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Chapter 1 Introduction
Bio-Process Industries
Use micro-organisms to produce useful products Pharmaceutical industry Ethanol from grain industry
A control system must be able to absorb a variety of disturbances and keep the process in a good operating region:
Thunderstorms, feed composition upsets, temporary loss of utilities (e.g., steam supply), day to night variation in the ambient conditions
Time
New Controller
Impurity Concentration
Limit
Time
Time
New Controller
Impurity Concentration
Limit
Time
Time
Improved Performance
Impurity Concentration
Limit
Time
Setpoint
+-
Controller
c
Actuator
Process
CV
Sensor
Feed
Condensate
DO Control in a Bio-Reactor
Setpoint AC AT
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
Setpoint
+-
Controller
c
Actuator
Process
CV
Sensor
The key feature of all feedback control loops is that the measured value of the controlled variable is compared with the setpoint and this difference is used to determine the control action taken.
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.
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.
FV CA0
CA,CB, CC
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 calculatedfrom 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.
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).
Process Model
FV CA0
CA,CB, CC
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.
Industrially Relevant Skills Control hardware and troubleshooting (Ch 2&10) Controller Implementation and tuning (Ch 7-9) Advanced PID techniques (Ch 12-14) MIMO control (Ch 15-18)
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.