OF A DISTILLATION COLUMN WITH TIME-VARYING ENERGY COSTS 66
INTRODUCTION 66
QUASI-STATIC OPTIMIZATION 66
DESCRIPTION OF THE APPARATUS 67
STATIONARY OPERATION 68
DYNAMIC MODELLING 68
FEED-BACK CONTROLLERS 68
SWITCH-OVER WITH HELP OF FEED FORWARD CONTROL 69
RESULTS 69
DISCUSSION AND CONCLUSIONS 70
REFERENCES 70
CHAPTER 9. CONTROLLING AND OPTIMIZING INTEGRATED FRACTIONATION PROCESSES IN A PETROLEUM REFINERY 72
UNIT CONFIGURATION OF THE NAANTALI REFINERY 72
CONTROL STRATEGY 73
PARAMETERS AFFECTING THE SEPARATION 74
OPTIMIZATION OF ENERGY RECOVERY AND YIELDS 74
CONTROL PERFORMANCE AND RESULTS 75
REFERENCES 75
CHAPTER 10. CONTROL STUDIES OF A COMPLEX GAS PHASE REACTOR SYSTEM 78
INTRODUCTION 78
THE PLANT AND PROCESS 78
DYNAMIC MODEL 79
SIMULATION STUDIES 79
CONCLUSIONS 80
REFERENCES 81
CHAPTER 11. AN ADAPTIVE CONTROL ALGORITHM FOR A THERMAL CRACKING FURNACE 84
INTRODUCTION 84
CONTROL PROBLEM 85
CONCLUSIONS 88
NOMENCLATURE 88
GREEK SYBMOLS 89
REFERENCES 89
CHAPTER 12. DYNAMIC SIMULATION OF RESIDUE HYDRODESULFURIZATION TRICKLE-BED REACTOR 92
Introduction 92
Mathematical model 92
Results and discussion 96
Summary and conclusions 96
References 96
CHAPTER 13. FUZZY CONTROL OF A PILOT BATCH POLYMERIZATION REACTOR 98
INTRODUCTION 98
STATEMENT OF THE PROBLEM 98
DESIGN OF FUZZY CONTROL ALGORITHM FOR PRESSURE-TEMPERATURE CONTROL 99
EXPERT FUZZY CONTROLLER 99
RESULTS AND DISCCUSION 100
CONCLUSION 101
REFERENCES 101
APPENDIX 101
CHAPTER 14. EARLY DETECTION OF HAZARDOUS STATES IN CHEMICAL REACTORS 104
INTRODUCTION 104
CRITERIA 104
PREDICTION 105
MULTIPLE FILTER METHODS 105
REFERENCES 107
CHAPTER 15. AN ANALYTICAL APPROACH TO APPROXIMATE DYNAMIC MODELING OF DISTILLATION TOWERS 110
INTRODUCTION 110
REVIEW OF PAST WORK 110
REDUCING THE FINAL TRANSFER FUNCTION 112
REFERENCES 115
CHAPTER 16. ANALYSIS OF THE DYNAMIC BEHAVIOR OF DISTILLATION TRAINS 116
INTRODUCTION 116
PROBLEM FORMULATION 116
ANALYSIS OF THE OPENLOOP DYNAMIC RESPONSE 117
IMPLICATION ON PROCESS DESIGN AND CONTROL 118
CONCLUSIONS 118
REFERENCES 118
CHAPTER 17. AN INTERACTIVE SIMULATION PACKAGE FOR THE DYNAMIC BEHAVIOUR OF BINARY DISTILLATION COLUMNS 122
1. INTRODUCTION 122
2. THE DYNAMIC DISTILLATION MODEL 122
3. THE NUMERICAL INTEGRATION ALGORITHM 123
4. FEEDBACK CONTROL OF THE INTEGRATION PARAMETERS 124
5. STRUCTURE AND ORGANIZATION OF THE PACKAGE 126
6. EXAMPLES 127
7. CONCLUDING REMARKS 127
