Distributed Heat Supply for Distillation Control to Reduce Feed Composition Disturbance Effects

The introduction of heat in stages combined with a reboiler as a distillation control strategy is proposed aiming to reduce the transition time when a feed composition disturbance occurs. This is the most severe type of perturbation and results in long transition times which are economically undesirable. Experiments were carried out in a pilot distillation column with ethanol and water for testing two different control strategies: conventional, i.e., using both last stage and reboiler temperature controllers, and distributed, i.e., conventional strategy plus stage temperature controllers. The results with this operational approach indicated a significant reduction in the time required for the column to stabilize when compared with the conventional approach. The proposed strategy proved to be a viable alternative, enabling faster dynamics and smaller volumes to be processed outside the predefined quality parameters.     

Temperature inferential control of a reactive distillation column with double reactive sections

Temperature inferential control(TIC) is studied for a reactive distillation column with double reactive sections(RDC-DRSs) processing a hypothetical two-stage consecutive reversible reaction(A + B?C + D, C + B?E + D with αDN αBN αCN αAN αE). Because of the complicated dynamic behaviors, the controlled stages by sensitivity analysis lead to great steady-state deviations(SSDs) in top and bottom product purities. Since TIC involves considerably reduced settling times in comparison with direct composition control, small SSDs in product qualities correspond generally to small transient deviations(TDs) in product qualities. An objective function that measures SSDs in product qualities is formulated to represent the performance of a TIC system and an iterative procedure is devised to search for the best control configuration. The application of the procedure to the RDC-DRS gives considerably suppressed TDs and SSDs in top and bottom product qualities as compared with the one by sensitivity analysis. The method is simpler in principle and less computationally intensive than the current practice. These striking outcomes show the effectiveness of the proposed principle for the development of TIC systems for complicated reactive distillation columns.     

多进料脱甲烷塔进料位置切换的控制策略

进料位置和控制器的操作参数是显著影响精馏塔单元分离和节能效率的重要参数。为此提出一种动态多进料切换和控制器参数切换控制策略。在脱甲烷塔系统动态模拟和控制的基础上,对脱甲烷塔多进料位置切换的控制方案进行验证,并分别实现对进料位置和控制器参数的分步和同步切换。结果表明:同步切换方法更有利于实现多进料位置和控制器参数的切换。     

Approximations to expected stopping times with applications to sequential estimation

In this paper we consider sharp asymptotic aproximations to renewal functions associated with general stochastic sequences. We establish a variant of Smith's renewal theorem with a bounded remainder term imposing moment conditions on the underlying stochastic sequence. This result is then applied to an asymptotic analysis of stopping times arising in sequential estimation problems. We show that the renewal theorem can be used for deriving approximations to the expected values of first passage times for random walks with dependent increments     

Separation of n-heptane/isobutanol via eco-efficient vapor recompression-assisted distillation: process optimization and control strategy

In this study, vapor recompression and heat integration assisted distillation arrangements with either the low or high pressure in the reflux drum are proposed to reduce and/or eliminate the application of the costly refrigerant for the separation of n-heptane and isobutanol mixture. The high-pressure arrangement with vapor recompression and heat integration is the most attractive among these four intensified configurations since it can reduce total annual cost by 18.10%, CO₂ emissions by 75.01% based on natural gas (78.78% based on heavy oil fuel), and second-law efficiency by 61.20% compared to a conventional refrigerated distillation system. Furthermore, exergy destruction in each component is calculated for the heat integration configurations and is shown in pie diagrams. The results demonstrate that the high-pressure configuration presents unique advantages in terms of thermodynamic efficiency compared to the low-pressure case. In addition, dynamic control investigation is performed for the economically efficient arrangement and good product compositions are well controlled through a dual-point temperature control strategy with almost negligible product offsets and quick process responses when addressing 20% step changes in production rate and feed composition. Note that there are no composition measurement loops in our developed control schemes.     

Offset‐Free Inferential Feedback Control of Distillation Compositions Based on PCR and PLS Models

An offset‐free inferential feedback control strategy for distillation composition control using principal component regression (PCR) and partial least squares (PLS) models is presented in this paper. PCR and PLS model based software sensors are developed from process operational data so that the top and bottom product compositions can be estimated from multiple tray temperature measurements. The PCR and PLS software sensors are then used in the feedback control of the top and bottom product compositions. With this strategy the problem of substantial time delay in composition analyzer based control and of substantial bias in single tray temperature control can be overcome. A practically very important issue in software sensor based feedback control is that static control offsets often exist due to a static estimation bias, especially when the process operating condition changes. A technique for eliminating the static estimation bias and the resulting static control offsets through mean updating of process measurements is proposed in this paper. Applications to a simulated methanol‐water separation column demonstrate the effectiveness of this control strategy.     

