1.

= ratio of latent heats of vaporization. moles .4mole B

(lb. A/lb. B)
K = total latent heat content of vapor stream in rectifying
section, B.t.u./hr.

LT

12

L = liquid flow rate, moles/hr. (lb./hr.)

.E

S = bottom boilup ratio

V = vapor flow rate, moles/hr. (lb./hr.)
TV = bottoms product rate, moles/hr. (lb./hr.)
x = mole fraction of component A in liquid (weight fraction)
y = mole fraction of component A in vapor (weight fraction)
cy
= relative volatility
X = heat of vaporization, B.t.u./mole (B.t.u. lb.)

U
LL

.E

o_
Io

E
w

0
5

= mole fraction of feed which is vapor (weight fraction)

R = overhead reflux ratio

.2

.2

.4

.6

.8

1.0

MOLE FRACTION OF A IN LIQUID

Figure 7. McCabe-Thiele plot for R = 2, g = 1

8 stages indicated, feed above 5ih p l d e

possible range of g is much greater. For instance, in mass

units, g = 4.4 for the acetone-\vater system.
Nomenclature
D = distillate product rate, moles/hr. (lb./hr.)
F = feed rate, moles/hr. (lb./hr.)

SUI~SCRIPTS
A = low boiling component
B = high boiling component
D = distillate
F = feed
m = plate number in stripping section
n = plate number in rectifying section
,V = bottom plate in column
TV = b o t t o m
literature Cited

(1) Alleva, R. Q., Chem. Eng. 69,111 (Aug. 6, 1962).

(2) Hovarth, P. J., Schubert, R. F., Zbid., 64, 129 (Feb. 10, 1958).
(3) Lewis. W. K.. J . Znd. Ene. Chem. 14.492 (1922).
/4\ Lowenstein. J. G.. Znd. E m . Chem. 54. 61(1962).
(5j McCabe, W, L., Smith, f C.. Unit Operations of Chemical
Engineering, McGraw-Hill, New York, 1956.
(6) McCabe, W. L., Thiele, E. W., Znd. Ene. Chem. 17, 605 (1925).
(7) Peters, W. A., J . Ind. Eng. Chem. 14, 476 (1922).
(8) Robinson. C. S., Gilliland, E. R., Elements of Fractional
Distillation p. 127, McGraw-Hill, New York, 1950.
RECEIVED
for review January 14, 1963
ACCEPTEDJune 14, 1963

CONTROL OF A DISTILLATION COLUMN FOR

PRODUCING HIGHIPURITY OVERHEADS
AND BOTTOMS STREAMS
J . S. MOCZEK, ROBERT E. OTTO, AND THEODORE J . W I L L I A M S

Monsanto Chemical Co., St. Louis, Mo.

A digital computer study was performed to investigate the control of a large column for producing very highpurity overheads and bottoms. The column simulated represents the first unit of a BTX (benzene, toluene,
xylene) distillation train. The operation involves removal of low boiling constituents b y pasteurization,
with benzene withdrawal as a side stream. Extremely close control of side-stream flow rate i s necessary to
satisfy material balance requirements. Since small deviations from the correct rate exhibited large effects
on plate temperature, temperature-indexed control of side-stream rate appeared promising. However,
trays having the greatest temperature sensitivity to side-stream rate showed an anomalous behavior-their
temperature increased with both decreases and increases of boilup rate. A control system adapted to the
effects noted was developed. No results from actual operating columns are included.

considerable information has appeared concerning

the dynamics and automatic control of distillation
columns, much of this discussion has been confined to relatively small columns ( 7 , 6-8, 70, 72, 73, 75, 78, 79). This
is due mainly to the very large amount of calculation necessary
to develop such data on digital computing machines for large
columns (9, 7 7 , 72) and the difficulty of obtaining sufficient
valid experimental data on such columns (2-4).
HILE

288

I&EC PROCESS DESIGN A N D DEVELOPMENT

This paper presents some of the results of a n extensive digital

computer study of the dynamics and control of large columns
by the Monsanto Chemical Co. T h e operation of columns
designed for very close separation of overhead and bottoms
products was chosen for study, since their control is especially
critical. A typical illustration is provided by the first distillation unit of a BTX (benzene, toluene, xylene) fractionation
train.

