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 3 Staff: • Claudia Bianchi, Giulia Bozzano, Flavio Manenti, Sauro Pierucci, Carlo Pirola • Guido Buzzi Ferraris Collaborators: • • • • • • • • • • • • 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 Students: 16 ongoing thesis projects Flavio Manenti – Dipartimento CMIC “Giulio Natta” Motivation to study process control 4 • Relevance Manage chemical/power generation plants Control-room/DCS operators Needed everywhere “Driving” license • Advanced skills Process control means: • • • • 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) 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: Process modeling • Numerical methods • Conservation principle Process dynamics • Mass, energy, momentum balances • ODE/DAE systems • Open-loop dynamic simulation Process control • Essentials of process control • P, PI, PID controllers • Closed-loop dynamic simulation • Data analysis Data interpretation and correlation Flavio Manenti – Dipartimento CMIC “Giulio Natta” 6 MS course program 7 Data fitting Data reconciliation Outliers • Process modeling Total continuity equation (mass balance) • Atmospheric tank, Pipeline Component continuity equations (component mass balances) • Continuous stirred tank reactor, Consecutive reactions, Plug flow reactor Energy equation • Continuous stirred tank reactor with exothermic reactions, Cooled two-phase continuous stirred tank reactor, Jacketed tubular reactor Equation of motion • Gravity tank, Pipeline and pig for oil operations Transport equations Flavio Manenti – Dipartimento CMIC “Giulio Natta” MS course program Equation of state Equilibrium • Chemical, Physical Chemical kinetics • Arrhenius, Reaction rate • Reactors and unit operations Series of isothermal constant-holdup CSTRs CSTRs with variable holdups Two heated tanks Gas-phase CSTR Nonisothermal CSTR • • • • Perfectly mixed cooling jacket Plug flow cooling jacket Lumped cooling jacket Metal wall capacitance Flavio Manenti – Dipartimento CMIC “Giulio Natta” 8 MS course program Single-component vaporizer • • • • Steady-state model Liquid-phase dynamics Liquid and vapor dynamics Thermal equilibrium model Multicomponent flash drum • Steady-state model • Rigorous model • Practical model Batch reactor • Heating phase • Cooling phase Reactor with mass transfer Ideal binary distillation column Multicomponent nonideal distillation column Batch distillation with holdup pH system Flavio Manenti – Dipartimento CMIC “Giulio Natta” 9 MS course program 10 • Energy storage Concentrating solar plant, Archimede plant • Advanced process control Ratio, cascade Plantwide process control • 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 • Essentials of strategic levels (process optimization) Production scheduling, planning (business-wide process control) Enterprise-wide process control Essential of mixed-integer optimization • CAPE industrial applications Flavio Manenti – Dipartimento CMIC “Giulio Natta” MS course program 11 LABORATORIES • Essential of C++ Grammar & syntax Numerical methods, BzzMath® library ODE and DAE systems (C++) • Dynamic simulation and conventional control 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 Flavio Manenti – Dipartimento CMIC “Giulio Natta” MS course program 12 • Gas processing (refrigeration and/or separation sections) Process simulation Plantwide control Conditions, scenarios, grade changes, OTS • Final project Flavio Manenti – Dipartimento CMIC “Giulio Natta” References 13 • 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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