Product and Process Modelling. A Case Study Approach PDF
Preview Product and Process Modelling. A Case Study Approach
Product and Process Modelling Product and Process Modelling A Case Study Approach Ian Cameron SchoolofChemicalEngineering TheUniversityofQueensland Australia Rafiqul Gani DepartmentofChemical&BiochemicalEngineering TechnicalUniversityofDenmark Denmark AMSTERDAM.BOSTON.HEIDELBERG.LONDON.NEWYORK.OXFORD PARIS.SANDIEGO.SANFRANCISCO.SINGAPORE.SYDNEY.TOKYO Elsevier TheBoulevard,LangfordLane,Kidlington,OxfordOX51GB,UK Radarweg29,POBox211,1000AEAmsterdam,TheNetherlands Firstedition2011 Copyright(cid:1)2011ElsevierB.V.Allrightsreserved Nopartofthispublicationmaybereproduced,storedinaretrievalsystem ortransmittedinanyformorbyanymeanselectronic,mechanical,photocopying, recordingorotherwisewithoutthepriorwrittenpermissionofthepublisher PermissionsmaybesoughtdirectlyfromElsevier’sScience&TechnologyRights DepartmentinOxford,UK:phone(+44)(0)1865843830;fax(+44)(0)1865853333; email:permissions@elsevier.com.Alternativelyyoucansubmityourrequestonlineby visitingtheElsevierwebsiteathttp://elsevier.com/locate/permissions,andselecting ObtainingpermissiontouseElseviermaterial LibraryofCongressCataloging-in-PublicationData AcatalogrecordforthisbookisavailablefromtheLibraryofCongress BritishLibraryCataloguinginPublicationData AcataloguerecordforthisbookisavailablefromtheBritishLibrary ISBN:978-0-444-53161-2 ForinformationonallElsevierpublications visitourwebsiteatwww.elsevierdirect.com PrintedandboundinGreatBritain 11 12 13 14 10 9 8 7 6 5 4 3 2 1 Contributors Inadditiontotheauthors(CameronandGani),thefollowingpersonscontrib- utedtothechapters-sectionslistedbelow. Chapter/ Author Address section Title Dr.Ricardo CAPEC,Departmentof 7.2 Complexintegrated Morales-Rodriguez ChemicalandBiochemical operation:Direct Engineering,Building229, methanolfuelcell TechnicalUniversityof 12.1 Microcapsule-based Denmark,DK-2800Lyngby, controlledrelease Denmark MartinaHeitzig CAPEC,Departmentof 5.3 Evaporationfroma ChemicalandBiochemical droplet Engineering,Building229, 7.3 Multiscalefluidised TechnicalUniversityof bedreactor Denmark,DK-2800Lyngby, 11.6 Parameterregression– Denmark dynamicoptimisation Dr.ChiaraPiccolo CAPEC,Departmentof 5.2.3 Activitycoefficient ChemicalandBiochemical model-2:Elec-NRTL Engineering,Technical UniversityofDenmark, Building229,DK-2800 Lyngby,Denmark Dr.RavendraSingh PROCESS,Departmentof 12.2 Fermentationprocess ChemicalandBiochemical modelling Engineering,Building229, 12.3 Milkpasteurisation TechnicalUniversityof modelling Denmark,DK-2800Lyngby, 12.4 Millingprocessmodel Denmark 12.5 Granulationprocess model 12.6 Pharmaceuticaltablet pressingprocess modelling NoorAsmaFazli CAPEC,Departmentof 10.1 Batchcooling AbdulSamad ChemicalandBiochemical crystallisation Engineering,Building229, modelling(population TechnicalUniversityof balancemodelling) Denmark,DK-2800Lyngby, Denmark (continued) ix x Contributors Chapter/ Author Address section Title Prof.Maurico DepartamentodeProcesosy 7.4 Dynamicchemical Sales-Cruz Tecnolog´ıa,Divisio´nde reactor CienciasNaturalese 7.5 Dynamic Ingenier´ıa,Universidad polymerisation Auto´nomaMetropolitana– reactor CuajimalpaArtificiosNo, 8.3 Short-pathevaporation 40.SegundoPiso, model Col.Hidalgo,Del.A´lvaro 9.1–9.2 TennesseeEastman Obrego´n,01120,M(cid:1)exicoD.F. ChallengeProblem 11.1–11.5 ModelIdentification (Parameter Estimation) 14.2 ICAS-MoTmodel library Preface Thisisacasestudybookonproductandprocessmodelling.Ithasarisenfrom over30yearsofworkinginprocesssystemapplicationsthatrequiredmodelsto