REFERENCES 127
CHAPTER 18. APPLICATIONS OF A DYNAMIC SIMULATION OF DISTILLATION COLUMNS FOR A NEW MANUFACTURING PLANT 128
INTRODUCTION 128
FEASIBILITY STUDY - DYNAMIC ANALYSIS 128
CONTROL SYSTEM DESIGN 129
OPERATOR TRAINING 130
CONCLUSION 130
REFERENCES 131
CHAPTER 19. NONLINEAR MODEL REDUCTION FOR BINARY DISTILLATION 134
INTRODUCTION 134
DYNAMIC BEHAVIOUR 134
MODEL REDUCTION TECHNIQUE 135
REDUCED MODEL BEHAVIOUR 137
CONCLUSIONS 138
REFERENCES 138
CHAPTER 20. NON-LINEAR DISCRETE TIME MODELLING AND CONTROL OF A PILOT NEUTRALIZATION CHEMICAL REACTOR 140
INTRODUCTION 140
PRESENTATION OF THE CHEMICAL PILOT PLANT 140
IDENTIFICATION AND OPTIMAL CONTROL FOR TIME-VARYING VOLUME WORKING CONDITION 141
LINEARIZING CONTROL FOR BILINEAR WORKING CONDITION 142
CONCLUSION AND PROSPECTS 143
REFERENCES 143
CHAPTER 21. SEMIBATCH REACTOR DYNAMICS AND STATE ESTIMATION 146
INTRODUCTION 146
DIFFERENT SEMIBATCH OPERATION MODES 146
SEMIBATCH REACTOR MODELS 147
DYNAMIC BEHAVIOR OF SEMIBATCH REACTORS 147
STATE ESTIMATION 149
NOTATION 150
CONCLUSIONS 150
LITERATURE 151
CHAPTER 22. CONTINUOUS ESTIMATION OF THE CHAIN LENGTH DISTRIBUTION IN A POLYMERIZATION REACTOR: KALMAN FILTERING CONSIDERING GEL-PERMEATION CHROMATOGRAPHIC MEASUREMENTS 152
INTRODUCTION 152
MODELLING OF FREE RADICAL POLYMERIZATION OF STYRENE 152
SYSTEM STRUCTURE 153
SENSOR MODEL AND MEASUREMENT EQUATIONS 153
FILTER STRUCTURE 154
EXPERIMENTAL RESULTS 155
CONCLUSIONS 155
NOMENCLATURE 155
REFERENCES 156
ACKNOWLEDGEMENT 156
CHAPTER 23. STATE ESTIMATION FOR POLYMERIZATION REACTORS 158
INTRODUCTION 158
STATE ESTIMATION 159
MODEL FOR THE EMULSION POLYMERIZATION OF STYRENE 160
EXPERIMENTAL RESULTS 161
REFERENCES 161
CHAPTER 24. VIBRATIONAL CONTROL OF CHEMICAL REACTORS: STABILIZATION AND CONVERSION IMPROVEMENT IN AN EXOTHERMIC CSTR 164
INTRODUCTION 164
METHOD OF ANALYSIS 164
THE REACTOR SYSTEM 164
VIBRATIONAL CONTROL OF THE CSTR 165
THEORETICAL RESULTS AND SIMULATIONS 166
EXPERIMENTAL RESULTS 166
CONCLUSIONS 167
ACKNOWLEDGEMENT 167
REFERENCES 167
CHAPTER 25. OPERATION PLANNING AND QUALITY DESIGN OF A POLYMER PROCESS 170
REFERENCES 176
CHAPTER 26. THE DYNAMICS AND CONTROL OF A DEPROPANIZER 178
INTRODUCTION 178
DYNAMIC SIMULATOR 178
DEPROPANIZER COLUMN 179
OPEN LOOP DYNAMIC BEHAVIOR 180
CONTROL BEHAVIOR 180
CONCLUSION 181
ACKNOWLEDGEMENT 182
NOTATION 182
REFERENCES 182
