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Abstract: An integrated framework of simulation and heuristics is proposed. The main emphasis is
on vertical integration of simulation and heuristics which exploits the inherent interlink between
them. By adopting this framework, simulators can be more efficiently utilized and they also offer
invaluable support to the decisions taken by heuristics. This framework is successfully applied to
Hydrodealkylation of toluene (HDA) process. An analysis of the results shows that the proposed
framework builds synergies between the powers of simulation and heuristics thereby resulting in a
practical PWC methodology to develop a viable control system. Copyright 2005 IFAC
1. INTRODUCTION
In the past, unit-based control system design
methodology has been widely used to design PWC
control systems. However, recent stringent
environmental regulations, safety concerns and
economic considerations, demand design engineers to
make chemical processes highly integrated with
material and/or energy recycles. Several researchers
(e.g., Luyben et al., 1998) studied the effect of these
recycles on the overall dynamics and concluded that
these recycles need special attention while designing
PWC systems as they change the dynamics of the
plant in a way which may not always be apparent
from the dynamics of the individual unit-operations.
Hence, because of the highly integrated nature of
recent plants, unit-based methodology seems to be
scarcely equipped to design the control system for
such complex plants. This necessitates development
of better methodologies which can deal with the
highly integrated processes in a more efficient way.
This leads to the concept of PWC which demands
Plant-Wide perspective while designing PWC
systems.
Designing control systems for the integrated
processes is challenging because of the large
combinatorial search space available. For example,
Plant-Wide
Control
Heuristics
Rigorous
Nonlinear
Simulation
Models
1
2
3
5
6
7
4. APPLICATION OF PROPOSED
METHODOLOGY TO HDA PROCESS
Because of space limitations, only a brief description
of all steps in the application of the proposed
methodology to the HDA process is given. This part
of the study would reveal features of the proposed
integrated framework of simulation and heuristics in
the context of PWC. Step number in the following
refers to that in Table 1.
Step
1.1:
Control
objectives
(production
specifications and process constraints) are taken from
Douglas (1988). Coming to the stability related
objectives, steady-state perturbation analysis showed
that the process is open-loop unstable because of the
presence of plug flow reactor with feed effluent heat
exchanger. It is also observed that the process can be
stabilized by fixing the reactor inlet temperature.
Step 1.2: Control degrees of freedom is found to be
23.
Step 2.1: Most anticipated load disturbances (toluene
feed flow rate/composition variations) and set-point
85
60
40
CV
MV
20
0
0
100
200
300
Time (Minutes)
400
500
80
75
70
65
ProductionRate
(lbmol/hr)
200
400
600
Time (Minutes)
800
1000
285
280
275
270
265
260
Conversion (%)
Conversion (%)
TolCondLC (%)
75
70
65
0
200
400
600 800
Time (Minutes)
100
200
300
Time (Minutes)
400
500
1000
(lbmol/hr)
ProductionRate
285
280
275
270
265
260
Before
After
200
300
70
CV
60
MV
50
40
0
100
200
300
Time (Minutes)
400
500
290
(lbmol/hr)
ProductionRate
100
Time (Minutes)
280
270
260
0
500
Toluene Component
Inventory (lbmol/hr)
Conversion (%)
80
5
0
-5
Series1
Series2
Series3
-10
-15
-20
0
200
400
600
Time (Minutes)
800
1000
72% ( )
70% ( )
80% ()
70% ( )
100 ( )
100 ( )
1000 ()
300 ( )
Conversion
(Measure of
Economic
Performance)
Settling Time
(Measure of
Dynamic
Performance)
Equipment
Constraints
(Measure of Safe
Operation)
5. CONCLUSIONS
An integrated framework of simulation and heuristics
for PWC system design of industrial processes is
proposed and successfully applied to HDA process. It
also includes an improved heuristic methodology for
PWC system design. Results show that a viable
control system can be generated by the proposed
framework which retains the powers of both
heuristics and simulation. The gist of the present
work is that the control system design (especially for
complex processes) cant be accomplished just by
heuristics and/or quantitative techniques without the
aid of rigorous nonlinear simulation tools. It seems
like common sense but it is worth repeating at this
stage, especially in the context of PWC as researchers
in the past have not given enough attention to the
Plant-Wide simulators in PWC system design.
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