Chemical process dynamics

and control
Flavio Manenti

CMIC Giulio Natta Dept.

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Contacts
Flavio Manenti

Alexander von Humboldt Professor of Chemical Plants and Operations

POLITECNICO DI MILANO
Dipartimento di Chimica, Materiali e Ingegneria Chimica "Giulio Natta"
Centre for SuPER (Sustainable Process Engineering Research)
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 23418

Fax IT +39.(0)2.2399.3280
Email flavio.manenti@polimi.it
Web http://super.chem.polimi.it
Excellence Cluster: www.reinforce.polimi.it

Students: Wednesday 10:15 11:15 (please, ask via email for)

MSc and PhD students and visiting: no limitations

Flavio Manenti Dipartimento CMIC Giulio Natta

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People
Staff:
Claudia Bianchi, Giulia Bozzano, Flavio Manenti, Laura Piazza, Sauro Pierucci,
Carlo Pirola Guido Buzzi Ferraris, Eliseo Ranzi
Collaborators:
Andr Furtado Amaral, Brazil-Italy, Biorefinery (Plant)
Andrea Bassani, Italy, Sulfur & Coal Gasification (Process)
Lorenzo Cabianca, Belgium-Italy, Biomass gasification (Numerics)
Michele Corbetta, Italy-USA, Biorefinery downstream (Process)
Andres Ricardo Garzon-Leon, Colombia-Italy, Polymer Science (Kinetics)
Ergys Pahija, Hong Kong, Biorefinery (Plant)
Davide Papasidero, Italy-The Netherlands, Food Engineering (Kinetics)
Francesco Rossi, Italy-USA, Optimization (Process)
Mattia Vallerio, Belgium, Optimal Control (Process)
Anton Ochoa-Bike, Russian Fed., Nuclear (Process)
Zhaoli Zhang, China, Solar (Plant)
Muhammad Rizwan, South Korea (Plant)
Industrial Consultants:
Maria Grazia Grottoli, Lucio Molinari
Students: 22 ongoing thesis projects
Flavio Manenti Dipartimento CMIC Giulio Natta
 Motivation to study process 4

control
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

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MS course program
Nonlinear Systems Economy
Parallel Just in time
Optimizers
Solvers
Differential systems DCS, OTS, Plantwide control, Computing Market-driven

Stiff systems Soft sensing, process transients, Logistics

grade/load changes
ODE,DAE,PDE,PDAE
Efficiency Dynamic Corporate
Simulation Supply Chain
Planning
Scheduling
Mathematical
Optimization Dynamic optimization
Modeling Distributed predictive control

Model
Model
Predictive
Data Reduction
Control
Reconciliation Uncertainties
Optimal production
Outlier Detection
Optimal grade changes
Robust methods
Linear/nonlinear Regressions Raw Data Decisions Multi-objective
Real-time optimization
Performance Monitoring
High accuracy
Yield Accounting
Reliable process control
Soft sensing
Production improvement

Flavio Manenti Dipartimento CMIC Giulio Natta

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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

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MS course program
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

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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

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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

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MS course program
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

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MS course program
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

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MS course program
Gas processing (refrigeration and/or separation sections)
Process simulation
Plantwide control
Conditions, scenarios, grade changes, OTS

Exam
Pre-test (optional)
Oral (mandatory)

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References
Some names for process dynamics and control (books):
G. Stephanopoulos - Chemical process control: an introduction to theory and
practice, Prentice-Hall, 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