Figure 1 presents a dragram of a typical benzene distillation

unit of a B T X separation train.
T h e feed. containing some 50 mole % benzene and a small
amount of .light ends (mostly water), is separated into a n
overhead product having a specified benzene content in excess
of 99.94 mole yoand a bottoms product containing less than 0.05
mole % benzene. Because of the wet feed, a pasteurizing
section at the top of the column provides light ends removal,
and the benzene product is withdrawn as a liquid side stream
directly belo\+ the pasteurizing section. T h e wet distillate,
normally about 1% of the feed, is removed a t conditions
approaching total reflux, and recycled to process.
Operation of this column is extremely critical because of the
very high purity requircbments placed on the benzene product.
and on the subsequent products of the fractionation trainLe., toluene and xylene. Thus, not only must the benzene be
exceptionally pure in the column overhead, but the column
must send as much as possible of this benzene to the overhead
product to prevent its contaminating the heavier constituents
in the bottoms product stream.
Many designers tend to employ reflux ratio adjustment as a
standard method of product purity control. A control scheme
for the present columr based on this principle is shown in
Figure 1. Here, a temperature controller set for maintaining
a specified temperatur: a t a given location in the column
controls reflux flow. T h e side-stream r a t e is regulated by a
level controller in rhe reflux accumulator. An analyzer for
the bottoms product guides the control of column boilup.
\Vhile reflux ratio contrtol is normally satisfactory. its suitability

Figure
2.
Alternative
scheme for top product
composition control

Sidestream P r o d u c t

for the operation described was questioned because of the

apparent need of maintaining exact material balance flow of
the side stream to achieve the high degree of separation required.
An alternative control method for the top section of the
column (Figure 2) involves the adjustment of side-stream
withdrawal, rather than reflux ratio per .re, for maintenance of
product composition. This scheme employs temperature
control of side-stream rate, with reset of the temperature or
flow set point provided by a chromatograph-controller which
analyzes the side-stream product. O u r discussion here is
confined to comparing these methods of top product control.
T h e related problem of bottoms composition control is covered
in earlier references (75, 77, 78).
Digital Computations and Preliminary Results Obtained

3TX F e e d
P

FC--

--t-y--

?e:oiier

Column

--

Sidestrear Product

-2
a
>

i/

Bettors

Figure 1.

Diagram of distillation system

AC.
AR.
FC.
11C.
RAC.
TC.

Analyzer controller
Analyzer recorder
Flow controller
liquid level controller
Ratio controller
Temperature controller

,4 series of digital computer calculadons was made to investigate the effect of operating changes on product quality and
column conditions existing a t steady-state conditions, to
appraise the relative merits of the two control methods, and
to establish a desirable location for the sensing element of the
temperature controller, which would be used with either
method of control. A program similar to that of Rose,
Sweeney, and Schrodt ( 9 )and that of Rosenbrock ( 7 7 , 72). with
added provisions for a complete heat balance of each plate,
was employed with the IBM 704 computer. I n common
with all other known multicomponent programs employing the
relaxation method, computations are made in terms of theoretical, rather than actual, plates. Thus, 39 theoretical rather
than 50 actual trays were simulated on the computer. This is
a necessary and to all indications valid approximation to the
real case. Pertinent data on the column simulated and the
operating conditions selected for study are given in Table I.
Calculated values of physical time constants of various parts
of the column system, representative of the simulated conditions, are given in Table 11.
T h e results of the steady-state calculations made for establishing the characterisrics of the column (Table 111) indicate
the effects of reboiler heat input, side-stream rate, and feed
composition changes on the purity of the product streams
and on the temperature and composition a t several theoretical
plates in the column. T h e conditions a t theoretical plates
21. 22. and 23 are of special interest, since they are sufficiently
close to the feed plate to provide large temperature sensitivity,
but sufficiently removed from it to avoid appreciable temperaVOL.

