Journal of Process Control: Volume 8, Issues 5-6
Journal of Process Control: Volume 8, Issues 5-6
Journal of Process Control: Volume 8, Issues 5-6
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Journal of Process Control
Volume 8, Issues 5-6, October-December 1998, Pages 355-368
ADCHEM '97 IFAC Symposium: Advanced Control of Chemical Processes
Full paper
Dominique Bonvin
Abstract
This paper presents a personal, thus necessarily subjective, view of the operation of batch
and semi- batch reactors. The emphasis is on safety, product quality and scale-up. Key
characteristics of discontinuous reaction systems are discussed, along with the resulting
implications for monitoring, control and optimization. The industrial needs are compared
with the research solutions proposed by academia. It is argued that, in industry, measurement
and modeling issues are often more important than the algorithmic aspects related to the
computation of control and optimization strategies. Major challenges and selected research
opportunities are discussed.
Author Keywords: batch industry; batch processes; batch reactor control; process
monitoring; optimal control; optimization
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Abstract
Design and control of batch reactors provide challenging problems with respect to basic
functionality and safety of a process as well as product quality and yield related issues. In this
paper examples for the use of modelling, dynamic simulation and advanced control
techniques for industrial problems are given. They are evaluated with respect to economic
benefit as well as effort for development and implementation.
Author Keywords: Batch reactors ; process design; advanced control; operator training;
dynamic simulation; model based control; fuzzy control
Article Outline
Process dynamics and temperature control of fed-batch reactors
Abstract
The dynamics of a fed- batch reactor was studied using the detailed first principle model of
the system. The conditions of reaction runaway, the typical sources of hazardous operation in
fed- batch techniques are determined. Considering these conditions a model-based control
scheme is proposed to ensure robustness. When the stability criterion predicts that the range
of operation is safe the cooling is set to its maximum and the temperature is controlled by the
reactant feed. Otherwise the reactant feed is stopped and the flow rate of the cooling medium
is the control variable.
Author Keywords: Fed- batch reactor ; temperature runaway; tendency model; operation
safety; model-based control.
Article Outline
• References
Regular paper
Development of a mathematical model and a simulator for the analysis and optimisation of
batch reactors: Experimental model characterisation using a reaction calorimeter*1
Abstract
To obtain the data necessary to simulate the dynamic behaviour of the reactor, a set of
characterisation tests was carried out. Once the different parameters of the model were
evaluated, some experiments were performed to compare with the predicted dynamic
behaviour obtained with the simulator. These experiments invluded the heating/cooling
dynamic behaviour with different fluids, and the neutralisation reaction between sodium
hydroxide and hydrogen chloride.
Article Outline
William B. Zimmermana, ,
, P.O. Mchedlov-Petrossyanb and G.A. Khomenkoc
a
University of Sheffield, Department of Chemical and Process Engineering, Newcastle Street,
Sheffield S1 3JD, England, UK
b
Institute of Theoretical Physics, NSC, Kharkov Institute of Physics and Technology, Ukraine
c
Laboratoire d’Océanografie Côtière du Littoral, ELICO, Université du Littoral Côte d’Opale,
MREN, 32, Avenue Foch, 62930, Wimereux, France
Abstract
Recent studies by the authors of the heterogeneous catalysis of fast binary reactions have
taken a dynamical systems approach, assuming that fast enough reactions are confined to a
manifold upon which surface equilibrium holds. This approximation makes substantial
simplification possible, for instance in the case of a batch reactor, it allows a naturally sixth
order system to be approximated by a two dimensional manifold for the dynamics of two
modified Thiele moduli. Nevertheless, a proper assessment of how much faster must the
velocity of surface reaction be than the velocity of mass transfer to the catalytic surface
before the quasi-equilibrium on the surface holds should be made. In this paper, a theory for
the systematic correction to infinitely fast reactions is made for large but finite velocity
reactions. It is compared to full numerical solutions to the model equations.