beconceptualised,formulated,builtanddeployedforarangeofuses.Modelling is ultimately goal-driven and we are particularly mindful that for modelling ‘‘onesizedoesnotfitall’’applications.Weneedtobecognizantoftheend-goal aswecarryoutthemodellingactivity.Onethingthathasbeenreinforcedover those30yearsisthatmodellingisastructuredactivity–weneedamodelling methodologytobeeffectiveinmodelbuildinganddeployment.Throughthese case studies you will see that methodology is being exercised across a wide range of modelling applications. Case studies can be a powerful means of understanding how models are formulated, built and used, so we hope this understandingmightbeenhancedthroughtheseexamples. Thebookisessentiallypracticalinnature,asthereareseveralwell-known books that deal with the theory and methodologies that underpin modelling practice.Ourintentionisnottorepeatthoseideasbutgivepracticalexpression tothoseprinciples. Tothisend,wegiveabriefcoverageoftheuseandnatureofmodellingto helpsetthecontextofwhatfollows.Thisincludesthepracticalaspectsthatare importantinmodellingandsomereflectionsontheburgeoningavailabilityof modellingtools,manyofwhichcanhelpconceptualisemodels,provideexpert analysisofthe propertiesofthe model aswellasprovideefficientsolutionof thosemodels.Wearenowaccustomedtoseeinglarge-scalecommercialmodels solvedaspartofreal-timeapplicationsintheindustry. The following chapters provide insights into such areas as constitutive models as well as models for steady-state and dynamic applications. We also consideraspectsoflumpedparameteranddistributedparametermodellingvia industrialapplicationsdrawnfromawiderangeofindustries.Thereareexam- ples around specific industry sectors which are of current interest. The case studiesillustratetheubiquitousnatureofmodellingapplicationsandshow,ina measuredway,justwhatcanbederivedfromsuchactivities. Inconcludingthecasestudies,wemakeanumberofreflectionsaroundthe future of product and process modelling – a dangerous activity, given how quickly developments and innovations take place! Not only the benefits from modellingneedtobeappreciatedbypractitionersbutarealeffortneedstobe madeby practitioners tomoreeffectivelycommunicate the benefitsofappro- priate modelling and deployment across the product and process life cycle. Muchstillneedstobedone. xi xii Preface Of course this book is the product of many people, not just the principal authors.Weareverythankfultothelargenumberofresearchstudentswhohave worked with us over many years in developing methodologies, exercising the principlesandapplyingtheresultantmodellingtoarangeofapplications.Inthis matter,wealsoacknowledgethemanyindustrialsupportersofworkleadingto model development and application. This has been through collaborative researchprogrammesandindustrialconsultingactivities.Wethankthosewho havegivenpermissiontopresentsomeofthiswork. Notably,wewouldalsothankmanyclosecolleaguesinouracademicinsti- tutionsaswellasmanyintheprocesssystemsengineeringcommunityworld- widefromwhomwehavebenefittedfrominsights,conceptsandpractice. Wearehopefulthatthesecasestudieswillbehelpfultomanywhoareinthe various stages of the modelling experience – from the novice through experi- encedpractitionertotheexpert. IanCameronandRafiqulGani Chapter 1 Modelling: Nature and Use Thisbookdealswithabroadcoverageofmodellingconceptsandapplications forthedevelopmentofproductsandprocesses.Itpresentstheseideasthrough case studies, showing the importance of modelling to a wide spectrum of discovery activities and decision making processes, that ultimately bring new insightsandideastorealityforsocial,industrialandeconomicapplications. Therearenumerousbooksandpapersavailablethatdealwithspecificissues