NO. 4

OCTOBER 1 9 6 3

289

Table 1.

Physical Data and Operating Specifications for

Column Sim ulated

Diameter
Trays
Number
Efficiency, %
Pressure drop, p.s.i.
Feed location

8 feet 6 inches

Side-stream location
Pasteurizing section
Condenser
Operating pressure, p.s.i.g.
Calculated holdups, moles
Condenser, accumulator, and
reflux piping
Trays
Above feed
Below feed
Sump, reboiler, and piping
Total
Feed
Rate, moles/min.
Temperature, O F.
Composition, mole

50 plus reboiler
78
0,14/theoretical tray
Plate 23, actual
18, theoretical
Plate 46, actual
36, theoretical
Plates 47-50 inc., actual
37-39 inc., theoretical
Total
3 . 0 (top of column)
240
139
174
470
1023

Table II.

Calculated Physical Time Constants of Simulated

Column

Column trays
Weir flow time constant
'FT

= A/K =

27.1 sq. ft.

700 sq. ft./min.

0.039 min.

weir flow area

weir coefficient

Liquid mixing time constant

'.WIT =

V/F

11.80 cu. ft.

94.4 cu. ft./min.

0.125 min.

volume
liquid flow rate
Sump? reboiler, and piping
H e a t transfer time constant
W,C,
UA

HR

6,290 Ib. metal x 0.124 B.t.u.ilb.. O F.

2.78 (B.t.u./'F.,min.,sq. ft.) x 2090sq. ft.

0.134 min. =

heat capacity
heat flow rate

Liquid mixing time constant

Overhead rate,
mole/min.
Side stream
Rate, moles/min.
Required composition, mole %
Bottoms
Rat?, moles/min.
Required composition, mole %

22.26
200
-50 benzene
-50 toluene, xylene, and
heavy ends, small amounts
of light ends, water, etc.
0.2233 (li ht ends plus some
benzene?
11.204
>99,94 benzene

'MR =

V/F

967 cu. ft.

97.6 cu. ft./min.

9.91 min.

Condenser, accumulator, a n d reflux piping

Liquid mixing time constant
'.WA

365 cu. ft.

V / F = 52.3 cu. ft./min.

6.98 min

10.833
<OO. 05 benzene
Effects of Boilup Rate on Tray Temperatures

ture effects from the xylene present in the feed. T h e steadystate conditions a t theoretical plate 28 illustrate the behavior a t
the more removed location.
I n all cases, feed a t essentially saturated conditions was
admitted a t theoretical plate 1 which had been established
by previous calculations as the optimum feed location for the
"base conditions" selected. T h e calcuIaTed values corresponding to these conditions a r e given in item 1 of Table 111.
T h e effects of a 25% increase a n d a 25% reduction in heat
input on product composition a r e given in items 2 a n d 3>
respectively. T h e effects of corresponding changes in the
side-stream flow rate, shown in items 4 a n d 5: illustrate the
relatively minor effect of vapor rate o r reflux ratio. T h e
critical importance of maintaining correct material balance
flow conditions is indicated in items 6 a n d 7> which show the
pronounced effect of minute changes in side-stream rate on The
product compositions. These results demonstrate conclusively that the purity of the side-stream a n d bottoms products is
primarily dependent on the control of side-stream rate: rather
than on reflux ratio, thus establishing the basic superiority of
the proposed control scheme shown in Figure 2.
A comparison of items 1> 6, a n d 7 in Table I11 shows that
small changes in product composition resulting from incorrect
material balance are accompanied by significant temperature
changes a t theoretical plates 21 to 23. As would be anticipated, rhe temperature changes a t locations further removed
from the feed point, such as a t theoretical tray 28, are considerably smaller. This directs the choice of locations for the
sensing element of the temperature controller, a t least for this
particular case, to the former plates.
290