Recommendations about the regime of applicability of the quasi-equilibrium approximation
are made. In general, the predictions of the quasi-equilibrium theory hold for ratios of mass
transfer coefficients to reaction velocity ξ of less than 1/1000, with qualitative agreement in
regimes of less than 1/100. The general trend, however, is that the stronger the kinetic
asymmetry between the mass transfer coefficients of the reactants, the slower the reaction
rate can be and still have the quasi-equilibrium theory hold. A perturbation analysis
demonstrates that the quasi-equilibrium theory is a regular limit of the fast non-equilibrium
theory. In the irreversible case, a matched asymptotic analysis gives the same prediction for
the switch time from effective surface depletion of one reagent to the other as the quasi-
equilibrium theory. Furthermore, it gives an estimate of the smoothing out of the transition
zone with a temporal width of ξ1/2. It should be noted that the continual drive for improved
catalyst activities inevitably leads to mass transfer limited reactions, and thus this regime is
not uncommon.
N. Aziz1, ,
, M.A. Hussain2 and I.M. Mujtaba3
1
School of Chemical Engineering, Engineering Campus, Universiti Sains Malaysia, 14300
Nibong Tebal, Pulau Pinang, Malaysia.
2
Department of Chemical Engineering, University of Malaya, 59100 Kuala Lumpur,
Malaysia
3
School of Engineering, University of Bradford, West Yorkshire BD7 1DP, UK.
Abstract
...
Fig.1
The figure shows a) the temporal and b) the spatial dependence of the concentration of
the reactive component A for a continuously operated ideal stirred tank reactor. The
continuously added reactants are mixed immediately with the contents of the reactor
and products are constantly being removed. This borderline case is referred to as
"homogenous, steady state" which means the composition of the reactor mixture and
the reaction rate are identical at all times and at every spot for all components in the
reactor.
...
Fig.2
The figure shows a) the temporal and b) the spatial dependence of the concentration of
the reactive component A for the ideal plug flow reactor. The residence time is the same
for all parts and is equivalent to the mean residence time. The composition of the
reactor mixture is constant through the cross section of the reactor (radial) and no
mixing of the reactants occur in the flow direction (axial)(plug flow). At steady state the
concentration is all times constant at every point of the flow reactor. In accordance to
the reaction, a concentration gradient in flow direction (axial) appears. This borderline
case is referred to as "non-homogenous, steady state".
...
Fig.3
The figure shows a) the temporal and b) the spatial dependence of the concentration of
the reactive component A for an ideally stirred batch reactor. It is also characterized by
a fully mixed content. The reactants are brought into the reactor prior to reaction and
the products are removed after of reaction-conclusion. The concentration of the
reactants decrease a) in time and are b) spatially constant. In this case, all particles
have the same mean residence time. This borderline case is referred to as
"homogenous, non-steady state" (regarding the operation of the reactor).
...
Fig.4
a
Mining Engineering and Natural Resources Department, Escola Universitàtia Politècnica de Manresa,
Universitat Politècnica de Catalunya, 61-73-08240, Manresa, Spain
b
Chemical Engineering Department, Escola Tècnica Superior d’Enginyers Industrials de Barcelona, Universitat
Politècnica de Catalunya, 647-08028 Barcelona, Spain
Received 19 October 1998;
revised 10 February 1999;
accepted 19 February 1999.
Available online 24 January 2000.
Abstract
In this work, a study of a batch and semibatch reactor has been carried out based on a very exothermic reaction
between thiosulfate and hydrogen peroxide. The experiments were carried out in a glass-jacketed reactor of 5 l,
provided with different sensors and a data acquisition system. Thermal and kinetic studies were carried out
previously using an adiabatic batch reactor. Then, these results have been used for experiments in semibatch
mode of operation with heat transfer. Several experiments have been carried out at different operating conditions
(addition flow, initial temperature, initial concentration of reagents…). In batch and adiabatic mode of operation,
experimental measures of the reaction mass temperature provided concentration profiles of reagents and
products which have been compared to those determined by simulation. In semibatch mode of operation,
temperature profiles have also been simulated and validated with experimental results. An algorithm describing
the mathematical model has been developed and implemented in a software module written in FORTRAN 77
language. With this mathematical model it has been possible to obtain concentration and heat profiles for the
semibatch mode of operation.
Abstract
An experimental study of two nonlinear model based control methods for the temperature control of a
multipurpose batch reactor is presented. A combination of a cascade control structure and suitably chosen
controllers is shown to provide robust control in the presence of severe measurement error and model mismatch.
Various nonlinear or linear control techniques can be accommodated in the cascade structure. Furthermore, the
theoretical equivalence of GMC and GLC controllers is confirmed experimentally.
Author Keywords: Nonlinear control; GLC; GMC; cascade structure; batch reactor; experiments.