基于软测量技术的先进控制在DCS上的实现和应用

针对丁二烯生产装置精馏塔塔顶控制回路不能实时测量丁二烯-1,3的问题,提出了基于软测量技术的先进控制方案。利用从集散控制系统采集的大量现场数据,运用基于多元线性回归方法的软测量建模技术,建立了塔顶丁二烯-1,3产品纯度的软测量模型,并基于此对控制回路进行改造,设计了推断控制方案。通过DeltaVDCS系统自带的CL语言编写软仪表程序,并在控制策略组态环境Control Stud io中实现控制回路的改造。现场运行结果表明,控制系统能够有效地解决精馏塔产品质量不能在线实时检测和直接质量闭环控制的问题,实现了丁二烯-1,3产品纯度的闭环控制,显著改善了控制效果。     

On-line multivariable adaptive control of a binary distillation column

An experimental evaluation of the simultaneous control of top and bottom product compositions of a binary distillation column utilizing multi-variable self-tuning control algorithms is presented. The study was carried out using an 8-tray, 22.86 cm diameter methanol–water pilot scale column with continuous capacitance analysis of top product composition and bottom composition analyzed on a 3 minute cycle, by a gas chromatograph. Column control is studied for ±25% step disturbances in feed flow rate. Terminal composition regulation using both ‘positional’ and ‘incremental’ forms of a generalized minimum variance self-tuning control algorithm is compared with that achieved using a conventional digital PI/PID multiloop control strategy.     

Time optimal start-up strategies for reactive distillation columns

In this contribution, a rigorous process model to simulate the start-up of a cold and empty reactive distillation (RD) column is developed and experimentally validated with a transesterification process. Strategies for time optimal start-up of an RD column are presented. The mostly used strategy for conventional distillation of total reflux for RD is only recommendable with limitations. New, alternative strategies, like the recycling of the off-spec bottom and top product or the initial charging with product, to minimize the necessary start-up time are presented. Suitable strategies can save up to 82% of the needed time for the column start-up.     

About the possibility of a direct concentration control for distillation columns

The results of simulations of direct concentration control of a distillation column in industrial scale are presented. Both controlled variables, the two product concentrations, are determined by on-line gas chromatographs and are characterised by high dead times of about 30 min. For the resulting scanning control of the product concentrations corresponding decentralised PI controllers were developed and applied. The control of the product concentrations developed presents a conventional DV structure and was exemplarily tested for disturbances in feed flow and feed concentrations. The calculations carried out exhibit a good time behaviour of the whole system. On this occasion it can be stated that the control quality could be clearly improved if a steady-state decoupling by output transformation was employed. In this case the results achieved are totally comparable to those of internal model control (IMC), which was in use at the production plant for over two years.     

高纯乙腈连续精制工艺及计算机智能控制系统设计与应用

设计了高纯度乙腈连续精制工艺流程,应用先进的计算机监控技术与智能控制技术实现过程的实时监测与自动控制。工艺应用变压、共沸、精馏等技术,有效地解决了产品纯度和收率低等难题,计算机监控系统由S7-300 PLC、IPC及iFIX加以构建,针对大惯性、大时滞对象,采用自适应模糊-Smith智能控制策略来提高系统稳态精度与自适应能力。工业应用表明,过程运行稳定、系统实时性强、控制精度高、产品质量高、经济效益显著。     

二异丁烯反应精馏生产过程控制策略设计

二异丁烯是一种重要的化工中间体,近年来研究者提出了以催化裂化C₄为原料、采用反应精馏技术同时生产高纯二异丁烯和汽油添加剂的新工艺。由于反应精馏过程中非线性程度高,稳定控制困难,使得采用反应精馏技术生产二异丁烯过程的控制策略研究较少。采用Aspen dynamic软件进行动态模拟,针对反应精馏生产二异丁烯过程开发了温度控制方案、组分温度联合控制方案和组分温度串级控制方案。对3个控制系统进行（±10）%的进料流量扰动和（±5）%组成扰动测试并进行对比。结果表明：组分温度串级控制方案在添加扰动的情况下依然保证了二异丁烯质量分数99%,三异丁烯质量分数小于10%以及异丁烯转化率大于99%的要求,并且最终稳定时间约5 h,具有更好的抗干扰性能。研究结果能够为二异丁烯产品的生产工艺工业化应用提供设计依据。     

Design and Control of Heterogeneous Azeotropic Distillation for Separating 2‐Methylpyridine/Water

In industrial processes, 2‐methylpyridine/water mixtures can be separated via the conventional heterogeneous azeotropic distillation (HAD) using benzene as entrainer. 2‐Methylpyridine and water can form a heterogeneous azeotrope by themselves, based on which an improved HAD process is proposed. This allows for reducing the total operating cost and total annual cost (TAC) by more than one‐tenth compared with the conventional HAD process. Two different control structures were established for the enhanced HAD process. The results indicate that applying the feedforward ratio controllers to the control structure can handle the feed disturbances and maintain product purities with smaller transient deviations and shorter settling times.     