I&EC

PROCESS DESIGN A N D DEVELOPMENT

However, upon comparing items 2 and 3 with item 1? a n

anomalous behavior is noted-the temperatures a t theoretical
plates 21 to 23 increase when the column boilup is either reduced or increased by 25% from the base value. A s shown in
items 8, 9, and 11, a similar temperature increase of varying
magnitude is obtained a t these plates \vhen the reboiler heat
input is increased by 3 5 15: and 5%. Item 12 shows that
under conditions where the boil up is reduced by 5%. plate
temperature may be either reduced o r increased. depending on
the plate location. Theoretical plate 28 exhibits relatively
normal temperature and composition behavior with respect to
the boilup changes, a n d the effect of boilup on product composition also appears normal.
Figures 3 a n d 4 illustrate the anomaly just mentioned by
plotting the tray temperature offset caused by boilup changes.
Tray 28 is the first tray which does not show significant "reverse
tem,perature behavior" in the range of boilup rate considered.
Calculations were then made for several other types of upset
conditions Ivhich might affect the column, to determine if the
anomalous behavior just exhibited occurred for these conditions as well. Reductions in feed rate and feed composition
cause termperatme changes of approximately the same magnitude (items 14 and 16) and thus set u p nearly equal control
correction errors whether the temperature sensor is on tray 21
or 28.
O n the other hand, as indicated by items 13 and 15, increases in feed rate a n d feed composition cause decidedly
different responses a t the t\vo plates in question. T h e response
on tray 21 is approximaeely one third the size a n d opposite in
sign to that for decreases in rate and composition, while the
response of tray 28 amounts to only a fraction of a degree change
in temperature or about one fiftieth of that previously obtained. If one were to use temperature response alone from

Table 111.

