Simulation and Design of a Process Control System for a Pilot Plant-Scale Distillation Unit

1. Chemical Reaction Engineering Laboratory Simulation and Design of a Process Control System for a Pilot Plant-Scale Distillation Unit Washington University Department of Chemical Engineering Department of Electrical and Systems Engineering Bia Henriques Jonathan Lowe Rachel Vazzi Kwaku Opoku-Mensah December 2004

2. Overview Chemical Reaction Engineering Laboratory • Introduction • Methodology • Problem Segmentation • Steady State Vs. Dynamic • Assumed Process • Challenges • DeltaV Control Blocks • Testing Procedures • Team Work • Control Diagrams and Graphics • Wrong and Right • Interface Demo • Accomplishments • Future Work • Lessons Learned

3. Introduction Chemical Reaction Engineering Laboratory • Southern Illinois University – Edwardsville Federal Corn to Ethanol Pilot Plant needs simulation of its ethanol distillation unit • Washington University partnered with SIUE to provide this service to achieve a better way of predicting the system’s behavior • Assumptions • No solids in inlet stream • Degasser treated as 2-tray column instead of separator • Did not include all control loops

4. Methodology Chemical Reaction Engineering Laboratory • Design and setup of control system for distillation unit • Distillation unit simulation performed in Hysys to predict steady state and dynamic behavior of process • Process control instrumentation simulated in Hysys for dynamic state • Process control system configured in DeltaV in both control studio and explorer • Both simulations interfaced so the behavior of the control system can be studied when a load change is made in Hysys

5. Chemical Reaction Engineering Laboratory Problem Segmentation • P&IDs used to build graphics for DeltaV • Hysys used to simulate process • DeltaV used to control process • Programs interfaced to provide optimum process control design

6. Chemical Reaction Engineering Laboratory Steady State Vs. Dynamic • Hysys model must be configured to run both in steady-state and dynamic mode • Temperature and pressure profiles for streams and equipment connected need to match in dynamic mode • Tank sizes, valve sizing, and inlet conditions must remain constant throughout

7. Assumed Process Chemical Reaction Engineering Laboratory

8. Challenges Chemical Reaction Engineering Laboratory • Hysys would not run dynamics if solids existed in streams • Cascade mode would not work without external references in DeltaV • Hysys would not switch to dynamics if all 3 columns were present • Simplified the process to get it to work • Created own dynamos in DeltaV because the ones found in the library did not match the P&IDs • Required more overall time and effort than was originally predicted

9. Chemical Reaction Engineering Laboratory DeltaV Control Blocks • PID • AI • AO • CALC • External References

10. Chemical Reaction Engineering Laboratory Testing Procedure • Testing reasonability of HYSYS simulation • Testing reactions of the DeltaV control system prior to link to HYSYS • Test the linked systems

11. Chemical Reaction Engineering Laboratory TeamWork TEAM DUNCAN!!! • Bia Henriques (Captain) • Hysys simulation and implementation • Jonathan Lowe • DeltaV simulation, module design and implementation • Kwaku Opoku-Mensah and Rachel Vazzi • DeltaV graphic design and implementation

12. AI Chemical Reaction Engineering Laboratory

13. PID Chemical Reaction Engineering Laboratory

14. PID with Cascade Chemical Reaction Engineering Laboratory

15. Heat Exchanger Chemical Reaction Engineering Laboratory

16. Beer Well P&ID Chemical Reaction Engineering Laboratory

17. Beer Well DeltaV Graphic Chemical Reaction Engineering Laboratory

18. Hysys Simulation Chemical Reaction Engineering Laboratory

19. What Went Wrong/Right Chemical Reaction Engineering Laboratory • Wrong: • Hysys dynamic mode did not behave correctly • Mass balance around column did not sum • Right: • Creation of DeltaV graphics went smoothly • DeltaV configuration works sufficiently • Steady-state Hysys converged properly • Hysys and DeltaV talked correctly

20. Accomplishments Chemical Reaction Engineering Laboratory • Each of us learned new skills in DeltaV or Hysys • A real-world process was modeled and controlled in the lab • This model, once perfected, could be used to estimate costs and feasibility of process control

21. Future Work Chemical Reaction Engineering Laboratory • Tune model to achieve process optimization of pilot plant thus increasing ethanol production • Create full interactive model of pilot plant in HYSYS and DeltaV • Design process control system for other unit operations in the pilot plant

22. Lessons Learned Chemical Reaction Engineering Laboratory • Jonathan & Bia: Hysys dynamic mode, linking DeltaV and Hysys • Kwaku & Rachel: DeltaV graphics, configuration, reading PnID’s, linking DeltaV graphics and configuration References: http://www.meadmadecomplicated.org/science/fermentation.html http://www.andrew.cmu.edu/user/jitkangl/Fermentation%20of%20Ethanol/Fermentation%20of%20Ethanol.htm

23. Acknowledgements Chemical Reaction Engineering Laboratory • Thanks to Dr. Terry Tolliver for assisting with the simulation of the SIUE pilot plant.

24. The End Chemical Reaction Engineering Laboratory • QUESTIONS???