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A Real-time Approach to Distillation Process Control PDF

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A Real- time Approach to Distillation Process Control iii A Real- time Approach to Distillation Process Control Brent R. Young University of Auckland New Zealand Michael A. Taube S&D Consulting, Inc Houston, Texas, USA Isuru A. Udugama The University of Waikato New Zealand This edition first published 2023. © 2023 John Wiley & Sons, Inc. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording or otherwise, except as permitted by law. Advice on how to obtain permission to reuse material from this title is available at http://www.wiley.com/go/permissions. The right of Brent R. Young, Michael A. Taube, and Isuru A. Udugama to be identified as the authors of this work has been asserted in accordance with law. Registered Office John Wiley & Sons, Inc., 111 River Street, Hoboken, NJ 07030, USA For details of our global editorial offices, customer services, and more information about Wiley products visit us at www.wiley.com. Wiley also publishes its books in a variety of electronic formats and by print- on- demand. Some content that appears in standard print versions of this book may not be available in other formats. Trademarks: Wiley and the Wiley logo are trademarks or registered trademarks of John Wiley & Sons, Inc. and/or its affiliates in the United States and other countries and may not be used without written permission. All other trademarks are the property of their respective owners. John Wiley & Sons, Inc. is not associated with any product or vendor mentioned in this book. Limit of Liability/Disclaimer of Warranty In view of ongoing research, equipment modifications, changes in governmental regulations, and the constant flow of information relating to the use of experimental reagents, equipment, and devices, the reader is urged to review and evaluate the information provided in the package insert or instructions for each chemical, piece of equipment, reagent, or device for, among other things, any changes in the instructions or indication of usage and for added warnings and precautions. While the publisher and authors have used their best efforts in preparing this work, they make no representations or warranties with respect to the accuracy or completeness of the contents of this work and specifically disclaim all warranties, including without limitation any implied warranties of merchantability or fitness for a particular purpose. No warranty may be created or extended by sales representatives, written sales materials or promotional statements for this work. The fact that an organization, website, or product is referred to in this work as a citation and/or potential source of further information does not mean that the publisher and authors endorse the information or services the organization, website, or product may provide or recommendations it may make. This work is sold with the understanding that the publisher is not engaged in rendering professional services. The advice and strategies contained herein may not be suitable for your situation. You should consult with a specialist where appropriate. Further, readers should be aware that websites listed in this work may have changed or disappeared between when this work was written and when it is read. Neither the publisher nor authors shall be liable for any loss of profit or any other commercial damages, including but not limited to special, incidental, consequential, or other damages. Library of Congress Cataloging- in- Publication Data Names: Young, Brent R., author. | Taube, Michael A., author. | Udugama, Isuru A., author. Title: A real-time approach to distillation process control / Brent R. Young, University of Auckland New Zealand, Michael A. Taube, S&D Consulting, Inc, Isuru A. Udugama, The University of Waikato, New Zealand. Description: Hoboken, NJ, USA : Wiley, [2023] | Includes bibliographical references and index. Identifiers: LCCN 2022051966 (print) | LCCN 2022051967 (ebook) | ISBN 9781119669210 (cloth) | ISBN 9781119669241 (adobe pdf) | ISBN 9781119669272 (epub) Subjects: LCSH: Distillation. | Chemical process control. Classification: LCC TP156.D5 Y58 2023 (print) | LCC TP156.D5 (ebook) | DDC 663/.506–dc23/eng/20230111 LC record available at https://lccn.loc.gov/2022051966 LC ebook record available at https://lccn.loc.gov/2022051967 Cover Image: Wiley Cover Design by © 06photo/Shutterstock Set in 11.5/13.5pt STIXTwoText by Straive, Pondicherry, India Dedicated to those from whom we (and you, the reader) have benefited: William Y. Svrcek, PhD Robert V. Bartman, PhD Robert D. Kirkpatrick, PhD Contents Preface � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � xiii About the Companion Website � � � � � � � � � � � � � � � � � � � � � �xv 1 Introduction ���������������������������������������1 1�1 The Purpose of Process Control ������������������������������1 1�2 Introduction to Distillation ����������������������������������5 1�3 Distillation Process Control ����������������������������������7 1�4 A Real- Time Approach to Distillation Process Control Education ��9 Tutorial and Self-Study Questions �������������������������������11 References � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �11 2 Fundamentals of Distillation Control �����������������13 2�1 Mass and Energy Balance: The Only Means to Affect Distillation Tower’s Behavior � � � � � � � � � � � � � � � � � � � � � � �15 2�2 Control Design Procedure ����������������������������������19 2�3 Degrees of Freedom ��������������������������������������20 2�4 Pairing � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �24 2�5 Gain Analysis ���������������������������������������������29 2�6 Common Control Configuration ����������������������������31 2�7 Screening Control Strategies via Steady-S tate Simulation �������33 Tutorial and Self-S tudy Questions ������������������������������34 References � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �35 3 Control Hardware ����������������������������������37 3�1 Introduction ���������������������������������������������37 3�2 Control Hardware Overview ��������������������������������38 3�3 Sensors � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �39 3�3�1 Process Considerations �������������������������������40 viii Contents 3�3�2 Flow Measurement Devices ����������������������������41 3�3�3 Pressure Measurement Devices ������������������������43 3�3�4 Level Measurement Devices ���������������������������44 3�3�5 Temperature Measurement Devices ��������������������47 3�3�6 Direct Composition Measurements ���������������������47 3�3�7 Maintenance � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �48 3�4 Final Control Elements �������������������������������������48 3�4�1 Linearity � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �49 3�4�2 Time Constant and Failure Mode �����������������������49 3�4�3 Mechanical Design Considerations ���������������������50 3�5 Controllers/CPU ������������������������������������������50 3�5�1 Level 0 � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �52 3�5�2 Level 1 � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �52 3�5�3 Levels 2 and 3 � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �53 3�5�4 General Set Up and Considerations ���������������������54 3�6 Modern Trends �������������������������������������������54 3�6�1 Wireless Communication and Smart Devices �������������55 3�6�2 Smart CPUs � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �55 3�6�3 Digital Twins� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �56 Tutorial and Self-S tudy Questions �������������������������������56 References � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �57 4 Inventory Control ����������������������������������61 4�1 Pressure Control ������������������������������������������61 4�1�1 Total Condenser �������������������������������������62 4�1�2 Flooded Condensers ����������������������������������64 4.1.3 Sub- Cooled Reflux ������������������������������������67 4�1�4 Partial Condenser ������������������������������������69 4�2 Level Control ���������������������������������������������71 4�2�1 Surge Capacity Control� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �72 4�2�2 Open- Loop Stable versus Integrating Processes ����������75 4�2�3 Calculating the Process Gain for Vessel Levels ������������76 4�2�3�1 Vertical Cylinder Vessels ������������������������77 4�2�3�2 Horizontal Cylinder Vessels ���������������������80

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