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Nptel: Plantwide Control of Chemical Processes - Web Course

This document provides an outline for a course on plant-wide control of chemical processes. The course will address dynamic modeling, simulation, and control of complex chemical processes using commercial simulators like Aspen Plus and Hysys. It will cover topics like moving from steady-state to dynamic simulation, controlling common unit operations, and detailed case studies of multi-unit and complex plant-wide processes. The course totals 41 hours and will complement a related video course on this topic.

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114 views3 pages

Nptel: Plantwide Control of Chemical Processes - Web Course

This document provides an outline for a course on plant-wide control of chemical processes. The course will address dynamic modeling, simulation, and control of complex chemical processes using commercial simulators like Aspen Plus and Hysys. It will cover topics like moving from steady-state to dynamic simulation, controlling common unit operations, and detailed case studies of multi-unit and complex plant-wide processes. The course totals 41 hours and will complement a related video course on this topic.

Uploaded by

arunengg
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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NPTEL Syllabus

Plantwide Control of Chemical Processes -


Web course

COURSE OUTLINE

This course addresses the dynamic modeling, simulation and plant-wide control of
complex chemical processes with material and energy recycle using commercial
NPTEL
process simulators (Aspen Plus and Hysys). http://nptel.iitm.ac.in
T h e steps necessary in moving from steady state to dynamic simulation are
presented in detail.
Chemical Engineering
These include proper equipment sizing, correct plumbing, developing a basic
regulatory control structure and proper tuning of the control loops.

Dynamic simulation and control of common unit operations such as reactors,


distillation columns and multi-unit operations such as heterogenous azeotropic Pre-requisites:
distillation is covered first followed by elaborate case-studies on complex plant-
wide processes. UG level course on process control.

The material effectively complements the video counterpart of this course. Coordinators:
Contents: Dr. Nitin Kaistha
Department of Chemical Engineering IIT
Essentials: Kanpur
Proper plumbing and equipment sizing for moving to dynamics, tuning controllers.

Single Unit Dynamic Simulations:

Tank, CSTR, cooled packed bed reactor, simple distillation. column.

Multi-unit Dynamic Simulations:

Heat integrated distillation columns, heterogenous, azeotropic distillation, reactive


distillation.

Complex Plant-wide Case-studies:

Recycle process with side reaction, hydro-dealkylation process, cumene process.

COURSE DETAIL

S.No Topics No. of


Hours

Essentials for Smooth Transition from Steady State to Dynamics

1 Flow-driven vs pressure driven dynamic simulations. 2

Equipment sizing:

Surge tanks, distillation columns, heat exchangers.

Plumbing guidelines:

Liquid pumping systems, gas compression systems.Control


valve and pump sizing.

2 PID Controllers: 1

Direct/reverse action, manual/automatic/cascade mode,


tuning for typical flow, level and pressure loops.

Systematic tuning: relay feedback and step test.

Dynamic Simulation and Control of Single Unit Systems

1 Simple tank process. 1

2 CSTR: 3

Steady state and dynamic model equations and their


solution, typical control structure, Matlab case study, Aspen
Plus and Hysys case study.

3 Cooled packed bed reactor: 4

Steady state and dynamic model equations and their


solution, typical control structure, Matlab case study, Aspen
Plus and Hysys case study.

4 Simple distillation column: 6

Steady state and dynamic model equations and their


solution, single ended vs dual-ended temperature inferential
control, control tray selection using steady state
sensitivity/SVD analysis, steady state disturbance rejection
evaluation using flexibility in specifications, Aspen Plus and
Hysys case study.

Dynamic Simulation and Control of Multi-Unit Systems

1 Heat-integrated distillation system: 2

Control structure design using steady state analyses,


dynamic control performance evaluation in Hysys.

2 Heterogenous azeotropic distillation: 3

Example process, temperature inferential control structure


design using steady state analyses and dynamic control
performance evaluation in Aspen Plus.

3 Reactive distillation: 3

The methyl acetate RD column, example control structure,


steady state and dynamic simulation in Aspen plus.

Case-studies on Plant-wide Control of Complex Plants

1 Recycle process with side reaction: 6

Base case, alternative regulatory control structures, dynamic


simulation in Hysys. Linking Hysys with Matlab. Steady state
operating conditions for maximum operating profit using
optimizer in Matlab.

2 Hydrodealkylation process: 6

Base case design, plant-wide control structure, dynamic


simulation in Hysys and Aspen Plus.

3 Cumene alkylation process: 4

Base case design, plant-wide control structure, dynamic


simulation in Hysys.

Total 41

References:

Luyben, W.L., Tyreus, B.D. and Luyben, M.L. (1998) Plantwide Process
Control.McGraw Hill: New York.

A joint venture by IISc and IITs, funded by MHRD, Govt of India http://nptel.iitm.ac.in

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