Professional Documents
Culture Documents
551
SYSTEMS ENGINEERING
Spring 2011
Part-1:
Teaching Assistants:
Adekunle Adeyemo (66-060) Tel. (617) 253-0285 (adeyemo@mit.edu)
Matthew Stuber (66-363) Tel. (617) 253-6468 (stuber@mit.edu)
Reading Material:
Comprehensive notes and background articles will be distributed in
class. Students will be expected to read this material, and
homework assignments will test material in these notes not covered
in class.
Grade:
Homework (individual effort) 45%
Projects (group effort) 40%
Class Participation 15%
Course Schedule
Part-1: Introduction to Systems Engineering
Personal Statement
In the spirit and practice of MIT’s long-held “Honor
System”, I state that, in preparing the solution for this
problem set, I have not used material from the
homework solutions of past students or copies of
solutions provided by the instructor or the TAs in earlier
semesters.
___________________________________ Name
___________________________________ Signature
Network of Batch Synthesis of networks of batch operations; Planning and Scheduling (optimal) of batch operations into multi-
Operations purpose batch chemical plants; Monitoring-Analysis-Diagnosis of batch operations for equipment faults or/and
(Batch Plants) performance degradation; Modeling and simulation of dynamic batch operations
Oil and Gas Identify fields with hydrocarbons; Identify geological structure of deposits and their amounts; Select optimal
Production Systems production strategy over the life of the field; Design production system; Inherently safe and operable production
systems; Planning and scheduling production operations; Control and optimization of operations
Air Pollution Definition of system (Components; Interactions); Model Behavior; Simulate effects of various scenaria;
Diagnose sources of increased pollution; Develop strategies for pollution control
Cardiovascular Model the entire cardiovascular system; Monitor-Analyze-Diagnose its performance; Control and/or redesign.
System
Molecules as Define molecules as systems (components; Interactions); Model physical and chemical behavior (structure-
Systems properties relationships; structure-reactivity relationships); Synthesize reactions; Generate Supra-molecular
structures; Diagnose molecular failures
Reactions as Systems Synthesis of chemical reaction networks (to achieve desired products); Select network of reactions to model
(Systems Chemistry) chemical processes (e.g. combustion); Design self-replicating reaction networks; Identify networks of reactions
as catalytic mechanisms
Biological Systems Synthesis of metabolic networks; Identification of biological processes (signal transduction pathways; gene
(Systems Biology) transcription system; gene regulation system; immunological activity; circadian rythms).
Cooling Water
Gas Recycle Purge
Make-up
Hydrogen
Compressor
Benzene
Fuel Cooling Water
Toluene
Steam
Feed-effluent
Feed-effluent Furnace
Reactor Cooling Water
heat exchanger
heat exchanger
Stabilizer
Stabilizer
Furnace
Quench
Steam Steam
Toluene
bank Water
bankof
ofcoolers
coolers
Cooler Flash
Flash
Steam
Cooling Water
Toluene Recycle
Cooling Water
Benzene
Fuel
Feed-effluent Reactor
Toluene heat exchanger
Steam Cooling Water
Stabilizer
Furnace
Quench
Steam
Steam
Toluene
Water
bank of coolers
Cooler Flash Steam
Cooling Water
Toluene Recycle
Process Synthesis: The Methyl Acetate Process
Acetic Acid
Catalyst Methanol
Recovery
(Distillation)
Distillation
Water
Azeotropic
Distillation Color Column
(Distillation)
Liquid
Extraction
Water
Entrainer Heavies
Recovery
Distillation
Flash Column
From: Siirola, 1996
(Distillation)
Water
Inventing the Single Column Methyl Acetate Process
400,000,000 lb/yr
Distillation
Task G
Acetic Acid Methyl 1/5 capital investment
Extractive Acetate 1/5 energy consumption
Distillation
Task F
Reaction
Task A
Reactive
Distillation
Task B
Methanol
Distillation
Tasks
C and D
Aspen Plus®
Aspen HYSYS®
3. During Operations:
– Process Control
– Monitoring, Analysis, Diagnosis of Process Operations:
– Identification of Faults;
– Performance degradation: Catalyst decay; Fouling; Change of raw
materials, etc.
