The Integration of Process Design and Control

E. Zafiriou9780080423586, 0080423582

The existence of interactions between the design of a process and that of its control system have been known to industrial practitioners for a long time. In the past decade academic research has produced methodologies and tools that begin to address the issue of designing processes that are flexible, can be controlled reliably, and are inherently safe. This publication unites the work of academics and practitioners with interests in the integration of process design and control, in order to examine the state of the art in methodologies and applications. The scope covers the design of chemical plants at different stages of detail. It also examines control issues from the plantwide level, where, for example, recycles between units can be important, to the specific unit level, where the availability or selection of measurements might be the most important factor.

---

Table of contents :
Half Title Page……Page 2
COMPUTER-AIDED CHEMICAL ENGINEERING……Page 3
Title Page……Page 4
Copyright……Page 5
Preface……Page 6
List of Contributors……Page 10
Contents……Page 14
1. INTRODUCTION……Page 16
2. PROCESS CHARACTERIZATION AND CONTROLLABILITY ANALYSIS……Page 17
3. INTEGRATED PROCESS DESIGN AND CONTROL — METHODS……Page 18
4. PLANTWIDE INTERACTIONS OF DESIGN AND CONTROL……Page 20
5. INTEGRATED PROCESS DESIGN AND CONTROL — EXTENSIONS……Page 21
6. CONCLUDING REMARKS — FUTURE DIRECTIONS……Page 23
REFERENCES……Page 24
1. INTRODUCTION……Page 25
2. HISTORY AND CURRENT STATUS……Page 26
3. INHERENT CONFLICT BETWEEN STEADY-STATE ECONOMICS AND DYNAMIC CONTROLLABILITY……Page 29
4. JACKETED CSTR PROCESS……Page 33
5. AUTOREFRIGERATED REACTOR DESIGN……Page 40
6. TUBULAR REACTOR SYSTEM……Page 45
7. QUANTITATIVE ASSESSMENT OF CONTROLLABILITY……Page 50
8. LEHIGH DESIGN COURSE……Page 53
REFERENCES……Page 56
1. INTRODUCTION……Page 57
2. THE PROCESS CHARACTERIZATION CUBE……Page 58
3. SOME CANDIDATE MEASURES FOR PROCESS CHARACTERIZATION……Page 63
4. DESIGN OF CONTROL STRUCTURES……Page 69
5. CASE STUDIES……Page 74
REFERENCES……Page 89
1. WHY ASSESS NONLINEARITIES IN PROCESS CONTROL?……Page 91
2. INTRODUCTION TO NONLINEARITY MEASURES……Page 92
3. CONTROL-RELEVANT NONLINEARITY ASSESSMENT……Page 101
4. CONCLUSIONS……Page 108
REFERENCES……Page 109
1. INTRODUCTION……Page 111
2. OPERABILITY REVIEW……Page 113
3. STEADY-STATE OPERABILITY……Page 116
4. DYNAMIC OPERABILITY……Page 129
5. DISCUSSIONS AND CONCLUSIONS……Page 137
REFERENCES……Page 138
1. INTRODUCTION……Page 141
2. SPECTRAL ASSOCIATION……Page 142
3. THE SPECTRAL RESOLUTION OF A DYNAMIC RESPONSE……Page 143
4. FURTHER PROPERTIES OF THE UPSR……Page 147
5. UPSR LIMITATIONS……Page 153
6. APPLICATION TO A SUPERCRITICAL FLUID EXTRACTION PROCESS……Page 154
7. SUMMARY……Page 158
8. CONCLUSIONS……Page 159
REFERENCES……Page 160
1. INTRODUCTION……Page 161
2. SYSTEM DESCRIPTION WITH NON-EQUILIBRIUM THERMODYNAMICS……Page 162
3. PROCESS DESIGN: A THERMODYNAMIC APPROACH……Page 170
4. CONTROLLABILITY: AN APPROACH BASED ON NON-EQUILIBRIUM THERMODYNAMICS……Page 174
5. HEAT TRANSFER……Page 177
6. DISTILLATION……Page 179
7. CONCLUSIONS……Page 180
REFERENCES……Page 181
1. INTRODUCTION……Page 183
2. CONTROLLABILITY MEASURES……Page 184
3. IMPROVING THE PROCESS……Page 186
4. MAKING STRUCTURAL IMPROVEMENTS……Page 194
References……Page 200
1. INTRODUCTION……Page 202
2. SIMULTANEOUS DESIGN AND CONTROL USING MIXED-INTEGER DYNAMIC OPTIMIZATION……Page 203
3. AN EXAMPLE ON SIMULTANEOUS PROCESS AND CONTROL DESIGN……Page 208
4. PARAMETRIC CONTROLLERS IN SIMULTANEOUS PROCESS AND CONTROL DESIGN……Page 213
5. DISTILLATION PROCESS EXAMPLE – RESULTS……Page 223
ACKNOWLEDGMENTS……Page 228
REFERENCES……Page 229
1. INTRODUCTION……Page 231
2. PROCESS SYNTHESIS AND LINEAR BACK-OFF……Page 233
3. NONLINEAR BACK-OFF SYNTHESIS……Page 241
4. CONTROL STRUCTURE SELECTION FOR A MODEL FCC……Page 244
5. SUMMARY AND CONCLUSIONS……Page 251
