Cornput. ckm. En@& Vol. 12, No. 1, pp. l-14, 1988 0098.1354/88 $3.00 + 0.

00
F’rintedin Great Britain. AI1 rights reserved Copyright 0 1988 Pcrgamon Journals Ltd

A GENERALIZED DYNAMIC MODEL FOR DISTILLATION

COLUMNS-III. STUDY OF STARTUP OPERATIONS
C. A. Rurz, I. T. CAMERON? and R. GANI$
Planta Pilot0 de Ingenieria Quimica, UNS-CONICET, 8000 Bahia Blanca, Argentina

(Received 4 September 1986; received for publicohm 3 June 1987)

Abstract-The dynamic behavior of distillation columns during startup operations have been studied and
analyzed. A procedure is proposed for determining appropriate startup policies for distillation column
operations based on the analysis of the dynamic behavior. The final startup policy consists of three
strategies corresponding to the three characteristic stages of the startup operation. The proposed
procedure has been successfully applied to a test problem. Numerical results of the dynamic behaviour
and the test problem are presented.

Scope--Startup operations of chemical processes and in particular, distillation columns, represent

interesting problems in operability, control and simulation. Most research efforts on startup operations
of distillation columns in the past have concentrated on actual plant experiences [I-3]. These papers have
mainly described the problems related to plate hydraulics during the early stages of the startup period
and operability problems.
A good understanding of the dynamic behavior is necessary for the development of appropriate startup
policies. Procedures by which these policies can bc deteimined could serve as useful tools both for the
operators and designers of plants. For the operators, the information would prepare them better to
diagnose and handle many possible operational problems and also give them a knowledge of the effects
of the different actions taken during the startup operations. For the designers, the information could help
them enormously in the screening of alternatives as well as avoiding as many operability and control
problems as possible.
Simulations of startup operations is difficult because of the complex plate hydraulics. For example,
predictions of the sealing of downcomers, the sealing of the plate holes from the liquid flow, effect of
pressure drop on the liquid holdup on plates and many more. These hydraulic effects can become
important in the determination of appropriate startup policies. One way of attacking this problem is to
develop a reasonably reliable dyn model for distillation columns, verify the model against
experimental/plant data and then “r” hrough simulations of different startup operations, study the
corresponding dynamic behavior. From this analysis, a procedure for obtaining the appropriate startup
policies can be developed.

Conclusions nnd Si-The ability of the dynamic model to predict, at least qualitatively,
reasonably correct dynamic behavior during startup operations of distillation columns has been
confirmed. Analysis of the simulated results have indicated trends in the dynamic behavior which enables
the representation of the startup operation by the three characteristic stages. The first stage, called the
discontinuous stage, is characterized by its short time period and the discontinuous nature of all the
variables. The second stage, called the semi-continuous stage is characterized by the non-linear transients
of the variables (but without any discontinuity) and approach of the hydraulic variables to their
steady-state values. The time period of this stage is larger than the first stage. The third stage, called the
continuous stage, is characterized by the linear transient responses of all the variables. At the end of this
stage, all the variables reach their steady-state values. The proposed procedure for obtaining the
appropriate startup policies has been successfully tested through a test problem. The method of solution
employed to determine the strategies for the three stages were found to be satisfactory from a numerical
stability point of view and in terms of robustness. The computing time, however, was found to be quite
large. Present work is concentrating on this area and especially in the reduction of computing time during
the discontinuous stage. With the developments of faster computers and parallel processors, this problem
might not remain so significant as at present.