– Optimization of Operations
Example of Process Synthesis: Hierarchical Synthesis
of Hydro-dealkylation of Toluene Plant to produce Benzene
Recycle Structure
Input-Output Plant Energy, Q Gas Recycle (H2, T, CH4, B) 3 Purge
1 3 Purge (H2, CH4)
Toluene 7
I/O Plant 4
2 Product (B; 99%) 1 6 4
Hydrogen Toluene Product
By-Product (D) Reaction Separation
5 2
Hydrogen Section Section 5
By-Product
Toluene (T) + H2 Æ Benzene + CH4 8
2Toluene Æ Diphenyl (D) + H2 Liquid Recycle (T, B, D)
7
3
10
The Complete Process Flowsheet 1 6
Reaction Generalized Phase
Gas Section Separation
Purge 2
Recycle 9
Hydrogen Compressor F13
4
Product
Toluene Q
Recovery
Steam-(b)
Exchanger Reactor 5
8
Furnace
Coolers Flash
Quench
Hydrogen,
Benzene Methane
Stabilizer
Toluene
Benzene
Toluene
Diphenyl
Examples of Systems: Control Structures
FI CC
F8 FI F9
FI
Short-horizon
A Purge
Control Strategies
F1 (A, B) JI
CW2
FI XA
LI PI
D TI XB
F5 LC
F2 (D, B) A
N XC
Long-horizon
A
L XD Control Strategies
FI F7 TI Y
PC Z XE
LC
E E
XF
F3 (E, F) SC PI R
FI XG • What is the
XA
LI
PI XH intention
A F10
XB
N
TI TC
(purpose) of
XC A CW1 A XD
L
Y FI FI
N
A XE
each control
XD TC
XE
Z
E TI
L
Y XF
loop?
R LI Steam Z
F6 XG
XF
%A, %C
E
R XH
• How were
LC
FI
Control
TI
FI
F11
they selected?
F4 (A, B, C)
Product
C
x11,G , F11
Control Loops for : Stabilization of Reactor Operation
FI
F8 FI F9
FI
A Purge
F1 (A, B) JI
CW2
FI XA
PI
D TI XB
F5
F2 (D, B) A
N XC
A
L XD
FI F7 TI Y
PC Z XE
LC
E E
XF
F3 (E, F) SC PI R
FI XG
PI XH
XA
LI
XB A F10
N
XC A CW1 A XD
L N
Y FI FI A XE
XD TC
Z L
XE E TI Y XF
R Steam Z
F6 XG
XF E
R XH
FI
FI TI F11
F4 (A, B, C)
Product
C
Control Loops for : Material Inventory Control
FI
F8 FI F9
FI
A Purge
F1 (A, B) JI
CW2
FI XA
LI PI
D TI XB
F5 LC
F2 (D, B) A
N XC
A
L XD
FI F7 TI Y
Z XE
E E
XF
F3 (E, F) SC PI R
FI XG
XA XH
XB A F10
N
XC A CW1 A XD
L N
Y FI A XE
XD
Z L
XE E Y XF
R LI Steam Z
F6 XG
XF E
R XH
%A, %C
Control LC FI
FI TI F11
F4 (A, B, C)
Product
C
Control Loops for: Production Rate and Product Quality
FI
F8 FI
FI
A Purge
F1 (A, B) JI
CW2
FI XA
PI
D F5 XB
F2 (D, B) A
N XC
A
L XD Long-horizon
FI F7 TI Y Control Strategies
Z XE
E E
XF
F3 (E, F) PI R
FI XG
XA XH
XB A F10
N
A TI A XD
XC CW1
L N
Y FI FI A XE
XD
Z L
XE E Y XF
R Steam Z
XG
XF F6 E
R XH
FI
FI TI F11
F4 (A, B, C)
Product
C
x11,G , F11
Control Loops for: Minimization of Production Cost
FI CC
F8 FI
FI
Short-horizon
A Purge
Control Strategies
F1 (A, B) JI
CW2
FI XA
PI
D TI XB
F5
F2 (D, B) A
N XC
Long-horizon
A
L XD Control Strategies
FI F7 TI Y
Z XE
E E
XF
F3 (E, F) SC PI R
FI XG
XA XH
XB A F10
N
XC A TI TC A XD
CW1
L N
Y FI FI A XE
XD
Z L
XE E Y XF
R Steam Z
F6 XG
XF E
R XH
FI
FI TI F11
F4 (A, B, C)
Product
C
x11,G , F11
Missing Control Loops
Safety
• Given
– Process with all its units, their sizes, and interconnections
– Desired operating conditions, e.g.
