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A Real-time Approach to Distillation Process Control

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A Real-Time Approach to Distillation Process Control

A practical and hands-on discussion of modern distillation control

In A Real-time Approach to Distillation Process Control, a team of distinguished researchers and industrial practitioners delivers a practical text combining hands-on and active learning using process simulation with discussions of the fundamental knowledge and tools required to apply modern distillation control principles. The book offers a balanced, real-time approach integrated with practical insights. It includes many exercises designed to be simulator agnostic that can be performed on the process simulator locally available to the reader.

Readers will discover explorations of topics including distillation control hardware, distillation composition control, refinery versus chemical plant distillation control, distillation control tuning, advanced regulatory control, and more. They’ll also find:

  • A thorough introduction to distillation fundamentals, as well as basic and advanced modern controls from a practical point of view
  • Comprehensive explorations of known base controls combined with modern control practices
  • Practical discussions of hands-on modelling and simulation exercises, allowing the reader to design and tune controls on a distillation column
  • Fulsome treatments of control structure design integrated with controller tuning using a real-time approach

Perfect for senior undergraduate and graduate students studying general process control or distillation process control, A Real-time Approach to Distillation Process Control will also benefit plant managers, production supervisors, startup supervisors, operations engineers, production engineers, and chemical engineers working in industry.

Author(s): Brent R. Young, Michael A. Taube, Isuru A. Udugama
Publisher: Wiley
Year: 2023

Language: English
Pages: 255
City: Hoboken

Cover
Title Page
Copyright Page
Contents
Preface
About the Companion Website
Chapter 1 Introduction
1.1 The Purpose of Process Control
1.2 Introduction to Distillation
1.3 Distillation Process Control
1.4 A Real-Time Approach to Distillation Process Control Education
Tutorial and Self Study Questions
References
Chapter 2 Fundamentals of Distillation Control
2.1 Mass and Energy Balance: The Only Means to Affect Distillation Tower’s Behavior
2.2 Control Design Procedure
2.3 Degrees of Freedom
2.4 Pairing
2.5 Gain Analysis
2.6 Common Control Configuration
2.7 Screening Control Strategies via Steady-State Simulation
Tutorial and Self-Study Questions
References
Chapter 3 Control Hardware
3.1 Introduction
3.2 Control Hardware Overview
3.3 Sensors
3.3.1 Process Considerations
3.3.2 Flow Measurement Devices
3.3.3 Pressure Measurement Devices
3.3.4 Level Measurement Devices
3.3.5 Temperature Measurement Devices
3.3.6 Direct Composition Measurements
3.3.7 Maintenance
3.4 Final Control Elements
3.4.1 Linearity
3.4.2 Time Constant and Failure Mode
3.4.3 Mechanical Design Considerations
3.5 Controllers/CPU
3.5.1 Level 0
3.5.2 Level 1
3.5.3 Levels 2 and 3
3.5.4 General Set Up and Considerations
3.6 Modern Trends
3.6.1 Wireless Communication and Smart Devices
3.6.2 Smart CPUs
3.6.3 Digital Twins
Tutorial and Self-Study Questions
References
Chapter 4 Inventory Control
4.1 Pressure Control
4.1.1 Total Condenser
4.1.2 Flooded Condensers
4.1.3 Sub-Cooled Reflux
4.1.4 Partial Condenser
4.2 Level Control
4.2.1 Surge Capacity Control
4.2.2 Open-Loop Stable versus Integrating Processes
4.2.3 Calculating the Process Gain for Vessel Levels
4.2.4 Relative Gain Analysis, aka Closing the Loop in Plant Design
Tutorial and Self-Study Questions
References
Chapter 5 Distillation Composition Control
5.1 Temperature Control
5.1.1 Setting Up a Single Temperature-Based Composition Controller
5.1.2 When Temperature Is Like an Integrating Process
5.1.3 Reboiler Outlet Temperature Controls
5.2 Actual Composition Control
5.3 More Complex Control Configurations
5.3.1 Ryskamp’s Scheme
5.3.2 Dual Composition Control
5.4 Distillation Control Scheme Design Using Steady-State Models
5.5 Performance Analysis Using Steady-State Data for an Existing Distillation Tower
5.6 Distillation Control Scheme Design Using Dynamic Models
Tutorial and Self-Study Questions
References
Chapter 6 Refinery Versus Chemical Plant Distillation Operations
6.1 New Generation of Refinery Controls
6.1.1 Atmospheric and Vacuum Refining Columns
6.2 Improving Thermodynamic Efficiency Through Control
6.3 Blending and Its Implications on Control
Tutorial and Self-Study Questions
References
Chapter 7 Distillation Controller Tuning
7.1 Model Identification: Step Testing
7.2 Typical Process Responses
7.3 Engineering Units Versus Percent-of-Scale
7.4 Basics in PID Tuning
7.5 Tuning in Distillation Control
7.6 The Role of Tuning in a “Value Engineering” Era
Tutorial and Self-Study Questions
References
Chapter 8 Fine and Specialty Chemicals Distillation Control
8.1 Key Features
8.2 Measurement and Control Challenges
8.3 Nuances of Fine Chemicals Distillation
8.4 Side-Draw Distillation
8.5 Composition Control in High-Purity Side-Draw Distillation
8.6 Advanced Distillation Column Configurations
8.7 Petlyuk and Divided Wall Columns
8.8 Optimal Design Versus Optimal Operations
8.9 Conclusions
Tutorial and Self-Study Questions
References
Chapter 9 Advanced Regulatory Control
9.1 Introduction
9.2 Cascade Control
9.2.1 Cascade Control in Distillation
9.2.2 Inferential Cascade Control
9.3 Ratio Control
9.3.1 Ratio Control in Distillation
9.4 Feedforward Control
9.5 Constraint/Override Control
9.6 Decoupling
Tutorial and Self-Study Questions
References
Chapter 10 Model Predictive Control
10.1 Introduction to MPC
10.2 To MPC or not to MPC
10.3 MPC Fundamentals
10.4 Dynamic Matrix Control
10.5 Setting Up a MPC in Distillation
10.5.1 Model Setup
10.5.2 Objective Function
10.5.3 Tuning
10.6 Digitalization and MPC
Tutorial and Self-Study Questions
References
Chapter 11 Plant-Wide Control in Distillation
11.1 Distillation Column Trains
11.1.1 Average Flow Control
11.1.2 Alternatives to Average-Level Control
11.2 Heat Integration (Energy Recycle)
11.2.1 Auxiliary Steam Boilers
11.2.2 Feed Preheating
11.2.3 High-pressure/Low-pressure Columns
11.2.4 Mechanical Vapor Recompression
11.3 Materials Recycling
Tutorial and Self-Study Questions
References
Workshop 1 Hands-on Learning By Doing
Workshop 2 Fundamental Distillation Column Control
Workshop 3 Distillation Column Model Predictive Control
Workshop 4 Distillation Column Control in a Plant-Wide Setting
Appendix A P&ID Symbols
Index
EULA