CHAPTER 27. CONTROL OF A DISTILLATION COLUMN ANALYSIS OF NOMINAL PERFORMANCE AND ROBUSTNESS FOR MULTIVARIABLE CONTROL SYSTEMS 186
INTRODUCTION 186
ANALYSIS 186
A CASE STUDY OF DISTILLATION CONTROL 187
CONCLUSION 189
REFERENCES 190
CHAPTER 28. EFFECT OF PROCESS AND MECHANICAL DESIGN ON THE DYNAMICS OF DISTILLATION COLUMNS 192
INTRODUCTION 192
MODEL OF A PLATE DISTILLATION COLUMN 192
DYNAMIC EQUATIONS FOR A GENERAL DISTILLATION STAGE 193
STARTUP OF A DISTILLATION COLUMN 194
DYNAMIC BEHAVIOUR DURING STARTUP 194
INFLUENCE OF TRAY METAL THERMAL CAPACITANCE 195
EFFECTS OF DOWNCOMER DESIGN 196
GENERAL OBSERVATIONS 196
NOMENCLATURE 197
GREEK LETTERS 197
SUBSCRIPTS 197
ABBREVIATIONS 197
REFERENCES 197
CHAPTER 29. PARAMETRIC TRANSFER FUNCTIONS FOR BINARY TRAY-DISTILLATION COLUMNS 200
INTRODUCTION 200
2. SYSTEM EQUATIONS AND IDEALISATIONS 200
3. SOLVING FOR THE T.F.M. 202
4. PREDICTION OF COLUMN BEHAVIOUR 202
5. APPROXIMATE MULTIVARIABLE FIRST-ORDER LAG MODEL 203
6. CORRELATION WITH PILOT PLANT DATA 203
7. CONCLUSIONS 204
8. REFERENCES 204
CHAPTER 30. PARAMETRIC TRANSFER FUNCTIONS FOR PACKED BINARY DISTILLATION COLUMNS 206
1. INTRODUCTION 206
2. EQUILIBRIUM AND MATERIAL BALANCE FORMULATIONS 206
3. NORMALISATION 206
4. LARGE-SIGNAL BOUNDARY CONDITIONS 207
5. STEADY-STATE SOLUTION 207
6. SMALL PERTURBATION EQUATIONS 207
8. BEHAVIOURAL PREDICTIONS 208
9. UNEQUAL VAPOUR AND LIQUID CAPACITANCE (c . 1.0) 209
10. RECONCILING TRAY AND PACKED COLUMN BEHAVIOUR 209
11. CONCLUSIONS 209
REFERENCES 210
CHAPTER 31. ESTIMATION AND CONTROL OF DISTILLATION PRODUCT COMPOSITION USING TRAY TEMPERATURE MEASUREMENTS 214
INTRODUCTION 214
PROCESS DISTURBANCES 214
STATE-SPACE APPROACH 214
INPUT-OUTPUT BASED ESTIMATOR 215
SIMULATION STUDIES AND DISCUSSION 216
CONCLUSIONS 217
ACKNOWLEDGEMENTS 217
REFERENCES 217
CHAPTER 32. SIMULTANEOUS ADAPTIVE REGULATION OF TERMINAL COMPOSITIONS IN BINARY DISTILLATION 220
INTRODUCTION 220
SYSTEM REPRESENTATION AND SELFTUNING CONTROL 220
EXPERIMENTAL IMPLEMENTATION AND RESULTS 222
CONCLUSIONS 223
ACKNOWLEDGEMENTS 224
REFERENCES 224
CHAPTER 33. ANALYSIS AND CONTROL OF DISTILLATION COLUMNS: A QUASI CLASSICAL APPROACH 226
1. INTRODUCTION 226
2. SYSTEM ANALYSIS VIA SPECTRAL FACTORIZATION 226
3. TOFA COLUMN 228
4. WAW0 COLWiN 229
5. SUMMARY AND CONCLUSIONS CONCERNING MODERN FREQUENCY DOMAIN APPROACH FOR ANALYSIS OF DISTILLATION COLUMNS 229
REFERENCES 229