INTRODLKTlON presented a dynamic model for distillation columns

The behavior of a chemical process can be studied capable of simulating startup operations. The model
from the plant data or, in their absence, by a reliable has &en verified to give, at least qualitatively, the
model of the process. Recently, Gani et al. 141, have correct dynamic behavior of distillation columns
during St&up operations. Also, the hydraulic sub-
tPresent address: Chemical Engineering Department, Uni-
model has been verified against plant/design
versity of Queensland, St Lucia, Australia.
f&sent address: Instituttet for Kemiteknik, Danmarks data 149 51.
Tekniske Hajskole, 2800 Lyngby, Denmark. The purpose of this paper is to thoroughly study
2 C. A. Rtnz et al.
the dynamic behavior of distillation columns during
startup operations and, based on this study, develop
a procedure for obtaining appropriate startup poli-
cies. Emphasis is given on improving the under-
standing of the dynamic behavior during these oper-
ations and to simplify the problems related to startup
operations. The dynamic model of Gani et al. [4] is
used for the purpose.
The dynamic behavior, obtained by simulation
with different startup procedures, is first compared
with known observations of other workers [l] and by
visualizing the behavior during actual operations,
Thus attempts have been made to confhm the validity
of the simulated results. The scarcity of actual
plant/experimental data however, makes this task
quite difficult.
The dynamic behavior of distillation columns are
then studied to identify trends which could be used
for characterizing the behavior and for simplifying
and/or solving problems related to operability, con-
trol and design. Based on the analysis of the dynamic
behavior, procedures for determining appropriate
startup policies are proposed. Application of the
proposed procedures are shown through a numerical
example.
SIMULATION OF STARTUP OPERATIONS
All simulations were performed by the generalized
dynamic model of Gani et al. [4]. For the purposes of
this work, an eight plate distillation column sepa-
rating a binary mixture of i-butane and i-pentane
has been considered. Details of the column is given
in Table 1. The different startup operational pro-
cedures are generated from a basic sequence of
actions whose time of employment, period of employ-
ment and nature can be varied. The sequence of
actions which forms the basis for different startup
operational procedures are listed below:
at time
t = 0, the column is empty and the liquid feed is
introduced (only liquid feed is considered);
t = t,, the liquid starts to “weep” to the plate
below through the plate holes rather than
through the downcomer. The liquid reaches
the bottom of the column (or reboiler) thus
increasing the liquid level there;
t =f*, heat is introduced into the reboiler and the
vapor starts to go up.
t =t,, the condenser starts to operate as the vapor
reaches the top plate and the reflux drum
starts to fill up;
t =t4, the reflux is introduced into the column and
operation at total reflux begins;
t =ts, the vapor flow through the plate holes seals
the plates in terms of liquid weeping
through the plate holes. This starts to in-
crease the liquid holdup on plates;
t =tb, all plates have enough liquid holdup so that
the liquid can start to fall down the down-
comers. The downcomers are sealed and no
vapor can go up through them;
f = t,, column operation is changed ‘from total
reflux. Distillate is taken out.
Note: the shift from total reflux to specified
reflux may be carried out in steps;
t = t8. column operation continues and steady-
state is attained.
As can be seen from the list above, most of the
actions in the beginning involve opening or closing
of valves. That is, when should a;valve be opened or
closed? During this period, some of the variables will
vary from zero to nonzero and back to zero values
(for example, liquid flow through the plate holes,
vapor flow through the downcomers) while others
will vary from zero values to nonzero values (for
example, plate pressure drops, liquid tlow through
the down-comers). At the beginning of the startup
operation (at time, t = t,), all the different thermo-
dynamic variables (for example, plate temperatures,
plate pressures, plate compositions, etc.) will be the
same on all plates while the hydraulic variables (for
example, liquid and vapor flows, plate pressure
drops, etc.) will have zero and nonzero values (de-
pending on the startup procedure employed). From
time t, until I,, therefore, “violent” changes in the
column can be expected to take place. From time
t = t,, conventional operation of the column may
begin even though the column may be far from the
desired steady-state. At time t = rg, the column is
very near its desired steady-state and the control
system designed to maintain the column operation
around this state, may be employed.
The generalized model [4] requires the user to
specify the sequence of actions, the timings of
different actions, length of period, valve position, etc.
This allows the simulation of distillation dynamics
for different startup configurations and procedures.
Details of three different startup configurations and
procedures are given in Fig. 1 and Table 2. These
three operational procedures are representations of
simulation problems of simple, intermediate and
complex characteristics. The actual analysis of the
dynamic behavior is made by using these procedures
and variations of these procedures.
ANALYSIS OF THE DYNAMIC BEHAYIOR
For the distillation column described in Table 1
and the three startup procedures illustrated in Fig. 1
and Table 2, the transient responses of the hydraulic
variables and thermodynamic variables are shown in
Figs 2-6. Figure 2 shows the responses of the liquid
flowrate through the downcomer of each plate for the
operational procedure OPl. Figure 3 shows the re-
sponse of the vapor flowrates through the plate holes
and through the downcomers for 0P2. Figure 4
compares the responses of the plate pressures (ther-
modynamic variable) against plate pressure drops
 A generalized model for distillation column+III 3

Table 1. Details of the column studied weeping of liquid etc. takes place on each plate at
Column description : 8 sieve trays, different instants of time. Figures 2-6 also show these
lateral downcomer
phenomena.
Feed specilZ;cation : liquid at bubble point The behavior of the bottom plate as shown in Fig.
Composition: i-butane 50%
n-pentane 50% 2 is due to the extra feed (Fig. 1) in the bottom plate
Flowrate: 113.4kmolh-’ which is stopped when the liquid starts to fall from
Temperature: 327.3 K
I4CSSUI-Z 441.94 kPa (initial plate pressure)
the plate above through the downcomers. Also, in
Fig. 2, the liquid flowrates for the plates above the
Design pwametem
R&oiler heat duty (QB,: 4.788 x 10skcal h-’ feed plate are different from the others because the
Condenser heat duty (PC): 3.780 x ltl’kcal h-’ reflux rate is not the same as the feed flowrate. In Fig.
R&IX rate (R): 68.0 kmol h -’
Reflux ratio: 2.3
3, plate 7 is sealed before plate 3 because plate 7
Feed plate number: 5 receives the liquid entering as reflux, earlier than plate
Plate dimensions 3. In Fig. 4 it can be seen that DP for all the plates
Weir length 0.532 m get nonzero values at t approximately equal to zero.
Weir height 0.030 m
Plate diameter 0.762 m
This is because, initially, when the liquid rate through
Active area 0.366 m* the plates are small and the downcomers are not
Plate spacing 0.457 m sealed, the vapor flows up the column through the
Downcomer clearance 0.030 m
Holes area 0.037 ml downcomers almost immediately. It is interesting to
Plate thickness 0.003 m note the time constants for DP and the plate pres-
Hole diameter 0.002 m sures in Fig.4. In Fig. 5a and 5b, the liquid holdups
on each plate are not approximately the same (at
(hydraulic variable) for OP3. Figure 5 shows the steady-state) because the liquid and vapor flowrates
dynamic responses of the liquid holdup on plates and for each plate are not the same. Figures 6a and 6b
Fig. 6 shows the responses of the plate temperatures show that the thermodynamic variables do not start
and liquid phase compositions for 0P3. with zero values and that different plates are dis-
It can be seen that the simulated results match turbed at different instants of time.
qualitatively the startup hydraulics as described by
Kister [I]. That is, at startup, vapor tends to flow Table 2. Different startup procedures details (corresponding to
Fig. 1)
through both the downcomer and the plate holes
P~OCCdUIC
(Fig. 3), the liquid initially weeps through the plate Option employed OPI OP2 OP3
holes and when the liquid height on the plate is high Bottom dynamics included , No YeS Yes
enough, it falls through the downcomers (Fig. 2),
Reflux drum dynamics included No No YCS
when the liquid seals the downcomer, the vapor flow
Bottom liquid height controlled
through the downcomer stops (Fig. 3), when the manipulating bottoms flowrate
vapor ffow becomes sufficiently large, the liquid flow (P controller) No Yes YCS
through the plate holes become negligible (Fig. 2). Reflux drum liquid height
If an actual startup operation is visualized, it can controlled manipulating
distillate flowratc (P controller) NO NO Yes
be poted that each plate is affected at different
Extra feed introduced Yes No NO
instants of time. That is, the sealing of the down-
comer, the flow of vapor through the plate holes, Reflex rate introduced progressively No No Yes