Item
1

2
3
4
5
6
7
8
9

10
11
12
13
14
15
16
17
18
19

20

Effects of Boilup, Side-Stream Rate, and Feed Changes on Product Composition and Plate Temperature
Temperature, F.
Side-Stream
( M o l e Fraction Benzene)
Rate,
Mole Fraction Benzene
Theo.
Theo.
Theo.
Moles/
Theo.
Description
plate 22
plate 23
plate 28
Minute
plate 21
Side stream
Bottoms
193.34
Base conditions
207.71
200.14
0.99986
206.04
0.89 x 10-4
11.2040
(0.986)
(0.870)
(0.815)
(0.748)
193.27
201.50
205.35
210.10
Reboiler heat input increased 25y0
0 . 1 8 x 10-4
11 ,2040
0.99993
(0.988)
(0.752)
(0.833)
(0.657)
199.53
208.44
Reboiler heat input reduced 25 %
209.88
0,99359
211.31
0.66 x
11 ,2040
(0.824)
(0.671)
(0.651)
(0.633)
223.33
226.04
Side-stream flow rate increased 25y0
226.70
14.0050
0.80008
227.55
0 . 5 9 x 10-4
(0.333)
(0.330)
(0,329)
(0.328)
192.86
195.88
Side-stream flow rate reduced 25%
196.94
0.99999
0.2054
8.4030
198.46
(0.999)
(0.978)
(0.962)
(0.934)
194.76
207.55
Side-stream flow rate increased 0.05 yo 0,99944
211.23
214.82
0.44 x 10-4
11.2091
(0,691)
(0.947)
(0.621)
(0.558)
195.38
213.15
209.57
Side-stream flow rate increased 0.07y0
0.41 X
11.2114
216.48
0.99925
(0.931)
(0.646)
(0.581)
(0.525)
193.30
202.50
Reboiler heat input increased 35y0
206.91
212.20
0.99993
0 . 1 2 x 10-4
11 ,2040
(0.987)
(0.716)
(0.808)
(0.611)
193.26
200.64
Reboiler heat input increased 15%
203.95
208.10
0.99991
0.31 X
11 ,2040
(0.988)
(0.855)
(0.785)
(0.701)
194.01
Reboiler heat input reduced 15%
204.00
201.60
0,99947
206.69
11 ,2040
0.49 x 10-3
(0.968)
(0.831)
(0.784)
(0.734)
Reboiler heat input increased 5%
193.30
202.97
200.10
206.55
11.2040
0.99989
0.59 X
(0.988)
( 0 , 8 0 9 ) (0.868)
(0.736)
Reboiler heat input reduced 5%
193.44
202.71
200.14
0.14 x 10-3
0.99981
205.81
11.2040
(0,983)
(0.867)
(0.815)
(0.753)
193.06
199.14
197.45
33% feed rate increase
0,2054
0.99993
201 .40
11 ,2040
(0.993)
(0.936)
(0.904)
(0.860)
20y0 feed rate reduction
227.40
230.18
0,80009
230.78
231.53
0 . 2 6 x 10-5
11 ,2040
(0.260)
(0,264)
(0.259)
(0.258)
Mole fraction benzene in feed in192.90
196.97
195.98
0,2055
0.99998
198.29
11 ,2040
creased 0 10
(0.998)
(0,961)
(0.976)
(0.939)
Mole fraction benzene in feed re227.09
230.50
231 ,27
11.2040
229.88
0.16 X
0.80141
ducrd 0 10
(0,269)
(0.265)
(0.264)
(0.263)
+ l o % benzene, -10% toluene
193.17
198.98
0 . 1 3 x 10-3
13.430
197.51
0,99985
200.85
change in feed compn.. side(0.935)
(0.990)
(0.873)
(0.909)
stream rate adjusted
-10% benzene. + l o % toluene
203,72
0.99988
0.96 X
193.53
212.96
8.977
208.06
change in feed compn., side-stream
(0,981)
(0.779)
(0,596)
(0,690)
rate adjusted
4-5y benzene. -7y0 toluene change
198.02
202.13
193.18
0,99988
0.92 x 10-4
12,399
199.82
in feed compn., side-stream rate
(0.990)
(0.922)
( 0 , 8 4 2 ) (0.887)
adjusted
- 11 g/, benzanc, +2% toluene
0,99993
193.23
200.75
208.89
204.31
0 . 5 9 x 10-4
8.756
change in feed compn., side-stream
(0.685)
(0.989)
( 0 , 7 7 7 ) (0.852)
rate adjusted

tray 28 as the control error measurement. a n entirely different

set of gain adjustrrents would be necessary. T h e use of the
chromatograph can be .a major aid in correcting this situation.
Thus, except for considerations in controller gain required,
either tray 21 or 28 could serve as the location of a temperature
sensor for these latter upsets; only the boilup changes cauw
the anomalous behavior described.
T h e anoiraly in respclnse obtained with boilup variations is
d u e to changes in the distribution of the heavier components
about the feed plate. This results from the slight variations in
colurrn liquid-vapor ralios present and causes corresponding
changes in colurrn operating te.i.perature. Since the vaporliquid equilibrium betu.een benzene and toluene is extrer.ely
sensirive to re-nperature: changes in the disrribution of the
heavier components can easily lead to a radical displacement
of plate locations on the McCabe-Thiele diagram with a
corresponding feed plate mismatch.

Temperature Offsets on Test Trays after

Correction of Various Upsets

Several additional calculations were made to establish the

degree of consistency between the final operating temperatures
of the test trays and product quality a t altered operating conditions. I n these calculations, the concentration of rhe individual components in the feed \vas varied over a r o d e r a t e
range, and the side-stream Lvithdrawal rate was adjusted to
yield product com.positions approximating those obtained
under the base conditions. T h e results are shown in iterrs 17
through 20 of Table 111. T h e computed producc compositions illustrate the pronounced material balance behavior
of the co1um.n under the conditions of the study. I n each case,
the side-stream rate exployed was sirrply calculated on rhe
assumption that the benzene content of the product stream.s
\vould be the sarre as that under the base conditions. T h e
close a g r e e r e n t of ihe results de-ronstrates the high fracrionatVOL. 2

NO.

