Post on 13-Jan-2016
description
Simulation and Design of a Process Control System for
a Pilot Plant-Scale Distillation Unit
Washington University
Department of Chemical Engineering
Department of Electrical and Systems Engineering
Bia HenriquesJonathan LoweRachel Vazzi
Kwaku Opoku-MensahDecember 2004
Chemical Reaction Engineering Laboratory
Introduction Methodology Problem Segmentation Steady State Vs. Dynamic Assumed Process Challenges DeltaV Control Blocks Testing Procedures Team Work Control Diagrams and Graphics Wrong and Right Interface Demo Accomplishments Future Work Lessons Learned
Overview
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Introduction
Chemical Reaction Engineering Laboratory
Southern Illinois University – Edwardsville Federal Corn to Ethanol Pilot Plant needs simulation of its ethanol distillation unit
Washington University partnered with SIUE to provide this service to achieve a better way of predicting the system’s behavior
AssumptionsNo solids in inlet streamDegasser treated as 2-tray column instead of separatorDid not include all control loops
Methodology
Chemical Reaction Engineering Laboratory
Design and setup of control system for distillation unit
Distillation unit simulation performed in Hysys to predict steady state and dynamic behavior of process
Process control instrumentation simulated in Hysys for dynamic state
Process control system configured in DeltaV in both control studio and explorer
Both simulations interfaced so the behavior of the control system can be studied when a load change is made in Hysys
Problem Segmentation
Chemical Reaction Engineering Laboratory
P&IDs used to build graphics for DeltaV
Hysys used to simulate process
DeltaV used to control process
Programs interfaced to provide optimum process control design
Steady State Vs. Dynamic
Chemical Reaction Engineering Laboratory
Hysys model must be configured to run both in steady-state and dynamic mode
Temperature and pressure profiles for streams and equipment connected need to match in dynamic mode
Tank sizes, valve sizing, and inlet conditions must remain constant throughout
Assumed Process
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Challenges
Chemical Reaction Engineering Laboratory
Hysys would not run dynamics if solids existed in streamsCascade mode would not work without external references in DeltaVHysys would not switch to dynamics if all 3 columns were presentSimplified the process to get it to workCreated own dynamos in DeltaV because the ones found in the library did not match the P&IDsRequired more overall time and effort than was originally predicted
DeltaV Control Blocks
PID
AI
AO
CALC
External References
Chemical Reaction Engineering Laboratory
Testing Procedure
Chemical Reaction Engineering Laboratory
Testing reasonability of HYSYS simulation
Testing reactions of the DeltaV control system prior to link to HYSYS
Test the linked systems
TeamWork
TEAM DUNCAN!!!Bia Henriques (Captain)
Hysys simulation and implementation
Jonathan LoweDeltaV simulation, module design and implementation
Kwaku Opoku-Mensah and Rachel VazziDeltaV graphic design and implementation
Chemical Reaction Engineering Laboratory
AI
Chemical Reaction Engineering Laboratory
PID
Chemical Reaction Engineering Laboratory
PID with Cascade
Chemical Reaction Engineering Laboratory
Heat Exchanger
Chemical Reaction Engineering Laboratory
Beer Well P&ID
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Beer Well DeltaV Graphic
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Hysys Simulation
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What Went Wrong/Right
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Right:Creation of DeltaV graphics went smoothly
DeltaV configuration works sufficiently
Steady-state Hysys converged properly
Hysys and DeltaV talked correctly
Wrong:
•
Hysys dynamic mode did not behave correctly
• Mass balance around column did not sum
Accomplishments
Chemical Reaction Engineering Laboratory
Each of us learned new skills in DeltaV or Hysys
A real-world process was modeled and controlled in the lab
This model, once perfected, could be used to estimate costs and feasibility of process control
Future Work
Chemical Reaction Engineering Laboratory
Tune model to achieve process optimization of pilot plant thus increasing ethanol production
Create full interactive model of pilot plant in HYSYS and DeltaV
Design process control system for other unit operations in the pilot plant
Lessons Learned
Chemical Reaction Engineering Laboratory
References:http://www.meadmadecomplicated.org/science/fermentation.htmlhttp://www.andrew.cmu.edu/user/jitkangl/Fermentation%20of%20Ethanol/Fermentation%20of%20Ethanol.htm
Jonathan & Bia: Hysys dynamic mode, linking DeltaV and Hysys
Kwaku & Rachel: DeltaV graphics, configuration, reading PnID’s, linking DeltaV graphics and configuration
Acknowledgements
Chemical Reaction Engineering Laboratory
Thanks to Dr. Terry Tolliver for assisting with the simulation of the SIUE pilot plant.
The End
Chemical Reaction Engineering Laboratory
QUESTIONS???