XF, =XF, =0.5

I

OPl oP2 OP3

Fig. 1. Configurations of the diRerent startup procedures.

4 C. A. RUE er al.

0 eomm plate (I)

x Feed pla(e (5)

o .Top plawl6)

1.75 2.0 2.25 2.5

t (bin)
Fig. 2. Responses of liquid flowrates through the downcomers (L) for different plates (OPI procedure).

64

Bottom plate (I)

56

: Feed pbte(5)
26

t(min)
Fig. 3. Responses of vapor flowrates through the downcomers (KS) and through the plate holes (V) for
each plate (OP2 procedure). Note: solid symbols correspond to V and open symbols correspond to VS.

;; 0.36
a
55
a
0 0.24

. Value of DP at (ims -0

1 I I I I I I I I I 1400
0.00 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.6 0.9 1.0
tl min)
Fig. 4. Responses of plate pressure (P) and pressure drop (DP) of each plate for 0P3 procedure (all the
plate pressures are lumped together because of the small DP between plates).
 A generalized model for distillation columns-III 5

6.25

0 ~Bottom pbate (1)

X .FBed plate(S)

0 -TOP plate (81

0.00

t(min)

0.25
(b)

0 Bottom plate (I 1

x -Feed plate (5)

0 -Top ptote 18)

_I

0.00 a25 0.5 0.75 1.0 1.25 1.5 1.75 2.0 2.25 2.5
t( min)

Fig. 5. (a) Responses of the liquid holdup (HOLD) on each plate (OPl procedure); (b) responses of liquid
holdup (HOLD) on each plate (OP3 procedure).

In all these figures (and many other responses not
presented in this work) it can be seen that there is a
very short period during which very “big” changes
take place. The length of this period is not affected
very much by the startup procedure. During this
period, the hydraulic variables undergo drastic
changes some taking on nonzero values at different
instants of time from the initial zero values and others
settling down to zero values after taking on nonzero
values. This is also the period when the “sealing” of
downcomers from vapor flow, “sealing” of plate
holes from liquid flow occurs. The thermodynamic
variables on the other hand, start with constant
values on all plates and gradually form profiles (each
plate variable changing at a different instant of time).
As all the changes are discontinuous in nature, this
period will be called the discontinuous stage of the
startup operation. The end of this period also coin-
cides with the time when all the criteria suggested by
Kister [1], have been satisfied. It should be noted that
during this period, it is more important to correctly
predict the hydraulic condition on the plate and their
effect rather than the actual timing of their occur-
rence. Thus, a model that is qualitatively correct, is
sufficient.
Two other characteristic periods are also no-
ticeable from the simulated dynamic behavior. The
first of these starts at the end of the discontinuous
stage. During this period, the thermodynamic vari-
ables undergo sharp changes (non-linear but not
discontinuous) and the hydraulic variables undergo
small changes (almost linear). Figures 2 and 3 show
the behavior of the hydraulic variables while Figs 6a
and 6b show the behavior of the thermodynamic
variables. Figure 4 shows the behavior of both the
hydraulic variable (pressure drop) and therrno-
dynamic variable (plate pressure). These figures
clearly show that the hydraulic variables reach their
steady-state values much earlier than the thermo-
dynamic variables. The end of the second period is
therefore marked by the time when the hydraulic
variables are almost near their steady-state values.
 C. A. Rum er al.

(a)
1 Bottom plate

350 -

0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0

t(min)

1.00
(b) 8 Top plate

0.85 -

0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0
t(min)

Fig. 6. (a) Responses of plate temperatures (T) for OP3 procedure; (b) responses of the compositions of
i-butane on each plate (liquid phase) for 0P3 procedure.