• Minimize total operating cost,
• Achieve desired product flowrate and composition,
• Maintain operating conditions within safe ranges, etc.
• Synthesize a set of control systems, which achieve the
desired objectives, i.e.
– Select what variables to measure in order to monitor the desired
operating objectives,
– Select what variables to manipulate in order to achieve the desired
operating objectives,
– Select the interconnections between (measurements) and
(manipulations) in order to form the control loops,
– Design the control laws, i.e. given the measurements, how much
should the manipulations change?
MPC Impact for 13 Ethylene Plants
Shut-Down
Valves
(1-out-of-2)
Reactor Cooler
Gas Analysis
Temperature Measurements
Measurements (2-out-of-3)
(1-out-of-2)
Safety
Circuits
- Given a Process with all its units and desired safe operating ranges
- Select
- what variables to measure and the redundancy of measurements,
- what variables to manipulate and the redundancy of the manipulations
In order to ensure safe operation in the presence of various failures.
Risk Management and Process Integrity:
Environmental Devastations and Industrial Accidents
3
Risk Management and Process Integrity
Love Canal, NY: 1955-80
Flixborough,
UKCyclohexane Plant
1974
Risk Management and Process Integrity
Bhopal, India: 1984
Piper Alpha,
North Sea: 1988
167 killed
Process Systems Engineering and Process Risk
Management
From
“React and Fix”
to
“Predict/Detect and Prevent”
Process Safety
Inherently Safer Advanced Monitoring Management
Process Designs Diagnostic, and Mitigating Through
Systems Continuous Improvement
Integrate
Process Safety • SIS: Rational instrumentation Culture
And • LOPAs: Rational protection
Control Strategies • HAZOPs: Science-based Work Processes
in early stages of design • Risk Registers: Knowledge-based
Management
Examples of Systems: Network of Batch Operations
(Production of Intermediates for Pharmaceuticals)
Trienone
(Primary raw
M1: material) THF
CH 3MgBr
O (I) OMgBr
M2: H2O/HOAc
H2O HOMgBr
NaOAc
OMgBr OH (II)
Carbinol
(Primary
Quench: product)
CH 3MgBr H2O CH 4 HOMgBr
Gel
Break: H2 O
HOAc HOMgBr Mg ++ H 2O Br- -
OAc
SR:
H+
H2O
CH4 Et2O
C6H12
Et2O
Condense Distill
Distill
Condense Distill Distill
THF
THF
C6H12 THF
Evaporate Condense
C6H12
Mg+2 H2O
Br-
-OAc
Evaporate Condense Distill
NaOAc Et2O
III THF
Ancillary Operations Condense Distill (II)
THF
Examples of Systems: Atmospheric Pollution
Activities
• Define system
• Components
• Interactions
• Model Behavior
• Diagnose, e.g.
• Sources of
increased
pollution
• Control pollution,
etc.
Examples of Systems: Human Cardiovascular System
Activities
• Model
• Monitor
• Analyze
• Diagnose
• Control
• Redesign (?)
• other (?)
Examples of Systems: Molecules as Systems
(6-amino-penicillianic acid)
Connected
Components
Activities
• Synthesize molecular (atoms through bonds)
structures Connected Components
• Model Behavior
• Physical Properties
(functional groups through bonds)
• Reactivity at various sites
• Diagnose molecular failures
• Generate reactions
Examples of Systems: Molecules as Systems
H O
H
C C C O H
H
Physical Property =
H O
H
C C C O H
H
R O
C C
R H
R R
C R C/O
C
C C
This does not inherit the
R R same Reactivity around
R H
the C=C double bond as
These two inherit the same Reactivity around the the “mother” group
C=C double bond as the “mother” group
Examples of Systems: Reaction Networks
Activities
• Synthesize reaction pathways
C3H8 producing desired chemicals.
C2H4 H2 • Syntrhesize reaction network including
reactions with substantial rates affecting
C2H5• the modeling of a chemical process (e.g.
CH3• H• combustion)
C2H6
• Model the behavior, e.g. composition
C2H6
of all reacting species in the network.
CH4
• Control the composition of reacting
species in the network.
• Diagnose the failure of reacting
networks
• other (?)