OCTOBER

1963

291

-101

85

90

35

100

IO5

110

115

120

125

130

135

P e r c e n t of Base Case RebDiler Heat Input

Figure 3. Effect of reboiler heat input variations on

temperature of theoretical plates 2 0 to 24
Time, Minutes

Figure 5. Effect of size of computation interval on accuracy of computed distillation transient

Time-

Figure 6.

Figure 4. Effect of reboiler heat input variations on temperature of theoretical plates 25 to 29

Method of estimating dead time

1. Draw o tangent to the transient response at the inflection point

and extend the tangent to the initial value of transient
2. Point a i s the composition change at intersection of the tangent with
the horizontal axis. Point b, 2.7180, is located on the graph at the
identical time value
3. A line parallel to the tangent through point b locates the equivalent
dead time, Td

Column Transients and Their Effect on Control

ing ability of the column under the given operating conditions.

Items 17 through 20 show that very significant changes in
the steady-state temperatures occur a t theoretical plates 21
through 23 as a result of feed composition changes, when
product composition is maintained relatively constant. Again,
only minor changes in the steady-state values occur a t theoretical plate 28 as a result of these changes.
292

l&EC PROCESS DESIGN A N D DEVELOPMENT

T h e computation methods used in this study can readily

give both the transient response of a column to a particular
upset and the steady-state condition of the column resulting
from the same upset. As in all such stepwise computations of
transient conditions by digital computers (77), care must be
taken to choose the computation interval time small enough to
give a true response while large enough no to waste machine
time. Figure 5 illustrates the effect of interval size on transient

Figure 7. Transient response of composition of

theoretical plates 0, 10,
and
18 with step
change of side-stream
flow to 1 25% of correct
value

1.0

09

Figure 8. Transient response of composition

of theoretical plates 23,
28, and 36 with step
change of side-stream
flow to 125yo of correct value

>

03
r
z

07

i
D

--

36

0 5

11

0.3

c
E

0.2

L 7

3.:

column response to a typical upset. 4n interval size of 0.10

minute or less must be used for accuracy.
However. in cases such as the present, where the tray
efficiency is not loo%, some small but unknown inaccuracy is
introduced in the transient response calculations, since these
are based on theoretical plates rather than actual stages.
Distillation column responses to step inputs usually have the
appearance sketched in Figure 6. Thus there is a definite
period of time (apparent dead time) during which a detecting device itould nor know that a n upset had occurred. T o
assign a definite number to it, the graphical procedure of
Figure 6 is often used (5, 74). The resulting number will
vary greatly betxteen different plates in the column as shown
by Figures to 12. Figures 7 and 8 illustrate the determination of the dead time for several plates in the column for the
same upset. one involving the imposition of a step change of a
2SyOincrease in side-stream flow rate. Figure 9 summarizes

these data for the whole column; Figures 10 and 11 show

corresponding data for differing sizes and directions of such
upsets. Dead time is confined to the end trays of the column
and is apparently larger for smaller upsets, in agreement with
previous work on column equilibration time ( 8 ) .
Since dead time can severely influence the stability and
response of a control system (76, 79), every effort must be
made to keep it as small as possible, Therefore, the temperature-sensing tray for the column control scheme must be
chosen to accomplish this while bearing in mind the temperature effects previously discussed. Thus, tray 28 would again
be chosen since it is the first tray without a temperaturereversal effect and has the smallest possible dead time.
Figure 12 gives the dead times found from the response to a
step change in feed composition. These results are very similar
to the responses to side-stream take-off rate changes, except
that a feed composition upset affects both ends of the column.
VOL. 2

NO. 4

OCTOBER 1963

293

Figure 9. Dead time

characteristics of column
with step change of
side-stream flow
to
125% of correct value

Figure 10. Dead time

characteristics of column
with step change of sidestream flow to 1 1 2.5y0
of correct value