This period will be called the semi-continuous stage
to distinguish from the last period which will be
called the continuous stage. The start of the second
period and the dynamic behavior during this period,
is equivalent to the behavior of a column subjected to
large disturbances. The validity of the predicted
results for such simulations have already been
established [4].
The operation during the continuous stage is sim-
ilar to maintaining the operation of a distillation
column around a desired steady-state subject to small
disturbances. The control system designed to main-
tain.the column operation at a particular steady state
can thus be employed at the start of this period. At
the end of the continuous stage therefore, all the
variables reach their steady-state values.
Figure’7 compares the dynamic responses of plate
pressure for these different startup operational pro-
cedures (OPl, OP2 and OP3). It can be seen that
although the total length of the operation is indepen-
dent of the procedure employed, the transient paths
followed can be quite different. Through an analysis
of these responses different startup procedures can
hence be screened. For example, the “kink” in the
pressure response for OPl may cancel this option.
Summarizing the analysis of above, the following
characteristic dynamic behavior during startup oper-
ations were noted. The period comprising the empty
column to the final steady state may be divided into
three stages. The time period of the first stage is very
short and independent of the operational procedure
employed. The time period of the last stage is the
largest. During the second stage the thermodynamic
variables undergo bigger changes than the hydraulic
variables. At the start of the third stage, almost all
hydraulic variables are at their steady-state values.
The different startup operational procedures may be
screened taking into account the possible operability
problems. The hydraulic stability conditions are
statisfied during the first stage.
 A generalized model for distillation columns--III 7

- OPi

- OP2

-x- OP3

I I I I I I I I I
0.0 0.5 1.0 1.5 2.0 2.5 3.0 35 4.0 4.5 5.0

t( min 1

Fig. 7. Comparison of the plate pressure (P) responses for three different startup procedures (fed plate).

DESCRIPTION OF THE PROPOSED problems will have to be solved. The generalized

STARTUP POLICY
dynamic model used in this work allows all of this.
Based on the analysis of the dynamic behavior The proposed solution procedure is described below.
given above, a methodology for obtaining an appro-
priate startup policy is proposed. The policy is di- SOLUTION PROCEDURE FOR OBTAINING
vided into three strategies each corresponding to the THE STARTUP POLICY
three stages of the dynamic behavior previously
As can be seen from the description of the strate-
described. For the discontinuous stage, the strategy is
gies for the three stages, a priori simulation is re-
to select a procedure which will have minimum
quired for the solution of the problems of the discon-
operability problems. The procedure involves open-
tinuous stage. A combination of physical insights,
ing or closing of valves at specified instants of time.
experience and analysis of the results of the dynamic
The procedure also ensures that no discontinuities
simulation is proposed (for the present) to obtain the
exist after this stage.
appropriate strategy. Examination of Figs 2-6 shows
The second stage (i.e. the semi-continuous stage) is
that alternative OP3 is better than the other two from
where an optimal control strategy may be employed.
an operability point of view. Also, from the descrip-
Because both the hydraulic variables and the thermo-
tion of the three alternatives (Table 2), alternative
dynamic variables are changing here, the dynamic
0P3 seems more reasonable. Thus, the solution pro-
responses are highly transient in nature and thus the
cedure for this stage is to simply perform simulations
column control system may not be applicable. The
for the different alternatives and to select the one
strategy here is to specify the values of the manipu-
which shows the least operability problems. Many of
lative variables (for example, reboiler heat duty,
the alternatives may be screened without simulation
reflux rate etc.) at different intervals of time, so that
through physical insights and experience. The simu-
the end of this stage is reached at a minimum cost.
lation in this case therefore serves the verify the
The end of the stage may be verified by monitoring
advantages of a proposed alternative.
the values of the hydraulic variables and the profiles
Solution of numerical optimization problems cou-
of the thermodynamic variables. The cost may be
pled with dynamic simulation is required in order to
evaluated from the cost of energy, the product lost,
obtain the strategy (for the startup policy) for the
etc. Changes in the manipulative variables should be
bounded so that no discontinuities or hydraulic in- semi-continuous stage. The problem can be formu-
lated thus.
stabilities occur during this stage.
Let us consider the distillation column model of
At the beginning of the third stage, the control
Gani ef al. [4] represented by a set of ordinary
system designed to maintain the column operation
differential equations (ODES) and a set of pro-
around the specified steady-state is switched on. Since
cedures. The above set of equations are represented
the open-loop responses during this stage showed
in the form:
linear behavior, this strategy seems reasonable.
Thus to obtain the proposed startup policy, com- Y’ = f(Y, P. t). (1)
plex dynamic simulation problems (for the discon- where the procedures p can be written in the general
tinuous stage), dynamic simulation coupled with form:
optimization problems (for the semi-continuous
stage) and simplified closed-loop dynamic simulation p = g(y, z, d, t) (2)
 The procedures are functions of the differential
variables y, a set of algebraic variables z and the
system parameters d. The set of algebraic variables z
includes a sub-set of variables q which are designated
as the manipulative variables (for example, reboiler
heat duty, reflux rate, feed flowrate, etc.). The vector
y ati t = to is known (i.e. the initial condition at the
start of the semi-continuous stage).
The performance of the startup policy (to be
determined) can be evaluated through a scaYar objec-
tive function of the type:
‘1
P,=dJIY(r,),t/l+ J KY 0)s u(t), 11dt,
I 10
where:
tf is the final time of the semicontinuous stage,
u(t) are the optimizing variables (for example, a
set of manipulative variables).
The startup policy to be selected should correspond
to a minimum in P, subject to the following con-
straints:
Umi”< u(t) < u, , (4)
t1 G &w.,
gmi. d g[u(tX
ah < a[yO), u(t), tl< G,,
where:
&u(t), t] is a set of linear constraints,
ah(r), U(t), ?] is a set of non-linear constraints.
Equation,(4) represents the limitations correspond-
ing to the valve action for the manipulative variables.
The linear constraints represent the restrictions im-
posed on the manipulative variables by the process.
For example, the reflux rate or reboiler heat duty
must satisfy a special criteria. The non-linear con-
straints represent the restrictions imposed on the
process reaching a desirable steady state. For exam-
ple, a specified product purity. Since these variables
number of intervals is also unknown (see discussion
below). The problem to be solved can therefore be
defined thus:
Determine the elements of each of the sub-vectors
such that equation (3) is minimized and equations
(4x6) are satisfied. In other words, specify the values
of the manipulative variables at the different intervals
of time so that the end of the semi-continuous period
is reached with the minimum cost (including time)
and without breaking any limiting conditions.
As a special case of the minimization problem, the
(3) objective function may be defined to measure the
difference between the desired steady state and the
state at any instant of time. Thus, when this difference
approaches a certain minimum value, the end of the
semi-continuous stage would be reached and the
switch to the linear controllers can be made. This
special formulation of the objective function will
therefore allow the specificatipn of the manipulative
variables at different intervals of time in such a way
that a particular “state” of the column is attained.
The objective function in this case would be (consid-
ering only the temperature profile),
(5)
(6) PI= &T,--(TPFAT,,)]*, (7)
ir; I
where:
NP = the total number of plates,
r;J = the steady state temperature of plate i,
T, = the instantaneous temperature of plate i,
AT,, = the permitted deviation from the steady
’ state of the plate temperature.
A more general form of equation (7) which takes
into account cost terms as well as other profiles (for
example, compositions) may be detined thus:
NT NP
Pr = C C wkbw - (x;li + A~,~,ll*
k-li-l

