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Chemical process dynamics and control - SuPER

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Chemical process dynamics
and control
Flavio Manenti
CMIC “Giulio Natta” Dept.
2
Contacts
• Flavio Manenti
Alexander von Humboldt Professor of Chemical Plants and Operations
POLITECNICO DI MILANO
Dipartimento di Chimica, Materiali e Ingegneria Chimica "Giulio Natta"
SuPER (Sustainable Process Engineering Research) Team
Piazza Leonardo da Vinci, 32 - I-20133 Milano, ITALY
TECHNISCHE UNIVERSITAT BERLIN
DBTA (Dynamic und Betrieb Technischer Anlagen) Faculty
Sekt. KWT 9, Strasse des 17.Juni, 135 - D-10623 Berlin, GERMANY
Phone IT +39.(0)2.2399.3273 - DE +49 (0)30 314 26905
Fax
IT +39.(0)2.2399.3280
Email
[email protected]
Web
http://super.chem.polimi.it
Excellence Cluster: www.reinforce.polimi.it
Students: Wednesday 10:15 – 11:15 (ask in advance by email)
MS thesis, PhD students and visiting: no limitations
Flavio Manenti – Dipartimento CMIC “Giulio Natta”
People
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Staff:
• Claudia Bianchi, Giulia Bozzano, Flavio Manenti, Sauro Pierucci, Carlo Pirola
• Guido Buzzi Ferraris
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Collaborators:
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André Furtado Amaral, Brazil-Italy, Coal/biomass Gassification
Andrea Bassani, Italy, Sulfur Recovery Units
Lorenzo Cabianca, Belgium-Italy, Multiobjective Optimization
Michele Corbetta, Italy-USA, Biorefineries
Andres Ricardo Garzon-Leon, Colombia-Italy, Polymer Science
Ergys Pahija, Hong Kong, 3rd generation biorefinery
Davide Papasidero, Italy-The Netherlands, Food Engineering
Francesco Rossi, Italy-USA, Process Optimization
Mattia Vallerio, Belgium, Optimal Control
Sergei Mikhalevitz, Russian Fed., Process Control
Eva M. Speelmanns, Germany, catalytic Reactors
Sandra Fillinger, Germany, MOSAIC platform
Industrial Consultants:
• Maria Grazia Grottoli, Lucio Molinari
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Students: 16 ongoing thesis projects
Flavio Manenti – Dipartimento CMIC “Giulio Natta”
Motivation to study process
control
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• Relevance
Manage chemical/power generation plants
 Control-room/DCS operators
 Needed everywhere
 “Driving” license
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• Advanced skills
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Process control means:
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Numerical methods
Process modeling
Process simulation
Process optimization
Last call for you
• Fun
Developing dynamic simulations, implementing every kind of
malfunctions, playing with the transients of the processes
 Dynamic simulation of the chemical plants is become a 3D tool (also with
XBOX, 2012; see Eyesim by Invensys operations Management)
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Flavio Manenti – Dipartimento CMIC “Giulio Natta”
5
MS course program
Nonlinear Systems
Solvers
Optimizers
Differential systems
DCS, OTS, Plantwide control,
Soft sensing, process transients,
grade/load changes
Stiff systems
ODE,DAE,PDE,PDAE
Parallel
Computing
Dynamic
Simulation
Efficiency
Economy
Just in time
Market-driven
Logistics
Corporate
Supply Chain
Planning
Mathematical
Modeling
Data
Reconciliation
Scheduling
Optimization
Distributed predictive control
Model
Reduction
Linear/nonlinear Regressions
Model
Predictive
Control
Uncertainties
Optimal production
Outlier Detection
Robust methods
Dynamic optimization
Optimal grade changes
Raw Data
Performance Monitoring
Yield Accounting
Soft sensing
Flavio Manenti – Dipartimento CMIC “Giulio Natta”
Decisions
Multi-objective
Real-time optimization
High accuracy
Reliable process control
Production improvement
MS course program
MAIN TOPICS
• Brief history of and introduction to process control
• Fundamentals of:
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Process modeling
• Numerical methods
• Conservation principle
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Process dynamics
• Mass, energy, momentum balances
• ODE/DAE systems
• Open-loop dynamic simulation
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Process control
• Essentials of process control
• P, PI, PID controllers
• Closed-loop dynamic simulation
• Data analysis
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Data interpretation and correlation
Flavio Manenti – Dipartimento CMIC “Giulio Natta”
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MS course program
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Data fitting
 Data reconciliation
 Outliers
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• Process modeling
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Total continuity equation (mass balance)
• Atmospheric tank, Pipeline
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Component continuity equations (component mass balances)
• Continuous stirred tank reactor, Consecutive reactions, Plug flow reactor
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Energy equation
• Continuous stirred tank reactor with exothermic reactions, Cooled two-phase
