Model predictive control of reactive distillation for benzene hydrogenation

Benzene hydrogenation via reactive distillation is a process that has been widely adopted in the process industry. However, studies in the open literature on control of this process are rare and seem to indicate that conventional decentralized PI control results in sluggish responses when the reactive distillation column is subjected to disturbances in the feed concentration. In order to overcome this performance limitation, this work investigates model predictive control (MPC) strategies of a reactive distillation column model, which has been implemented in gPROMS. Several MPCs based upon different sets of manipulated and controlled variables are investigated where the remaining variables remain under regular feedback control. Further, MPC controllers with output disturbance correction and, separately, with input disturbance correction have been investigated. The results show that the settling time of the column can be reduced and the closed loop dynamics significantly improved for the system under MPC control compared to a decentralized PI control structure.     

Two-point control of a reactive distillation column for composition and conversion

Reactive distillation is a hybrid process with dual process objectives: reactant conversion and product composition. Control schemes for reactive distillation frequently neglect the effect of the principal operating parameters on the reactant conversion, and this has a detrimental effect on the overall process profitability. An ETBE reactive distillation column has been used as a case study to show how a two-point control configuration, which recognises the importance of both composition and conversion, can be developed and implemented for a reactive distillation process. The combined composition and conversion control configuration was tested using SpeedUp dynamic simulations and proved to be effective in maintaining a high isobutylene conversion despite process disturbances. The two-point control scheme also had superior disturbance rejection capability, especially for feed rate changes, and composition set-point sensitivity compared with a one-point control scheme.     

Comparison of pressure-swing distillation and extractive distillation with varied-diameter column in economics and dynamic control

Pressure-swing distillation and extractive distillation are two common methods for azeotrope separation. The economics and controllability are two crucial factors for evaluating the feasibility of a separation process. A varied-diameter column (VDC) was used in the process design to evaluate its economics and controllability. Five azeotropic systems were investigated in order to compare the economics of pressure-swing distillation and extractive distillation with a VDC. Results indicate that pressure-swing distillation with a VDC saves more money than extractive distillation. The dynamic control were evaluated in the acetone-methanol system for both processes with a VDC. The improved control structure for pressure-swing distillation with a VDC can handle ±20% disturbances effectively, while the improved control structure for extractive distillation with a VDC can only handle ±10% disturbances. A comparison of the two methods from the viewpoint of economics and controllability demonstrates that pressure-swing distillation is more suitable when using a VDC.     

Role of multiplicity in reactive distillation control system design

The impact of steady-state multiplicities on the control of a simulated industrial scale methyl acetate reactive distillation (RD) column is studied. At a fixed reflux rate, output multiplicity, with multiple output values for the same reboiler duty, causes the column to drift to an undesirable steady-state under open loop operation. The same is avoided for a fixed reflux ratio policy. Input multiplicity, where multiple input values give the same output, leads to “wrong” control action under feedback control severely compromising control system robustness. A new metric, rangeability, is defined to quantify the severity of input multiplicity in a steady-state input–output (IO) relation. Rangeability is used in conjunction with conventional sensitivity analysis for the design of robust control structures for the RD column. Results for the two synthesized control structures show that controlling the most sensitive reactive tray temperature results in poor robustness due to low rangeability causing “wrong” control action for large disturbances. Controlling a reactive tray temperature with acceptable sensitivity but larger rangeability gives better robustness. It is also shown that controlling the difference in the temperature of two suitably chosen reactive trays further improves robustness of both the structures as input multiplicity is avoided. The article brings out the importance of IO relations for control system design and understanding the complex dynamic behavior of RD systems.     

Pattern-based predictive control for ETBE reactive distillation

Synthesis of ethyl tert-buty ether (ETBE), a high-performance fuel additive, through reactive distillation (RD) is an attractive route, while its operation and control are exceptionally difficult due to its functional combination and complex dynamics. Modern control technology greatly relies on good process models, while a reasonable RD model is too complex for control design. Moreover, RD contains considerable uncertainties that cannot be well described in process modelling. Alleviating the model requirement, this work aims to maintain the product purity in RD of ETBE through developing a pattern-based predictive control (PPC) scheme. Process dynamics, control structure, nonlinear transformation, feature pattern extraction, and pattern-based prediction and its incorporation with a conventional linear controller are discussed. Case studies show the effectiveness of the proposed method     