基于一般模型控制的高纯内部热耦合精馏策略

内部热耦合精馏塔（ITCDIC）是精馏节能控制的一个前沿。本文提出了一种基于一般模型控制（GMC）的内部热耦合精馏塔的先控策略,以解决导致传统线性控制策略难以得到较好控制效果的高纯下内部热耦合精馏塔的非线性。以苯-甲苯物系作为研究实例,对所提出的高纯ITCDIC控制策略进行了详细研究。设定值改变和过程扰动下的控制品质表明了所提出的高纯ITCDIC的GMC控制策略的切实有效性。     

A self tuning controller for multicomponent batch distillation with soft sensor inference based on a neural network

Multicomponent batch distillation is an operation difficult to control not only for its nonlinear and transient behaviour, but because the product quality cannot be measured rapidly and with reliability. In the present work, a computational system for direct digital control is developed for a pilot plant batch distillation column. The development of a self tuning regulator and a soft sensor of composition based on a neural network is described. Top and reboiler temperature measurements are the basis for the on-line composition inference. The computational system was experimentally tested in a computer operated pilot column. It could be seen that the neural network soft sensor is a feasible and a reliable tool to solve on-line operational problems of the control engineering systems. The developed control system permits to operate the batch distillation column efficiently and is easy to be implemented and operated.     

On the asymmetric behavior of distillation systems

The aim of this paper is to characterize a particular but relevant aspect of the dynamic behavior of binary distillation systems. More in detail, attention is paid to the well known result that, for step changes of reflux, the leaving and back transients of the top product concentration have different lastings. Such a phenomenon, here referred as “asymmetry”, is described by means of an “asymmetric function”, defined as the ratio of the settling times of the leaving and back transients. The analysis of the asymmetry function leads to the conclusion that the equilibrum state, at which distillation systems usually work, is such that every transient leaving this state is faster than the corresponding back one. Moreover, it is shown how the phenomenon is influenced by the operating conditions of the distillation system and by some characteristic parameters of the binary mixture (relative volatility and concentration).     

甲醇-苯共沸体系变压精馏分离工艺的动态控制

基于甲醇和苯共沸体系的压敏性,利用Aspen Plus和Aspen Dynamics软件对变压精馏分离该体系的稳态工艺进行了模拟和优化,研究了该工艺的动态特性,提出了控制产品纯度的3种控制结构：基础控制结构、比例控制结构和双比例与温度?组分联合控制结构,通过对控制结构添加±20%的组分和流量干扰测试控制结构的稳定性. 结果表明,基础控制结构基本能实现稳健控制,但不能解决组分干扰引起的产品纯度偏差过大等问题;比例控制结构可实现相对稳健的控制,但改进效果不显著;双比例与温度?组分联合控制结构在受到20%进料和组分干扰后,产品纯度能较快恢复至设定值的99.90%,实现稳健控制.     

Design and control of pressure-swing distillation for separating ternary systems with three binary minimum azeotropes

The separation of ternary nonideal systems with multi-azeotrope is very important because they are often found in the waste of chemical and pharmaceutical industries, which is much more difficult due to the formation of multi-azeotrope and distillation boundary. We propose a systematic procedure for design and control of a triple-column pressure-swing distillation for separating ternary systems with three binary minimum azeotropes. This procedure involves thermodynamic insights, a two-step optimization method, and effective control strategy. The separation of tetrahydrofuran (THF)/ethanol/water is used to illustrate the capability of the proposed procedure. It is found that the pressure limits in columns can be determined through the analysis of residue curve maps, distillation boundary, and isovolatility curves. The optimal triple-column pressure-swing distillation is generated with the minimum total annual cost (TAC) of $2.181 × 10⁶ in sequence A. The operating conditions are well controlled approaching their desired specifications in an acceptable time when disturbances occur. © 2019 American Institute of Chemical Engineers AIChE J, 65: 1281–1293, 2019     

乳酸提纯新工艺动态建模仿真和控制系统设计

基于非平衡级和拟均相假设,建立了乳酸提纯反应精馏新工艺实验装置的动态机理模型.通过改进的数值计算方法提高了模型的求解效率,设计并实现了包含物性估算系统的模型仿真平台,以促进新工艺的工业化应用.利用仿真平台对新工艺装置进行了动态特性分析,在此基础上设计了两种单端质量控制方案:直接物料平衡和间接物料平衡方案.在不同类型和幅度的过程扰动下,分析比较了两种控制方案的调节性能.结果表明直接物料平衡方案控制品质优于间接物料平衡方案,可在不同扰动情况下满足过程的产品质量和转化率的联合控制要求.非平衡级动态机理模型能够反映反应精馏过程的动态特性,分析发现反应精馏过程有着独特的过程特性,基于机理模型的仿真平台是分析反应精馏特性的有效工具.     

异构反应-分子蒸馏分离合成O,S-二甲基硫代磷酰胺

对O,O-二甲基硫代磷酰胺催化异构-分子蒸馏合成O,S-二甲基硫代磷酰胺的工艺进行了研究。得到了异构反应-分子蒸馏分离的优化工艺条件:反应温度40~50℃,反应时间3 h,蒸馏温度90~100℃,操作压力20~40 Pa。10 t/a中试装置运行表明:将分子蒸馏分离得到的原料重新异构得到O,S-二甲基硫代磷酰胺的质量分数与总收率分别为92.8%、94.2%。