can only be determined through simulation, these are

therefore non-linear functions of the manipulative + 5 C&u,
k=l
21, (8)
variables.
The problem formulated above can be defined where:
thus: NT = the total number of different variables to be
minimize equation (3) in terms of the variables u(t) considered in evaluating P,,
wk = weighting terms for each type of variable,
subject to the constraints given by equations (4)-(6).
xkei= the variable of type k of plate i and is a
A similar type of problem was solved by function of u.
Sullivan [6] and Sargent and Sullivan [7] for the devel-
opment of an optimal feed changeover policy. If the period of time is discretized in NZ intervals
The above problem treats u(t) as continuous vari- of control, the vector of variables of optimization will
ables. By discretizing u(t) with respect to time the be thus,
startup policy is coupled to this problem. That is, u = [Ui, 21, uzr 12,. . . , 4, ti, . . . , UN,,hlT. (9)
dividing the time period into intervals and for each
interval, determining the values of u(t). Thus, each where:
element of the vector u(t) will be represented by u, is the vector of the optimizing variables at
sub-vectors of dimension equal to the total number interval i,
of intervals. It should be noted that the end of the ti is the time at which a value is assigned to the
semi-continuous period is not known and hence the variable ui at interval i.
 A generalized model for distillation columns-111
Thus, the dimension of II will be (NC + 1)Nl and
the trajectory of the control variables (with respect to
time) will be given by:
n(t) = uI when t,<t <t,,
u(r) = ui when ti-, G t < fi,
i=l(l)NI-1
u(r) = UN1 when tNI_, ,< t < t,.
As a first approximation, the length of the intervals
are considered constant, i.e.
t,=iH+t,.
This simplifies the optimization problem further
and the vector of the optimization variables becomes:
u = [ut, U2, . . . , I&, . . . , uN,]T*
Special care is needed in the selection of the value
of Ax+ (or ATP,) which must be specified. If the
value is too large, then the “state” at which switch to
the linear control system of the column is made may
be too far away for it to work efficiently. On the other
hand, if the value is too small, the cost would
increase.
As can be seen from the problem definition, an
iterative solution technique needs to be employed,
and at each step, dynamic simulation is necessary.
Also, the problem to be solved simplifies considerably
if the end of the semi-continuous period is specified
and all the intervals are assumed to be of equal
length. This is quite feasible and reasonable since the
approximate time of the semi-continuous period can
bc determined from an a priori simulation of a startup
operation (open-loop).
At the start of the continuous stage, the controllers
designed to maintain the column operation around a
specified steady state is switched on. The controllers
can be of simple single level type or more complex
and advanced single and/or multi-level type. The
parameters for the controllers can be determined a
priori from open-loop transient responses around the
steady state. Simulation of this stage thus involves
closed-loop simulation with the linear version of the
dynamic model.
PROCEDURE FOR THE DETERMINATION OF
THE APPROPRIATE STARTUP POLICY
The three strategies corresponding to the three
stages of the startup operation make up the desired
startup policy. The procedure for determining these
strategies corresponds to the solution of the following
problem:
given: details of a distillation column,
details of the desired steady state,
details of operational restrictions,
required: strategies for the startup policy during the
three stages.
9
The solution procedure can be described through the
following algorithm.
step 1.
From previous experience, physical insights
(10) and the nature of the constraints corre-
sponding to the present system, generate
one or more strategies for the discontinuous
(11) stage.
step 2. Perform the dynamic simulation for each
(12) strategy and select the one which corre-
sponds to minimum operability problems.
step 3. For the selected strategy (the discontinuous
stage), continue the integration until the
column reaches the steady state. The values
of the manipulative variables are set to their
final steady-state values at the end of the
discontinuous stage for this simulation,
Step 4. From the dynamic response of Step 3, deter-
(13) mine the approximate end of the semi-
continuous stage.
Step 5. Select the interval length and determine the
number of intervals for the semi-continuous
stage.
Step 6. Define the objective function (i.e. equation
(3)], the constraint functions from the
knowledge of the final steady state and the
operational restrictions.
step I. Select the manipulative variables whose val-
ues should be specified at each interval by
minimizing the objective function.
Step 8. Select the initial estimates of the variables.
Step 9. Solve the minimization problem to obtain
the strategy for the semi-continuous phase.
Step 10. Repeat the simulation with the strategy of
Step 9 using the generalized version to
co&m that no hydraulic instability occurs.
Step 11. At the end of the semi-continuous stage,
switch on the controllers designed to main-
tain the column operation about the desired
steady state and integrate till this steady
state is reached. Confirm the ability to reach
the specified steady state and check if this
performance is better than that obtained in
step 3.
NUMERICAL AND COMPUTATIONAL ASPEcts
The computational effort necessary in obtaining
the appropriate startup policy according to the pro-
posed procedure requires dynamic simulation and
solution of a minimization problem. The numerical
and computational aspects related to dynamic simu-
lation has already been discussed in detail by
Cameron et al. [8]. Three different types of dynamic
simulation however are performed. All simulations
during the discontinuous stage involve the most
complex version of the dynamic model. Also, the
numerical method needs special options to handle the
discontinuous nature of the variables. During the
semi-continuous period, for which the minimization
10 C. A. Rum et al.