CHAPTER 34. IDENTIFICATION OF PERIODIC CYCLED DISTILLATION FOR CONTROL PURPOSES 232
1. INTRODUCTION 232
2. DYNAMICS 233
3. IDENTIFICATION 233
4. CONTROL 234
5. DISCUSSION 234
6. CONCLUSION 234
REFERENCES 234
SYMBOLS 234
CHAPTER 35. CONTROL OF AN EXTRACTIVE DISTILLATION PLANT 236
INTRODUCTION 236
EXTRACTIVE DISTILLATION 236
SIMPLIFIED DYNAMIC MODEL 237
LEVEL CONTROL LOOPS 238
PROFILE POSITION CONTROL 238
IMPLEMENTATION 239
STARTUP AND OPERATION OF THE PILOT PLANT 239
CONCLUSION 241
REFERENCES 241
ACKNOWLEDGEMENT 241
CHAPTER 36. COMPARISON OF THREE DIFFERENT APPROACHES TO THE SEMIBATCH DISTILLATION COLUMN CONTROL DESIGN 242
1. INTRODUCTION 242
2. DESCRIPTION OF THE PROCESS 243
3. CONTROL DESIGN 243
5. CONCLUSIONS 247
6. REFERENCES 247
CHAPTER 37. NON-INTERACTING CONTROL SYSTEM DESIGN OF A DISTILLATION COLUMN BY THE PARTIAL MODEL MATCHING 248
INTRODUCTION 248
THE MERIT OF PARTIAL MODEL MATCHING 248
DESIGN PROCEDURE OF I-PD TYPE NON-INTERACTING CONTROLLER 249
SIMULATED DISTILLATION COLUMN 250
MODELING FOR CONTROLLER DESIGN 250
CONCLUSIONS 252
REFERENCES 253
CHAPTER 38. RELATIONS BETWEEN STEADY-STATE PROPERTIES OF DISTILLATION CONTROL SYSTEM STRUCTURES 254
INTRODUCTION 254
CONSISTENCY RELATIONS BETWEEN PROCESS GAINS 254
RELATIONS BETWEEN GAINS IN DIFFERENT CONTROL SCHEMES 256
APPLICATION TO PUBLISHED DATA 257
CONCLUSIONS 258
NOTATION 258
REFERENCES 258
CHAPTER 39. INDEPENDENT SINGLE-INPUT-SINGLE OUTPUT CONTROL SCHEMES FOR DUAL COMPOSITION CONTROL OF BINARY DISTILLATION COLUMNS 260
INTRODUCTION 260
INTERACTION MEASURE 260
EQUIVALENCE CRITERION 261
RGA INDEPENDENT CONTROL SCHEMES 262
FOR HIGH PURITY COLUMNS 262
CONCLUSIONS 263
NOTATION 263
REFERENCES 263
CHAPTER 40. THE JACOBI EIGENVALUE CRITERION: A DYNAMIC EXTENSION AND STABILITY THEOREM 266
INTRODUCTION 266
THE JACOBI EIGENVALUE CRITERION 266
DYNAMIC EXTENSION OF THE JACOBI EIGENVALUE CRITERION 267
THE JACOBI EIGENVALUE CRITERION AND SYSTEM STABILITY 268
THE JACOBI EIGENVALUE CRITERION AND WEAK COUPLING MEASURES 268
EXAMPLES 269
CONCLUSIONS 270
REFERENCES 270
CHAPTER 41. CONTROL OF A DISTILLATION COLUMN WITH A HEAT PUMP 272
INTRODUCTION 272
STRUCTURES OF DISTILLATION SYSTEM WITH HEAT PUMP 272
MOVABLE REGION OF MANIPULATIVE VARIABLES 274
DYNAMIC MODEL AND DYNAMICS 275
CONTROL SYSTEM DESIGN AND THEIR PERFORMANCE 275
CONCLUSION 277
REFERENCES 277
CHAPTER 42. DYNAMICS AND CONTROL OF AN ADIABATIC FIXED BED REACTOR WITH VARYING CATALYST ACTIVITY 278