REFERENCES……Page 252
1. INTRODUCTION……Page 254
2. PERFORMANCE-LIMITING FACTORS……Page 255
3. OPTIMIZATION FRAMEWORK……Page 257
4. CONTROLLER PARAMETRIZATION……Page 258
5. INCLUSION WITHIN OPTIMIZATION FRAMEWORK……Page 262
6. CASE STUDIES……Page 269
7. FUTURE DIRECTIONS……Page 274
8. CONCLUSION……Page 275
REFERENCES……Page 276
1. INTRODUCTION……Page 279
2. MULTI-OBJECTIVE OPTIMISATION……Page 281
3. INTEGRATED FRAMEWORK TARGETING OPTIMAL DESIGN……Page 284
4. HEN CONTROLLABILITY ANALYSIS FRAMEWORK……Page 290
5. PLANTWIDE CONTROL AND DYNAMIC MODELLING FRAMEWORK……Page 297
6. CASE STUDY: VINYL CHLORIDE MONOMER (VCM) PLANT……Page 300
7. CONCLUSIONS……Page 317
REFERENCES……Page 319
1. INTRODUCTION……Page 321
2. INPUT-OUTPUT CONTROLLABILITY……Page 322
3. INTRODUCTORY EXAMPLE – REACTOR SEPARATOR PLANT……Page 324
4. MODEL DECOMPOSITION……Page 327
5. RELAXING CONTROL LIMITATIONS THROUGH PROCESS DESIGN……Page 329
6. RELAXING CONTROL REQUIREMENTS THROUGH PROCESS DESIGN……Page 331
REFERENCES……Page 339
1. INTRODUCTION……Page 341
2. DESIGN CRITERIA……Page 343
3. NONLINEAR SENSITIVITY METHOD……Page 350
4. DESIGN APPLICATIONS……Page 356
CONCLUSIONS — SUMMARY……Page 364
REFERENCES……Page 365
1. INTRODUCTION……Page 367
2. EFFECT OF A DESIGN DECISION……Page 369
3. ON-AIM PRODUCT QUALITY CONTROL……Page 371
4. DESIGN EXAMPLE……Page 376
5. DESIGN APPROACHES……Page 379
6. BIO-PROCESS HEAT INTEGRATION……Page 382
REFERENCES……Page 388
1. INTRODUCTION……Page 390
2. BACKGROUND……Page 391
3. THE MODIFIED ANALYTICAL HIERARCHICAL PROCESS……Page 394
4. HYDRO-DEALKYLATION OF TOLUENE TO BENZENE PROCESS……Page 398
5. PLANTWIDE CONTROL STRUCTURE FOR THE HDA PROCESS……Page 399
6. RESULTS AND DISCUSSION……Page 409
7. SUMMARY……Page 412
NOMENCLATURE……Page 413
REFERENCES……Page 414
1. INTRODUCTION……Page 416
2. PREVIOUS WORKS……Page 417
3. CONTROL OF REACTANT INVENTORY……Page 419
4. PLANTWIDE CONTROL OF IMPURITIES……Page 431
5. CONCLUSIONS……Page 441
NOTATION……Page 442
REFERENCES……Page 443
1. INTRODUCTION……Page 445
2. BASIC RESULTS ON I/O-CONTROLLABILITY OF LINEAR SYSTEMS……Page 448
3. THE ROBUST PERFORMANCE NUMBER……Page 451
4. COMPUTATION OF THE ATTAINABLE PERFORMANCE OF A CONTROL STRUCTURE……Page 457
5. EXAMPLE 1: LINDE’S AIR SEPARATION PLANT……Page 460
6. EXAMPLE 2: REACTIVE DISTILLATION PROCESS……Page 469
7. CONCLUSIONS……Page 474
REFERENCES……Page 477
1. INTRODUCTION……Page 479
2. STEADY-STATE DESIGN……Page 480
3. OPERABILITY……Page 487
4. CONTROL……Page 493
REFERENCES……Page 498
1. INTRODUCTION……Page 500
2. SELECTION OF CONTROLLED VARIABLES FOR SELF-OPTIMIZING CONTROL……Page 501
3. DISTILLATION CASE STUDY……Page 504
4. OPTIMAL CHOICE OF CONTROLLED VARIABLES……Page 509
5. EXAMPLE: OPTIMAL OPERATION OF BLENDING OF GASOLINE……Page 511
REFERENCES……Page 515
1. INTRODUCTION……Page 516
2. BATCH CONTROL REQUIREMENTS AND STANDARDS……Page 517
3. BATCH CONTROL……Page 519
4. CO-ORDINATION CONTROL……Page 525
5. INTEGRATION……Page 534
6. TEST PLATFORM (PROCEL PILOT PLANT)……Page 538
ACKNOWLEDGEMENTS……Page 546
REFERENCES……Page 547
1. INTRODUCTION……Page 548
2. SIX-SIGMA METHODOLOGY IN PRODUCT DESIGN AND MANUFACTURING……Page 549
3. THE ROLE OF INTEGRATED DESIGN AND CONTROL……Page 555
4. EXAMPLE APPLICATIONS……Page 556
5. CLOSING REMARKS……Page 568
REFERENCES……Page 569
1. INTRODUCTION……Page 570
2. PROBLEM STATEMENT……Page 571
3. OPTIMIZATION METHODS……Page 572
4. CASE STUDY: A WASTEWATER TREATMENT PLANT……Page 577
5. RESULTS AND DISCUSSION……Page 583
6. CONCLUSIONS AND FUTURE WORK……Page 593
REFERENCES……Page 596
1. INTRODUCTION……Page 597
2. A GLOBAL OPTIMIZATION ALGORITHM……Page 598
3. SIMULTANEOUS DECOUPLING AND POLE-PLACEMENT CONDITIONS……Page 601
4. CASE STUDIES……Page 604
REFERENCES……Page 617
1. INTRODUCTION……Page 619
2. PROCESS-CONTROL DESIGN……Page 623
3. PROCESS AND CONTROL DESIGN OF AN EMULSION POLYMER REACTOR……Page 634
4. CONCLUSIONS……Page 646
REFERENCES……Page 648
Author Index……Page 650
Subject Index……Page 652