problem is solved, a simpler version of the hydraulic The VMP method requires gradients of the objet- 1
model is used since the transients of the hydraulic tive function and the constraints with respect to the
variables during this stage is linear in nature. Thus, minimizing variables (in this case, the manipulative
the dynamic simulation is simpler than the discon- variables). As can be seen from the description of the
tinuous stage. However, since a minimization prob- problem, the gradients for the objective function and
lem needs to be solved by an iterative method, many non-linear constraint functions must be determined
simulations of the period is necessary. During the by finite difference. Furthermore, for each gradient
continuous stage, the column is near the desired evaluation, a dynamic simulation of the entire semi-
steady state and hence, the simplest version of the continuous period is needed. Since no hydraulic
dynamic model can be used. The simulation during operability problems are expected during this stage,
this stage therefore involves closed-loop simulation the simplest version of the hydraulic model is used.
with a linear dynamic model. The computing time This option only checks for hydraulic instabilities but
therefore is much less compared to the first two does not calculate the corresponding effects (i.e.,
stages. The computing time per dynamic simulation flooding rates, weeping rates, etc.) Thus, the com-
is much lower for the second stage than the first. putation time for each dynamic simulation is consid-
However, since the second stage requires more than erably reduced.
one dynamic simulation the total computing time for For the continuous stage, as the simplest version of
both the stages is about the same (for further details, the dynamic model is used, the AM integration
see the Application section and Tables 4 and 5). method is adequate and hence computation time
The procedure for obtaining an appropriate should be very low.
startup policy for the discontinuous stage involves
the verification that a strategy (or strategies) selected
a priori (by experience and physical insights), is free
APPLICATION OF THE PROPOSED PROCEDURE
of any operability problems. In terms of the numer-
ical and computational aspects, the objective was to By applying the proposed procedure, appropriate
ensure numerical stability and robustness of the startup policies for the distillation column described
method of integration in dealing with the discon- in Table 1 were determined. The specific min-
tinuities. Also, an effort was made to reduce the imization problem solved is defined thus:
computing time. As can be seen from the results
minimize,
presented in this paper and also in Gani et al. 141,the
integration method employed is capable of handling
the discontinuities. The computing time however is p,= : wi-2-yTTT,,)]2 (14)
i-l
very large because, everytime a discontinuity occurs,
for
the integration routine requires step size reduction
and suffers convergence and error failures and there- QRj. R, j = l(1)NZ.
fore, requires many extra Jacobian matrix evalu-
subject to
ations.
However, as pointed out in Cameron et al. [8], if a QBf G QB, < QB:, (1%
copy of the Jacobian matrix at the last successful step
R,+=SRj<R,f’, (16)
is stored and this is used until a new Jacobian is
necessary after a successful step (or steps), consid- dL $ xD = f (QB,, Rj) d d”, (17)
erable computing time can be saved through avoiding
bL<xB=g(QBj,Rj)<b”. (18)
unnecessary evaluations of the Jacobian matrices.
Thus, during the discontinuous stage, the integration Equations (15) and (16) represent the upper and
method always used the option of the Jacobian copy. lower limits for the manipulative variables QR (re-
Also, when the step size becomes too small (because boiler beat duty) and R(reflux rate). Equations (17)
of reductions when discontinuities appear) and the and (18) represent the non-linear constraints func-
use of AM methods is feasible, switch to this method tions and their limiting values. Equation (17) defines
from the BDF method is made. the restrictions on the composition of the light com-
As mentioned previously, to obtain the strategy for ponent in the distillate and equation (18) defines the
the semicontinuous stage, a minimization problem restrictions on the composition of the heavy com-
has to be solved. An efficient numerical method is ponent in the bottoms. These are non-linear func-
required to determine the values of the variables [i.e. tions, since they are determined (for different values
u(t)] that will minimize P, and satisfy the constraints. of QBj and Rj) after dynamic simulation.
The method should be able to handle multivariable Based on the analysis of the simulated dynamic
minimization problems with linear and non-linear responses during the discontinuous stage, the strategy
constraints and bounds on the variables and con- given for OP3 (see Table 2) was chosen for this stage.
straints. For the purpose of this paper, the variable For the continuous stage, PI controllers, tuned a
metric projection (VMP) method of Sargent and priori through analysis of dynamic responses around
Murtagh[9] was found adequate. the steady-state, were employed.
 A generalized model for distillation columns-III 11

