Chemical Engineering 3P04 Process Control Tutorial # 3 Learning goals

1. Discuss what questions we answer using dynamic models (a few interesting examples) 2. Continue to practice formulating dynamic models of processes

Dynamics Are Important for the Analysis of Process Safety

I suppose that I should have paid attention in Process Control!

Copyrights by CCPS/American Institute of Chemical Engineers and copied with the permission of AIChE

Dynamics Are Important for the Analysis of Process Safety

The cooling water pumps have failed. How long do we have until the exothermic reactor runs away?
F
feed

T A

Temperature

Dangerous

Cooling water

time

Dynamics Are Important for the Analysis of Process Safety

Temperature

Dangerous

time

This was in the news recently for the nuclear reactor at Chalk River. The cooling system did not have appropriate reliability.

McMaster University has a nuclear reactor on campus. Are you concerned? What can be done to provide time to repair?

Dynamics Are Important for the Analysis of Process Safety Bartek Maleic Anhydride Process Vaporizer

We must keep %C4 close to but below the combustion limit. We want to control this critical variable, which valve should we use?

Dynamics Are Important for the Analysis of Process Safety Causal yes & fast How about v3? Safety-critical variable

How about v4? Causal yes, & fast! How about v2? Causal yes, but rather slow

Dynamics Are Important for the Analysis of Process Inventories (Feed, Products, Intermediates)
Feed material is delivered periodically, but the process requires a continuous feed flow. How large should should the tank volume be?
Periodic Delivery flow Continuous Feed to process

Time

Dynamics Are Important for the Analysis of Process Inventories (Feed, Products, Intermediates)

The tank must be at least this large.

400

Volume (m3)

300 200 100 0 0 20 40 50 time (h) 70 80 100

Dynamics Are Important for Product Quality

Cooling Water (CW) PC-1

To flare

Weve studied distillation. I suppose that we should know what to manipulate to control the distillate composition!
F7

PV-3 P3 T5 TAL

L4

Feed
LC-1 17

F3 dP-1

16

15 T6 AC-1 T10 3 TC-7 T20 dP-2 2 F4

Distillate product

LAH LAL LC-3 F9 F8

Bottoms product

Dynamics Are Important for Product Quality

Cooling Water (CW) PC-1

To flare

PV-3 P3 T5 TAL

L4

Feed
LC-1 17 F7

Adjusting the reflux has a strong and fast response on the top composition

F3 dP-1

16

15 T6 AC-1 T10 3 TC-7 T20 dP-2 2 F4

Distillate product

AC

LAH LAL LC-3 F9 F8

Bottoms product

For all of these practical applications, we need to understand and use dynamic analysis.
Formulate models based on fundamental principles

Determine how the key model parameters depend on the process conditions and equipment design
- Steady-state gain (KP) - Time constants () - Dead time (discussed soon) Very important to know how the process affects the dynamics!

Determine the transient behavior for specific input function (e.g., step, impulse, ramp)
- Solve Linear equations analytically - Solve Non-linear equations using numerical methods (3E04!) - Solve linearized approximations analytically - Use qualitative analysis (e.g., step response)

Modeling: Practice, Practice, Practice!!! We apply this procedure 1. Define Goals 2. Prepare information 3. Formulate the model 4. Determine the solution 5. Analyze Results 6. Validate the model to many physical systems overall material balance component material balance energy balances

Modelling exercises: Perform the following modelling exercises from Tutorials on the PC-Education WEB:
3.1 mixing point 3.2 energy balance 3.3 isothermal CSTR