continuous stirred tank reactor, Jacketed tubular reactor
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Equation of motion
• Gravity tank, Pipeline and pig for oil operations
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Transport equations
Flavio Manenti – Dipartimento CMIC “Giulio Natta”
MS course program
Equation of state
 Equilibrium
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• Chemical, Physical
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Chemical kinetics
• Arrhenius, Reaction rate
• Reactors and unit operations
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Series of isothermal constant-holdup CSTRs
CSTRs with variable holdups
Two heated tanks
Gas-phase CSTR
Nonisothermal CSTR
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Perfectly mixed cooling jacket
Plug flow cooling jacket
Lumped cooling jacket
Metal wall capacitance
Flavio Manenti – Dipartimento CMIC “Giulio Natta”
8
MS course program
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Single-component vaporizer
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Steady-state model
Liquid-phase dynamics
Liquid and vapor dynamics
Thermal equilibrium model
Multicomponent flash drum
• Steady-state model
• Rigorous model
• Practical model
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Batch reactor
• Heating phase
• Cooling phase
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Reactor with mass transfer
Ideal binary distillation column
Multicomponent nonideal distillation column
Batch distillation with holdup
pH system
Flavio Manenti – Dipartimento CMIC “Giulio Natta”
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MS course program
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• Energy storage
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Concentrating solar plant, Archimede plant
• Advanced process control
Ratio, cascade
 Plantwide process control
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• Complex units, Gas processing, Industrial processes
• Optimal (predictive) process control
DMC (dynamic matrix control)
 Nonlinear model predictive control
 Dynamic real-time optimization
 Ringing, stability, numerical methods
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• Essentials of strategic levels (process optimization)
Production scheduling, planning (business-wide process control)
 Enterprise-wide process control
 Essential of mixed-integer optimization
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• CAPE industrial applications
Flavio Manenti – Dipartimento CMIC “Giulio Natta”
MS course program
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LABORATORIES
• Essential of C++
Grammar & syntax
 Numerical methods, BzzMath® library
 ODE and DAE systems (C++)
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• Dynamic simulation and conventional control
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Gravity-flow tank
 Series of isothermal CSTRs
 Nonisothermal CSTR
• Nonlinear model predictive control (C++)
• Dynamic optimization (C++)
• Commercial dynamic simulators (e.g. DYNSIM™, ASPENHYSYS™)
Tutorial, overview
 Ideal flash separator and related control scheme
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Flavio Manenti – Dipartimento CMIC “Giulio Natta”
MS course program
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• Gas processing (refrigeration and/or separation sections)
Process simulation
 Plantwide control
 Conditions, scenarios, grade changes, OTS
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• Final project
Flavio Manenti – Dipartimento CMIC “Giulio Natta”
References
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• Some names for process dynamics and control (books):
• G. Stephanopoulos - Chemical process control: an introduction to theory and practice, PrenticeHall, 1984
• D. Seborg, T. Edgar, D. Mellicamp - Process Dynamics and Control, J. Wiley, 2003
• S. Skogestad, I. Postlethwaite - Multivariable Feedback Control -Analysis and design, Wiley,
1996; 2005
• S. Skogestad - Chemical and Energy Process Engineering, CRC Press, Taylor&Francis, 2008
• J. Romagnoli, A. Palazoglu - Introduction to Process Control, CRC Press, Taylor&Francis, 2005
• M. Luyben, W. Luyben - Essentials of process control, McGraw-Hill, Chemical Engineering
Series, 1997
• W. Bequette - Process Control: Modeling, Design, and Simulation, Prentice Hall Professional,
2003
• T. Marlin - Process control: designing processes and control systems for dynamic performance,
McGraw-Hill, 2000
• G. Buzzi-Ferraris, F. Manenti – Interpolation and Regression Models for the Chemical
Engineering: Solving Numerical Problems, Wiley-VCH (Vol. 2), 2010
• G. Buzzi-Ferraris, F. Manenti – Nonlinear Systems and Optimization for the Chemical
Engineering: Solving Numerical Problems, Wiley-VCH (Vol. 3), 2013
• G. Buzzi-Ferraris, F. Manenti - Differential and Differential-Algebraic Systems for the Chemical
Engineering: Solving Numerical Problems, Wiley-VCH (Vol. 4), 2014
• Use database/library, ISI Web of Knowledge, Scopus for papers
Flavio Manenti – Dipartimento CMIC “Giulio Natta”
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