T h e o r e t i c a l P l a k Numbei

Use of Analyzer and Other Considerations

With the establishment of the best position for the temperature-sensing element and the determination of the penalties
involved with the use of this and other locations, one can
evaluate the best method of using the analyzer sampling the
side-stream product composition. Should it be used to reset
the temperature controller? Or: to reset the side-stream flow
controller itself along with the temperature controller to compensate for possible insensitivities in that element? These two
possibilities are illustrated by Figure 13.
I n the case of a tray 21 location for the temperature element,
the steady-state temperature offsets tested in Table I11 must he
removed by a n integral action on the part of the analyzer
controller. Since a large dead time is present a t the sidestream location, along with an appreciable analysis time for
many analytical devices such as chromatographs, this correc294

l&EC

PROCESS DESIGN A N D DEVELOPMENT

tion is a long process a t best. I n addition, systems with these

long dead times often exhibit a n oscillatory behavior. The
arrangement of Figure 13 (upper) would be necessary for an
adequate use of the analyzer controller to correct the operation of the temperature controller.
Since the tray 28 response is so one-sided, the best use of the
analyzer controller is to compensate for this effect-that
is,
allow the temperature controller to correct for decreases in feed
rate and feed composition where large errors in temperature
occur, but use the analyzer controller set a t a high gain to
correct for increases in feed rate and feed coinposition where
the temperature controller is very insensitive. To accomplish
this, the analyzer controller must be set to take positive composition errors only; otherwise, it will tend to overcorrect for
those cases where the composition should fall below the desired
side-stream value. T h e arrangement of Figure 13 (lower)

Figure 1 1 . Dead time

characteris:ics of column
with step change of sidestream flow to 75y0 of
correct value

i 10.0

7.5

5.0
I

2.5
Reboiler

IC

12

I4

;6

I8

20

22

24

26

28

yg;&y&

30

32

35

j6

Theoretical Plale Number

'

~I

I0

12

I4

16

I8

T b e o r e t i c a ' cla!e

20

22

24

26

28

30

32

34

j6

NuTier

would thus give the most satisfactory performance where tray

28 temperature responses were being used.
Conclusions

When temperature is being considered as the primary

sensing element for control of large distillation columns, the
following must be kept in mind in choosing the correct tray for
mounting the sensing element:
1. T h e possibility of a n anomalous temperature response of
trays near the feed plate, where the presence of minor components can upset the normal column-temperature pattern
and alter the vapor-liquid equilibria between the keys.
2. T h e magnitude of steady-state offsets in plate temperature in correcting for operating conditions away from the
design case. Kormally, these offsets decrease as one moves
further away from the feed plate.

3. For columns with a large number of plates, dead time

in column response profiles may seriously affect controllability.
Kormally, large dead time effects are confined to plates near
the ends of the column. This \yould direct the movement of the
temperature-sensing element to a tray near the feed tray-in
contradiction to the statements above.
1. T h e best compromise is, therefore. the lowest tray
(nearest the feed) which satisfies the requirements of items 1
and 2.
5. T h e addition of the chromatograph to the control loop
as a secondary sensing element provides the possibility of two
uses of this information.
In case of an incorrect temperature element tray location for
any reason, it can act as a set point changer to correct for the
temperature offset a t a new steady-state operating condition.
For correct temperature sensor locations, it can act as a
' f i n e tuner" of side-stream take-off rates to compensate for
possible errors in take-off flow rates due to instrument drift.
etc., in particular for correcting side-stream or product take-off
rates \vhen a n upset has increased product composition.
VOL. 2

NO.