Table 3a. Details of the optimal startup policy

Interval length (H) = l.Omin Performance index ’
No. of intervals (NI) = 3 (P,)
AT_r--
= 0.c0o1 K Initial Final
Reflw rate (R) = 68.0 km01 h-’ 89.304 K’ 0.153 K*
Manipulated variable (QE)
(kcal h-‘)
Initial 1st interval 2nd interval 3rd interval steady state
478800.0 504995.4 492906.9 482164.2 478800.0
Time required to reach steady state (min)
Temperature Composition Downcomer
profile profile liquid heights Plate pressures
10.5 7.1 3.8 9.1

Table 3b. Temperature profile and performance index behavior during the optimal startup policy
Plate temperature profdcs (K)
Startup End of discontinuous End of End of End of semi-continuous steady
initial stage I st interval 2nd interval stage state
Plate No. f = 0.0 min f = 1.8 min I = 2.8 min t = 3.8 min t = 4.8 min f = 10.5 mill

: 327.30 342.69
350.47 346.22
354.68 346.95
355.49 346.73
355.22 354.95
346.63
3 327.30 338.56 341.78 342.54 342.41 342.46
4 327.30 336.62 339.80 340.62 340.56 340.69
5 327.30 335.70 338.96 339.83 339.80 339.98
6 327.30 330.81 332.98 333.43 333.22 333.29
7 327.30 326.33 328.32 328.67 328.41 328.47
8 327.30 322.89 325.39 325.88 325.69 325.19
J’, (K’) 1747.6 89.304 2.815 0.496 0.153 0.000

Table 3a gives details of the final startup policy
determined through the application of the proposed
procedure. Figure 8 compares the dynamic response
of the liquid flowrate (hydraulic variable) with and
without the use of the “determined” startup policy.
Figure 9 compares the dynamic responses of the plate
temperatures with and without the use of the “deter-
mined” startup policy. Figures 10a and lob compare
the dynamic responses with and without the strategy
of the start-up policy for the semi-continuous stage.
Table 4 and 5 give some of the integration and
minimization statistics.
It can be seen that simulation of each stage is
always successfully performed. Also, the VMP
method is able to find the solution for the min-
imization problem. The initial estimates (required for
the minimization problem) are set to values at the
feasible interval. This ensures that the iteration al-
ways starts from a feasible point.
The length of the discontinuous stage was found to
be 108 s, the semi-continuous stage 3 min and the
continuous stage 5.7min. Thus, the column reached
the desired steady state after 10.5 min (from the
start). The semi-continuous period was divided into
three intervals of 1 min each. The small time period
for all the stages is due to the small total number of
plates for the column. In a bigger column, these
periods can be expected to be proportionally larger.
Only QB was chosen as the optimizing variable for
the example given in this work [i.e. equation (16) was
not used] and the II vector only contained QB,
(j = 1( l)NI]. The values of QB at the end of the
discontinuous period, during the two intervals of the
semi-continuous period and the final value are given

Table 4. Intearation statistics

Integration statistics Numerical method used
Jacobian
Run NJE NFE Model tvae Method coo”
OP1’ Discontinuous 338 11492 Generalized BDF No
Semi-continuous 35 1190 Simple + generalized’ BDF No
OP2Z Discontinuous 298 12032 Generalized BDF NO
Semi-continuous 31 1251 Simple + generalized’ BDF No
OP33 Discontinuous 213 8902 Generalized BDF YeS
Semi-continuous 22 919 Simple + generalized’ BDF YCJ
Continuous 0 652 Simple AM
‘Retlux drum and bottom dynamics not included.
*Reflux drum dynamics not included.
“Reflux drum and bottom dynamics included.
‘Generalized used only at the 1, values for verifying plate hydraulics.
12 C. A. RVIZ et al.

Table 5. Optimization (semi-continuous period) statistics I

VMP statistics Integration statistics
NJE NFE
NITER’ NOB’ NOBJG’ Interval 1 Interval 2 Interval 3 Interval 1 Interval2 Interval 3
2 3 2 ‘1 . IO 9 454 398 356
‘Number of iterations.
2N~ber of performance index evaluations.
3Number of pzrformancx index gradient evaluations.

