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Economic Plantwide Control using Commercial Process Simulation Software

Economic Plantwide Control using Commercial Process Simulation Software. Adriana Reyes Lúa. Supervisor: Sigurd Skogestad Co-supervisor: Vladimiros Minasidis. TKP4550 Specialization Project. Fall 2013. Name, title of the presentation. Plantwide Control.

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Economic Plantwide Control using Commercial Process Simulation Software

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  1. Economic Plantwide Control using Commercial Process Simulation Software Adriana Reyes Lúa Supervisor: Sigurd Skogestad Co-supervisor: Vladimiros Minasidis TKP4550 Specialization Project Fall 2013 Name, title of the presentation

  2. Plantwide Control • “Control structure design for complete chemical plants”. • Systematic procedure for the design of an economic plantwide control, based on steady state plant economics. • Top down • Bottom up

  3. Plantwide Control 1. Top-down Step 1: Define operational objectives (economics) and constraints. Step 2: Identify steady state degrees of freedom and determine steady state operation conditions. Step 3: Identify candidate measurements y and select CV1 =Hy . Step 4: Select the location of the throughput manipulator.

  4. Plantwide Control: The Challenge • To be accepted and used in industry, the procedure: • must result in processes with near optimal operation • should not employ complex control technology. • Proposed solution: • Develop an automated procedure. • Use of commercial process simulators? • Intuitive • Widely used • Pre-loaded information • Design mode vs. operation mode. • Poor numerical properties. • Not standardized.

  5. Objective To explore the use of commercial process simulators to generate process models suitable for an automated economic plantwide control procedure.

  6. Methanol Plant • Reactor, a separator, and a recycle stream with purge Scheme of a methanol plant (Løvik,2001)

  7. Methanol Plant 4 steady state degrees of freedom

  8. Methanol Plant Simulation

  9. ”Operation Mode” Simulation Reactor • Kinetics • Sizing • Ergun Δp

  10. ”Operation Mode” Simulation Circulation compressor • Actual gas flow is limited by compressor curve.

  11. ”Operation Mode” Simulation Heat Exchangers From recirculation From Reactor To Separator • UA is fixed. • Inlet temperatures are given. To Reactor Find Tc,out!

  12. Optimization Problem

  13. Plantwide Procedure: Step 1 • OK! Define operational objectives (economics) and constraints.

  14. Step 2 Optimizing the Simulation Hard constraints as inputs

  15. Optimizing the Simulation COM Matlab UniSim • NLP Solver • fmincon • NLP Model

  16. Plantwide Procedure: Step 2 • OK! • Identify steady state degrees of freedom. • Identify important disturbances • Determine steady state operation conditions.

  17. Conclusion • The use of commercial process simulators to generate process models suitable for an automated economic plantwide control procedure was explored. • NLP model independent of NLP solver. • The model for the methanol plant in ”operation mode” was generated. • Recommendations for set-up of heat exchangers and compressors were given. • Steps 1 and 2 of plantwide control procedure achieved.

  18. Thank you for your attention!

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