4 OCTOBER 1 9 6 3

295

literature Cited

(1) Archer, D. H., Rothfus, R. R., Chem. Eng. Progr. Symp. Ser.
57, NO. 36, 2-19 (1961).
(2) Berger, D. E., Campbell, G. G., Chem. Ens. Progr. 51, 348-52
(1 955).
(3) Berger, D. E., Short, G. R., Znd. Eng. Chem. 48, 1027-30
(1 9 56).
(4) Hoyt, P. R., Stanton, B. D., Petrol. Refiner 32, 115-19 (October
1953).
(5) Oldenbourg, R. C., Sartorius, H., The Dynamics of Automatic Control, pp. 99-1 57, American Society of Mechanical
Engineers, New York, 1948.
(6) Rademacher, O., Rijnsdorp, J. E., Dynamics and Control of
Continuous Distillation Columns, Proceedings of 5th World
Petroleum Congress, Paper 5, Section VII, May 1959.
(7) Rijnsdorp, J. E., Maarleveld, A., Use of Electrical Analogues
in the Study of the Dynamic Behavior and Control of Distillation Columns, pp. A63 ff., Symposium on Instrumentation and
Computation in Process Development and Plant Design, May
1959, Institution of Chemical Engineers, London.
(8) Rose, A,, Johnson, C. L., Williams, T. J., Znd. Ens. Chem.
48, 1173-9 (1956).
(9) Rose, Arthur, Sweeney, R. F., Schrodt, V. N., Zbid., 50, 737-40
(1958).
(10) Rose, A,, Williams, T. J., Ibid., 47, 2284-9 (1955).
(11) Rosenbrock, H. H., Brit. Chem. Ens. 3, 364-7, 432-5, 491-4
(1 958).
(12) Rosenbrock, H. H., Trans. Znst. Chem. Ens. London 35, 347-51
(1 9 5 7).
(13) Rosenbrock, H. H., Tavendale, A. B., Storey, C., Challis,
J. A,, Transient Behavior of Multicomponent Distillation
Columns, Preprints of Papers, International Federation of Automatic Control Congress, Moscow, June 27 to July 7, 1960,
pp. 1277-82, Butterworths, London, 1960.
(14) Smith. 0. J. M., ZSA J . 6 , 28-33 (February 1959).
(15) Williams, T. J., Znd. Ens. Chem. 50, 1214-22 (1958).
(16) Williams, T. J., ZSA J . 9, 39-42 (July 1962).
(17) Williams, T. J., Harnett, R. T., Chem. Eng. Progr. 53, 220-5
(19.57).
(18) Williams, T. J., Harnett, R. T., Rose, A,, Znd. Ens. Chem.
48, 1008-19 (1956).
(19) Williams, T. J., Min, H. S., I S A J . 6, 89-93 (September
1959).
RECEIVED
for review September 26, 1962
ACCEPTED
March 8, 1963
Division of Industrial and Engineering Chemistry, 142nd meeting,
ACS, Atlantic City, N. J., September 1962.

7
Figure 13. Uses of analyzer controller
as secondary control element in column
control

Upper.

Resetting of temperature set point

lower.

Fine tuning of flow control

PROCESS OPTIMIZATION B Y
SEARCH TECHNIQUES
D

H I MM ELB LA U

Department of Chemical Engineering, The University of Texas, Austin 12, Tex.

An adaptive search technique is proposed to solve the following type of problem: Maximize or minimize an
objective function subject to linear or nonlinear constraints of the form G i ( X I , x2 , x,) = 0, 1 5 i 5 m;
m
n. The objective function itself may b e linear, nonlinear, or expressed as some integral. An example
application is presented for a simplified butane isomerization process.

<

HIS REPORT is concerned with the general problem of finding

Ta
solution to a set of m simultaneous equations with n
unknowns, \\.here the n unknowns can be subject to constraints.
Of special interest here is the case where the number of unknowns is greater than the number of independent equations,
and consequently a best solution can be obtained only if a
criterion of best is available as some objective function.

296

l&EC PROCESS DESIGN A N D DEVELOPMENT

..

While a wide choice of methods of solution is available

when all the equations and the objective function are linear,
the same cannot be said if the equations and/or the objective
function are nonlinear. Certainly there is ample room in this
area for new suggestions as to iterative or other techniques to
resolve such difficult problems with simplicity and speed. A
new method of handling this problem is described, that of a n