Control of reactive distillation production of high-purity isopropanol

The process characteristics and control strategy of a high-purity IPA reactive distillation column were investigated. A robust nominal operation was found by maintaining an excess of propylene feed to the column and recycling the unreacted propylene to the feed instead of the top stage. Stage temperature and propylene composition with one-to-one relationship with reboiler duty and propylene feed are selected as controlled variables for maintaining bottom purity and feed ratio in the presence of possible measurement bias respectively. High nonlinearity between selected input–output pair was reduced by using variable transformation. Dynamic simulations demonstrated that such a control scheme with nonlinear transformed variable was capable of providing much superior control performance than the one using natural variable.     

Effect of interaction multiplicity on control system design for a MTBE reactive distillation column

The control strategy of a reactive distillation for synthesis of MTBE is investigated. Although steady state multiplicities occur in the column, a linear control is still possible since a controlled and manipulated variable-pairing scheme that exhibits a sufficiently large range of near linear relations can be found, if we operate at constant reflux ratio. Reboiler duty is used to control the temperature of a stage just below the reaction section and near the top of the stripping section. Stoichiometric balance is controlled by a feed ratio plus internal composition control scheme, using a control valve installed on the C4 feed-line as the manipulated variable. Such a scheme is capable of maintaining the desirable steady state that achieves high product purity and reactant conversion. However, a similar scheme that uses a control valve installed on the methanol feed-line as the manipulated variable shows severe oscillation. It is caused by multiplicity in the interaction between the temperature and stoichiometric control loops.     

Application of predictive control techniques to a distillation column

Model-based predictive control techniques are widely recognized as having useful application to control problems characterized by complex dynamics and severe time delay. The establishment of a representative process model is the key step in the procedure and for anything other than trivially simple systems is a major hurdle. This paper describes the application of predictive control techniques to a distillation problem which embodies a pure time delay of 2–3 h and time constants of 3–4 h. A sampled-data process model is identified from monitored input/output data and from this a predictive control algorithm is designed. The application of the controller has resulted in very effective closed-loop control of the base composition of the distillation column, where previously only manual supervision was possible.     

Adaptive dynamic matrix control of a distillation column with closed-loop online identification

This paper presents an online identification technique where a process is identified in terms of pseudo impulse response coefficients and subsequently used to update convolution type models to accommodate process-model mismatch. As an example, dynamic matrix control has been applied adaptively to control the top product composition of a distillation column for both servo and regulatory problems. The algorithm automatically detects a large step-like disturbance requiring fresh identification of the process and subsequently adapts the controller to the new model. Simulation studies using an analytical dynamic full order model of a distillation column demonstrated the usefulness of the adaptation scheme. Experimentation on a pilot scale distillation unit vindicated the simulation results.     

Combined internal model and inferential control of a distillation column via closed-loop identification

A procedure for designing distillation control systems with spe cified nominal properties is presented. The desired behaviour of the control system for both setpoint changes and disturbances in the feed flow rate and the feed composition can be specified. Both types of specifications can be handled because the disturbances can be inferred from the behaviour of the inventory control system. The control system is realized as a combined internal model and inferential control (CIMIC) system. A disturbance rejecting and decoupling (DRD) control structure is obtained as a special case. The performance of the control system is demonstrated experimentally on a pilot-scale distillation column. For comparison, experiments with pure internal model control (IMC) are also illustrated. A preliminary model of the distillation column was determined from step tests carried out in open-loop operation, but the final model used in the control system designs was obtained via a control-relevant closed-loop identification.     

Control of reactive distillation process for production of ethyl acetate

In this paper, plant-wide control for the production of ethyl acetate using reactive distillation is studied. Four important issues are considered in developing control schemes, including: (1) economics; (2) steady-state deviation of key product purities; (3) controllability in terms of degree of oscillation and settling time; and (4) feasible region of disturbances for effective control. Starting with two basic control schemes that have been studied before, new control schemes are developed to improve the operability of the process. These new control schemes have evolved from the basic schemes by making a trade-off between optimal design and control or by selecting sensor locations using closed-loop sensitivity analysis. It is found that, while being subjected to fluctuations in the composition of the acid feed or in the production flow-rate, sensor location based on traditional open-loop sensitivity causes a larger overshoot and steady-state deviation of key product purities. Sensor location on the basis of a closed-loop sensitivity analysis provides a better alternative for feedback control. The resulting scheme for control is found to be effective in reducing the steady-state deviation and in promoting good control performance.     