Examples of Systems: Generating Reaction Networks
Generate all reactions, which have substantial rates, and thus
affect the modeling of a particular process
Rj(t) < Rmin(t) Rate-based termination rule
.
.
.
C 3H 8
C 2H 4 H2
C2H5•
CH3• H•
C2H6
C2H6
CH4
Expanding
Envelope of
Reaction Set
Examples of Systems: Generating Reaction Pathways
R2,2,1 R2,1 R1
. . .R 2,2,2
.
R2,2 R2
.
P
.
. . (Desired
.
. . . Product)
R2,2,m-1 R2,k-1 Rn-1 .
R2,2,m R2,k Rn
Examples of Reaction Systems:
Identifying Catalytic Reaction Networks
1 5 1 5
1 +
C4 H8(m) C4 H8(m)
C4 H8(m) Other
Structures
3 2 3 2
2
H2 H2 H2
C4 H8 C4 H8
C4 H8
C4 H6(m) C4 H6(m)
• Example: OLED
Commercial
Gene/Target Target Lead Lead OP
Clinical and Patient
Identification Validation Identification Preclinical
Trials Mgmt
Metabolites
• Identification of system:
components and interactions.
• What are the proteins
triggering the expression?
• What part of the DNA
(gene) regulates the onset
of transcription?
• Modeling and analysis.
• Regulation and control of
transcription.
• Diagnosis of failures in
transcription.
• Coordination of transcription of
many genes.
Examples of Biological Systems: Gene Expression
Regulation Systems
• Identification of system:
components and interactions.
• What are the proteins
involved in gene regulation?
• What part of the DNA (gene)
regulates the onset of gene
expression?
• What is the structure of
regulation?
• Feedback,Feedforward
• Cascade, Ratio, other
• Modeling and analysis.
• Interaction of control loops.
• Diagnosis of expression failures
• Coordination of expression of
many genes.
Examples of Biological Systems: Functional Coupling
of Gene Clusters
2 7 9 11 12 13 14 15 16 17
ifcA phbC citH ppsA glk pfkA pykF humG devB talB
29
8 10 atpA
desB fumC atpB
acs
icfA
prk
rbcL
rbcS
4 phaD1
napA desA
desD
petF
τ=2 pdhA
τ=2 fabD
bgl
22 glcD
light 18 24 26 glcF
3 psbA2 accC phaB eno
rbcR humB pdhB fda
τ=2 gpmB
τ=5 pfkA
pgi
τ=2 pgk
pykF
tktA
psaB
apcA
28 19 cpcA
ndh psbD1 cpcB
ndh rpl2
desC rps1
icd
31
gap2
ndh 6 27 20
phaA phaE 5 sll0 psbD2
ftrC phaD3 phaD2 1
acnB gltA pta
ppc 30 fbp
petB ack psaA
accD gap1 23 psbA3 25 τ=6
glgA petA ftrV
glgA psbA1 gdh
glcE 21
rplA nblA
apcB τ=
nblA
rpl1 10
τ=1
Examples of Biological Systems: Metabolic Pathways
Allosteric
Regulation
in the TCA
Examples of Biological Systems: Metabolic Pathways
Lysine Production: gnd devB/opcA/zwf glucose-6-P
ribulose-6-P 6-P-gluconate
Over- and Under-Expressed Genes rpe rpi rbsK ribose
pgi
fructose-6-P
Glucose/Lactose Results xylulose-5-P ribose-5-P pfk
fructose-1,6-bisphosphate
tkt fba
Growth Factor
P
Receptor-Ligand binding
Receptor PTK Receptor PTK P
P
GRB2/Sos
Ras-GDP Ras-GTP
Signaling Raf
pathways
P
Mek Mek P
Gene
Nucleus P
induction MAPK MAPK
P
P
TF TF
Transcription
Examples of Biological Systems: Signaling Pathways
CEA
binding
DOTA
binding
Product Design
Selection of Antigen
Hapten
Bispecific Antibody
Clearing Agent
Therapeutic Process (Operation)
Administration of Antibody; dose, time
Administration of Clearing Agent; dose, time Clearing Agent
Administration of DOTA; dose, time
A new design element
Examples of Systems: Information System for CIM
FIELD OPERATIONS
Laboratory Process Utilities Storage Tanks Blending/Shipping
Example of Systems: Natural Gas and CO2
Supply Chain