Professional Documents
Culture Documents
James B. Riggs
M. Nazmul Karim
Chapter 1
Introduction
Hydrocarbon fuels
Chemical products
Pulp and paper products
Agrochemicals
Man-made fibers
Bio-Process Industries
Use micro-organisms to produce useful
products
Pharmaceutical industry
Ethanol from grain industry
Old Controller
Limit
Time
Time
New Controller
Impurity
Concentration
Impurity
Concentration
Old Controller
Limit
Time
Limit
Time
Improved Performance
Impurity
Concentration
Impurity
Concentration
Old Controller
Limit
Time
Limit
Time
DO Control in a Bio-Reactor
DO Control
Controlled variable- the measured dissolved
O2 concentration
Manipulated variable- air flow rate to the
bio-reactor
Actuator- variable speed air compressor
Sensor- ion-specific electrode in contact
with the broth in the bio-reactor
Disturbance- Changes in the metabolism of
the microorganisms in the bio-reactor
In-Class Exercise
Consider a person skiing down a mountain.
Identify the controller, the actuator, the
process, the sensor and the controlled
variable. Also, indicate the setpoint and
potential disturbances. Remember that the
process is affected by the actuator to change
the value of the controlled variable.
Characteristics of Effective
Process Control Engineers
Use their knowledge of the process to guide
their process control applications. They are
process control engineers.
Have a fundamentally sound picture of
process dynamics and feedback control.
Work effectively with the operators.
Operator Acceptance
A good relationship with the operators is a
NECESSARY condition for the success of a control
engineer.
Build a relationship with the operators based on
mutual respect.
Operators are a valuable source of plant experience.
A successful control project should make the
operators job easier, not harder.
Optimization Example
ABC
Mole balance on A :
Q C A0 Q C A k1 exp[ E1 / RT ] C A Vr
Solving for C A
C A0
CA
k1 exp[ E1 / RT ]Vr
1
Q
Likewise, C B and CC are calculated from mole
balances.
Optimization Algorithm
1. Select initial guess for reactor
temperature
2. Evaluate CA, CB, and CC
3. Evaluate
4. Choose new reactor temperature and
return to 2 until T* identified.
2
1.5
1
T*
0.5
0
-0.5
250
275
300
325
350
Process Optimization
Typical optimization objective function, :
=
Product values-Feed costs-Utility costs
The steady-state solution of process models is usually
used to determine process operating conditions which
yields flow rates of products, feed, and utilities.
Unit costs of feed and sale price of products are
combined with flows to yield
Optimization variables are adjusted until is
maximized (optimization solution).
Generalized Optimization
Procedure
Numerical
Optimization
Algorithm
Initial Estimate
of Optimization
Variables
Economic
Function
Value
Optimization
Variables
Process
Model
Optimum
Operating
Conditions
Model
Results
Economic
Function
Evaluation
Economic
Parameters
In-Class Exercise
Identify an example for which you use
optimization in your everyday life. List the
degrees of freedom (the things that you are
free to choose) and clearly define the
process and how you determine the
objective function.
Tuning loops
Control loop design
Control loop troubleshooting
Command of the terminology
Fundamental understanding
Process dynamics
Feedback control
Overview
All feedback control loops have a controller, an
actuator, a process, and a sensor where the
controller chooses control action based upon the
error from setpoint.
Control has to do with adjusting flow rates to
maintain controlled variables at their setpoints
while for optimization the setpoints for certain
controllers are adjusted to optimize the economic
performance of the plant.