Plant-wide design and control of acetic acid dehydration system via heterogeneous azeotropic distillation and divided wall distillation

Energy-saving plant-wide design and plant-wide control of an acetic acid dehydration system with the feed containing methyl acetate and p-xylene are investigated in the study. A heterogeneous azeotropic distillation using isobutyl acetate as an entrainer is designed to obtain high-purity acetic acid at the column bottom and to keep a small acetic acid loss through the top aqueous draw. The accumulation of p-xylene in the column is avoided by adding a side product stream. The mixture in the aqueous phase of decanter, containing mostly water, methyl acetate, and isobutyl acetate is separated using a divided wall distillation column. The whole acetic acid dehydration system includes a heterogeneous azeotropic distillation column and a divided wall distillation column.The control strategies using temperature loops are proposed for this acetic acid dehydration system. For the heterogeneous azeotropic distillation column, the requirements for acetic acid compositions in both the aqueous phase of the decanter and the column bottom can be satisfied by designing entrainer inventory temperature control and cascade temperature control simultaneously. The stages of controlled temperatures are chosen by singular value decomposition and closed-loop analysis methods based on the criteria of minimum entrainer makeup. For the divided wall distillation column, steady-state analysis methods are used for the selection of proper controlled and manipulated variables and the determination of their pairings. Dynamic simulation results demonstrate that the proposed plant-wide control strategy can maintain product purities and reject external disturbances in feed flow and composition changes as well as internal disturbances such as changes in liquid and vapor splits.     

模拟甲基叔丁基醚反应精馏的过程

为揭示反应精馏过程的耦合特性,从而为进一步开发新的反应精馏设计方法提供理论支持,采用Gibbs自由能平衡级模型,应用Aspen Plus软件模拟分析MTBE的反应精馏过程,研究了回流比与理论板数对反应和分离效果的影响。结果表明由于反应和精馏的相互作用,在固定回流比改变理论板数(或固定理论板数改变回流比)的情况下,存在最佳理论板数(或回流比)使产品组成最高,这种特性与普通精馏有所不同。     

Experimental investigation of conventional control strategies for a heterogeneous azeotropic distillation column

In this work, a laboratory scale sieve plate distillation column was constructed to investigate the conventional control strategies of an isopropyl alcohol (IPA), cyclohexane (CyH) and water (H₂O) heterogeneous azeotropic distillation column. Steady state process analysis showed that the optimal operation point should be located at a critical reflux, a transition point at which the distillation path switches from a route that passes through IPA+H₂O azeotrope to one that passes through IPA+CyH azeotrope. At this critical reflux, a high purity IPA product can be obtained with minimum energy consumption and maximum product recovery. However, the steady state is extremely sensitive to feed disturbances. A good control strategy must be able to maintain a steady column temperature profile that shows a plateau near 70°C to ensure passage around IPA+CyH azeotrope. In this study, an inverse double loop control strategy is recommended. Through experimental testing, the proposed control strategy was demonstrated to keep the product IPA purity at the desired high-purity level under all feed disturbance changes while other conventional control strategies fail.     

Object-oriented approach applied to ANFIS modeling and control of a distillation column

Neurofuzzy networks are hybrid systems that combine neural networks with fuzzy systems, and the Adaptive Neuro-Fuzzy inference system (ANFIS) is a particular case in which a fuzzy system is implemented in the framework of an adaptive neural network. This neurofuzzy approach represents an effective structure to the modeling of plant dynamics, and the oriented-object programming environments offer an intuitive way to address this task. In this paper the MODELICA object-oriented environment has been applied to the ANFIS modeling and indirect control of the heavy and light product composition in a binary methanol-water distillation column by using the adaptive Levenberg–Marquardt approach. The results obtained demonstrate the potential of the adaptive ANFIS scheme under MODELICA for the dual control of composition both for changes in set points with null stationary error even when disturbances are present.     