in Table 3a. It was found that the end of the If the column is started up by two different pro-
semi-continuous stage (or the beginning of the con- cedures but with same final values of the specified
tinuous stage) could be defined in terms of AT_ and variables (feed rate, rcflux rate, etc.), then the same
the convergence criteria (i.e. error bound) for the final steady state should be reached although the
minimization problem. If AT,, is large, then transient path can be different.
the convergence criteria can be made strict. If on the Figures 10a and lob show the trajectories in terms
other hand, AT_ is very small, the convergence of top plate pressure against top plate temperature
criteria can be relaxed. For either case, at the sol- and bottom plate temperature against bottom plate
ution, the profile of the corresponding variable would liquid composition of component 1 respectively. Fig-
be near the steady-state profile. For the results ure 10a compares the trajectory for the “determined”
presented in this work, AT_ = 0.0001 K and error startup policy with another startup policy (with no
bound = 0.1 were used. The temperature profiles at control during the semi-continuous stage). Figure lob
the start of the operation, at the start of the semi- compares the trajectory for the “determined” startup
continuous stage, at the start of the continuous stage policy with that of employing the column controllers
and at the final steady state are giGen in Table 3b. The from the beginning of the semi-continuous stage.
values of the objective function at the start and Figure 10a shows that the path to the steady state is
end of the minimization problem arc also given in shorter with the “determined” startup policy. Also, it
Table 3a. can be seen that both the pressure and temperature
Figures 8 and 9 show clearly the advantage of using reaches steady state earlier for the “determined”
the “determined’* startup policy. The advantage can startup policy. Figure lob shows that it is possible to
be appreciated by noting the time taken to reach the employ the column controllers from the beginning of
corresponding steady-state values and the differences the semi-continuous period if the state is not beyond
in the transient behavior during the semi-continuous the limits of applicability of the controllers. For the
stage. With the “determined” startup policy, the results of Fig. lob, in terms of cost (product loss and
steady state is approached before the end of the heat supplied), the “determined” startup policy was
semi-continuous stage while, without it, the steady found to be cheaper.
state is approached a longtime after the second The proposed strategies and solution procedures
period. The fact that the same steady state is reached can therefore be regarded as useful tools for off-line
with the two startup policies confirms also the re- studies of startup operations. Present work is looking
liability of the dynamic model used for the purpose. at different ways of testing the proposed procedures

Discontinuous ( Semicontinuous period Continuous period

- NO policy

-x- Optimal Dolicy

6 Top plate

1 I I I II I I I I I
0 1 2 3 4 5 6 7 6 9 10

t(min)

Fig. 8. Comparison of the responses of liquid flowrates through the downcomer, L, with and without the
“determined” startup policy.
 A generalized model for distillation columnpI 13

Discontinuous Semicontinuous period Continuous period

period
360 -
1 Bottoni plate
-I_,,-x_.

320 - _ No policy

-x- Optimal policy

-c .__

Cl0 4 5 6 7 6. 9 10
t(min)

Fig. 9. Comparison of the responses of plate temperatures, r, with and without the “determined” startup
-pOlky.

-*- Without ‘determined startup

- With ‘determined’ startup

policy

I I I I
561 567 593 599

Top plate temperature ( R)

Without “determined “startup policy

- With Udstsrmined”
startup poLlcy

0 End ol semi-continuous stage

. End of dlscontlnuous stage

0.30 0.31 0.32 0.33 0.34

Bottom plate composition of component 1 I mol fraction 1
Fig. IO. (a) Trajectories of top plate pressure against top plate temperature for startup policies with and
without the proposed procedure; (b) trajectories of plate temperature against liquid composition for
startup policies with and without the proposed procedure.

C.A CE. 1211-s

14 C. A. RUIZ et al.

more thoroughly as well as comparing with “other” y = Differential variables vector

policies. Also, work is in progress to find ways to z = Algebraic variables vector
reduce the computing time and to study the dynamic
behavior during shutdown operations. Greek letters
A = Discrepancy allowed between steady-state value
and end of semi-continuous stage value for a
NOMENCLATURE certain variable
Q = Performance index component dependent on the
A = Non-linear constraints vector final time
AM = Adams-Moulton integration method
b = Limit composition of the heavy component in the Subscripts
bottoms c = Composition
BDF = Backward differentiation formula inteeration f =final
method max = Maximum
C = Cost function min = Minimum
0 = Initial
d = Limit composition of the light component in the
perm = Permitted
distillate
g = Linear constraints vector P = pressure
T = Temperature
F = Feed flow rate (kmol hh’)
Hold = Plate liquid holdup (kmol)
Superscripts
H = Length of the control intervals during the semi-
continuous stage L = Lower
ss = Steady state
J = Performance index component dependent on the
trajectory u = upper
L = Liquid flowrate, kmol/h
NFE = Number of function evaluations
NI = Number of control intervals
REFERENCES
NJE = Number of Jacobian evaluations
NP = Number of plates
P = Plate pressure (kPa) I. H. Kister, Hydrocarbon Process 58, 89 (1979).
p = Procedures vector 2. R. M. Murray and J. E. Wright, Chem. Ettgttg Prog. 63,
DP = Plate pressure drop (kPa) 40 (1967).
P, = Performance index 3. J. W. Drew, Chemical Engng 90, 221 (1983).
QE = Reboiler heat duty (kcal h-‘) 4. R. Gani, C. A. Ruix and I. T. Cameron, Comput. them.
QC = Condenser heat duty (kcal h-i) Engng 10, 181 (1986).
R = Reflux rate (kmol h-‘) 5. C. A. Ruiz and R. Gani, Latin Am. J. Chem. Engng
f = Time (min) Appl. Chem. 16, 277 (1986).
7’ = Plate temperature (K) 6. G. R. Sullivan, Development of feed changeover
u = Control variable vector policies for refinery distillation units. PhD Thesis,
w = Weighting factor University of London (1977).
x = Variable considered for the performance index 7. R. W. H. Sargent and G. R. Sullivan, 2nd. Engng Gem.,
evaluation Process Des. Dew 18, 113 (1978).
X8 = Bottoms heavy component composition 8. I. T. Cameron, C. A. Ruiz and R. Gani, Comput. Chem.
XD = Distillate light component composition Engng 10, 199 (1986).
XF = Feed composition (molfraction) 9. R. W. H. Sargent and G. A. Murtagh, Math. Program.
X = Plate composition (molfraction) 4, 245 (1973).