INTRODUCTION 278
REACTOR SETUP AND REACTOR DYNAMICS 278
ADAPTIVE CONTROL DESIGN 282
EXPERIMENTAL RESULTS AND DISCUSSION 282
CONCLUSIONS 283
REFERENCES 283
CHAPTER 43. ESTIMATION OF THE DYNAMIC BEHAVIOUR OF A FIXED-BED REACTOR THROUGH FILTERING 284
INTRODUCTION 284
REACTOR MODEL 285
FILTER DESIGN 285
IMPLEMENTATION AND RESULTS 286
CONCLUSIONS 287
ACKNOWLEDGEMENT 287
REFERENCES 287
CHAPTER 44. MODEL REDUCTION FOR NONLINEAR SYSTEMS WITH DISTRIBUTED PARAMETERS 290
INTRODUCTION 290
PHENOMENOLOGY 291
MATHEMATICAL MODELLING 292
STRUCTURE ANALYSIS 293
APPLICATION 294
CONCLUSION 295
REFERENCES 295
CHAPTER 45. MULTIVARIABLE CONTROL OF A CATALYTIC TUBULAR REACTOR USING BOTH WIENER-HOPF CONTROLLER DESIGN AND INTERNAL MODEL CONTROLLER DESIGN APPROACHES 296
1. INTRODUCTION 296
2. MULTIVARIATE CONTROL 296
3. PILOT PLANT REACTOR SYSTEM 298
4. MODEL IDENTIFICATION 299
5. CONTROL STUDIES 300
6. CONCLUSIONS 301
REFERENCES 301
CHAPTER 46. DESIGN AND CONTROL OF TUBULAR AUTOTHERMAL REACTORS: AN EVOLUTIONARY APPROACH 306
1. INTRODUCTION 306
2. CONFIGURATION IDENTIFICATION 306
3. PHASE PLANE ANALYSIS 306
4. STRUCTURAL DOMINANCE ANALYSIS 307
5. PROPOSED REACTOR DESIGN 308
6. CONTROLLER DESIGN 309
7. SUMMARY AND CONCLUSIONS 309
REFERENCES 310
CHAPTER 47. ON THE DYNAMICS OF A BENCH-SCALE CALORIMETER 312
INTRODUCTION 312
CALORIMETER MODELLING 313
MODEL VALIDATION 314
PARAMETER AND STATE ESTIMATION 315
CONCLUSIONS 316
REFERENCES 316
NOMENCLATURE 316
CHAPTER 48. A NEW APPROACH FOR PARAMETER ESTIMATION APPLICATION TO HETEROGENEOUS CATALYSIS 318
INTRODUCTION 318
METHODOLOGY 318
CHEMICAL REACTION EXAMPLE 320
DISCUSSION AND CONCLUSIONS 323
Acknowledgement 323
REFERENCES 323
CHAPTER 49. FAST ADAPTIVE CONTROL ALGORITHMS IN pH MEASUREMENT 324
INTRODUCTION 324
NUMERICAL ANALYSIS PRELIMINARIES 324
ADAPTIVE CONTROL FOR pH MEASUREMENT 325
CONCLUSION 326
ACKNOWLEDGMENTS 326
REFERENCES 326
CHAPTER 50. DESIGN OF A MULTIVARIABLE SELF-TUNING CONTROL ALGORITHM FOR DISTRIBUTED SYSTEMS 328
INTRODUCTION 328
OPTIMAL SELF-TUNER 329
MODIFIED SELF-TUNER 329
DISCUSSION OF RESULTS 331
CONCLUSIONS 332
REFERENCES 332
ACKNOWLEDGEMENT 332
CHAPTER 51. AN ADAPTIVE SYSTEM WITH AN IDENTIFIER (ASI) FOR CONTROL OF THE TEMPERATURE PROFILE IN A TUBULAR REACTOR 334
PRODUCTION OF MALEIC ANHYDRIDE 334
BASIC CONTROL LOOP 335
CONTROL ALGORITHMS 335
REFERENCES 336
AUTHOR INDEX 338