intheconceptualisation,development,solutionanddeploymentofmodels,for applicationsinmanydomainsofresearch,business,manufacturingandproduc- tion.Modelsareubiquitous—fromthoseembeddedasfuzzymodelapplications in washing machines through medical applications in anaesthetics, to models thatattempttopredictclimatevariability.Modelsareroutinelyusedinallareas ofhumanendeavourandappearinvarioustypesandforms. Thisbookpresentsanumberofapplicationsareas,modelformsandtypes, givinginsightsintosomeoftheimportantconceptsbehindmodelling,andthe driversforusingmodelsinvariousapplications. 1.1. MODELLINGFUNDAMENTALS Modellinginprocessandproductengineeringhasalonghistory.Itisnowclear that much of the design and discovery processes in productand processengi- neering, are facilitated by various forms of modelling. The decision making processes that are interwoven into the whole of the life cycle, are heavily influencedbymodelling,simulationandvisualisation. Modelling, in its minimal form, is the representation of a real or virtual physico-chemical,economic,socialorhumansituation,inanalternatemathe- maticalorphysicalform,foranenvisagedpurpose. Thissimpledefinitionhasthreeimportantconcepts:anidentifiedsystem(S) whichisthesubjectofinterest,anintendedpurpose(P)forthemodelintermsof decisionmaking,andarepresentationalform(M)ofthemodel.Thekeycon- ceptshaveassociatedwiththemawiderangeofissues,relatingtodetailsofthe system,purposeandform.Anextendeddiscussionofsuchissuescanbefound elsewhere,asitisnotthepurposeinthisbooktodwellonthosematters(Aris 1999,Hangos&Cameron2001). 1 2 ProductandProcessModelling:ACaseStudyApproach However, the following sections sketch out some of the key ideas that underpin what is presented in the case studies that appear in subsequent chapters. 1.1.1. SystemsPerspectivesforModelDevelopment Weneedsystematicwaysoftacklingmodellingproblems.Ofparticularimpor- tanceistheapplicationofsystemsperspectivestomodellingactivities. Figure1showsatypicalsystemsframeworkusedforconceptualisationofa model.Allmodellingapplicationscanbecastintosuchaframework,allowing the modeller to formally describe the system under study. It is equally appli- cable to the modelling of a complex reactor, as to the interaction model of a humanoperatorwithtechnology,ortothemodelofactiveingredienttake-upof sprayedagrochemicalsontoaleafsurface.Assuch,theformalismhasasignif- icantdescriptivepower.Thechallengeforthemodellerisinunderstandingthe individualaspectsofthesystem,whichrequiremodelling.Modellingrequires significantinsightintothesystemunderstudy. InFigure1ageneralsystem(S)withitsboundaryastheboxisgiven.The statesofthesystemplusinputs,outputsanddisturbances,areshown. Thefollowingmeaningcanbegiventothecomponentsofthesystem– * Boundary:Thisprovidesthelimitsofthemodelconsideration.Itisvitalto restrict the modelling through a clearly defined boundary. Modelling the behaviourofasinglecomponentinaprocessoperationwilluseadifferent boundary,tothatforacompleteproductionunit. * Boundariescan alsobehierarchicalinnature,inthatboundariesforlower level detail can be agglomerated into higher levels of view. Likewise, the decompositionofhigherlevelviewsintofinerdetailcanbeachievedasthe modellinggoalchanges. * System: The principal entities within the boundary, and their interconnec- tions, including the primary mechanisms operating in that system. The entitiescanbepiecesofprocessingequipment,phases,people,particlesetc. [(Figure_1)TD$FIG] FIGURE1 Asystemsperspectiveformodellingpurposes.
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