Nonlinear observer-based Lyapunov boundary control of distributed heat transfer mechanisms for membrane distillation plant

This paper presents a nonlinear observer-based Lyapunov control for a membrane distillation (MD) process. The control considers the inlet temperatures of the feed and the permeate solutions as inputs, transforming it to boundary control process, and seeks to maintain the temperature difference along the membrane boundaries around a sufficient level to promote water production. MD process is modeled with advection diffusion equation model in two dimensions, where the diffusion and convection heat transfer mechanisms are best described. Model analysis, effective order reduction and parameters physical interpretation, are provided. Moreover, a nonlinear observer has been designed to provide the control with estimates of the temperature evolution at each time instant. In addition, physical constraints are imposed on the control to have an acceptable range of feasible inputs, and consequently, better energy consumption. Numerical simulations for the complete process with real membrane parameter values are provided, in addition to detailed explanations for the role of the controller and the observer.     

Nonlinear model-based control of a batch reactive distillation column

The inherent trade off between model accuracy and computational tractability for model-based control applications is addressed in this article by the development of reduced order nonlinear models. Traveling wave phenomena is used to develop low order models for multicomponent reactive distillation columns. A motivational example of batch esterification column is used to demonstrate the synthesis procedure. Tight control of the column is obtained with the use of reduced model in a model predictive control algorithm.     

Dynamics and control of totally refluxed reactive distillation columns

According to the mechanism of the reaction operation involved, reactive distillation columns are often designed to work in a totally refluxed operation mode. The totally refluxed operation mode makes the reflux drum interact solely with the reaction operation involved and retards considerably the dynamics of the latter. The resultant great difference in process dynamics between the reaction operation and the separation operation involved leads frequently to under-damped responses with the degree of under-dampness closely dependent on the inventory control of the reflux drum. With the tight inventory control of the reflux drum, the degree of under-dampness can be suppressed and this presents a favorable effect to process dynamics and controllability of the totally refluxed reactive distillation columns. Two hypothetical ideal reactive distillation columns with and without a side reaction, respectively, and a high-purity ethylene glycol reactive distillation column are employed to examine the unique dynamics and controllability of the totally refluxed reactive distillation columns. The results obtained are in good accordance with the above interpretation. The current work reveals the general behaviors of the totally refluxed reactive distillation columns and can be particularly useful in control system synthesis and design.     

High-purity control of internal thermally coupled distillation columns based on nonlinear wave model

Internal thermally coupled distillation column (ITCDIC) is a frontier of energy saving distillation researches, which is a great improvement on conventional distillation column (CDIC). However its high degree thermal coupling makes the control design a bottleneck problem, where data-driven model leads to obvious mismatch with the real plant in the high-purity control processes, and a first-principle model which is comprised of complex mass balance relations and thermally coupled relations could not be directly used as control model for the bad online computing efficiency. In the present work, wave theory is extended to the control design of ITCDIC with variable molar flow rates, where a general nonlinear wave model of ITCDIC processes based on the profile trial function of the component concentration distribution is proposed firstly; combined with the thermally coupled relations, a novel wave model based generic model controller (WGMC) of ITCDIC processes is developed. The benzene-toluene system for ITCDIC is studied as illustration, where WGMC is compared with another generic model controller based on a data-driven model (TGMC) and an internal model controller (IMC). In the servo control and regulatory control, WGMC exhibits the greatest performances. Detailed research results confirm the efficiency of the proposed wave model and the advantage of the proposed WGMC control strategy.     

乙酸丁酯反应精馏过程模拟设计

反应精馏偶合了反应和精馏两种单元操作,通过精馏促进反应,可以提高反应转化率和收率,为可逆反应的化工过程生产提供了新的设计途径。基于严格热力学分析计算,利用计算机模拟和优化手段。提出了乙酸丁酯反应精馏、分离纯化的生产流程。采用UNIQUAC方程表征乙酸-正丁醇-乙酸丁酯-水四元非理想体系的汽液平衡,首先,根据实验数据回归了热力学模型中的交互作用参数,并预测了体系中5个共沸物组成,模型的计算结果与实际数据吻合。基于平衡级模型,提出了由平衡反应器、反应精馏塔、倾析器和纯化塔构成的可行流程,对提出的设计流程进行了模拟、优化,得到了操作工艺参数。模拟结果对工业过程的设计和改造具有一定的指导意义。