Twin-Screw Food Extruder: A Multivariable Case...
Transcript of Twin-Screw Food Extruder: A Multivariable Case...
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Chemical and Biological Engineering
Twin-Screw Food Extruder: A Multivariable Case Study for a Process
Control Course
Joel SchlosburgB. Wayne Bequette
• Process Control Course Overview• Case Studies
• Realistic Industrial Problems• Motivating to Students• Integrate Techniques Learned Throughout Course
BES-0411693
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Process Control @ RPI
Four credit hours, Spring Junior yearThree 2-hour sessions/weekStudio: Lectures and SimulationsMajor Case Study Project
Selected from multiple options
Teamwork
Written reports & frequent meetings
Final oral presentation
Link between theory and practice“Feels real”
Multivariable
Noise, constraints
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Case Study ProjectsFinal 1/3 of CourseChoice of Projects
Reactive Ion Etcher
Lime Kiln
Fluidized Catalytic Cracking (FCCU)
Anaerobic Sludge Digester
Drug Infusion Control (Critical Care)
Different Advisor (Instructor/TA/RA) for Each ProjectWritten Reports & Final Presentation To Main Column
Feed Oil from Crude Unit
T1CTYC
F s
F a
Heat Exchange
Flue Gas
Air
T rg
Crc
Tcy
T 1
Steam
T 1sp
T cysp
Riser
Reactor (actually a separator)
Regenerator
Spent Catalyst
Regenerated Catalyst
Sensors Controller
Drugs Infused
Infusion pumps
Patient
Measured variables
MAP CO
SNP DPM
setpoints
Flourine MeasurementRF PowerVoltage Bias
Measurement
Computer Control
Power
Throttle
[F]V
bias
Reactive Ion Etcher
Gases In Gases Out
Heater
flow
Flow, % of range
voltage
Voltage, V
fluorine
Fluorine, % of range
throttle, %
power, W
Clock
t
time
power disturbance, W
Etcher
LC
PC
u1
u2
heat input
inlet flowrate
y1
substrate concentration
y2
temperature
Anaerobic Digester
biogas
disgested sludge
MIMO Control
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Project Stages
Literature review Week 1Model development Week 2Single input-single output (SISO) controller design Week 3Multiple loop design Week 4Oral presentation Week 5Final written report Week 5
Primary Goals: Learn MIMO Modeling, Analysis and ControlIntegrate basic concepts learned throughout the semester
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Twin-Screw Cooking Food Extruder
Common food processing unit, mostly in baking industryFast-speed bioreactor with heating, cooling, compressing, mixing, evaporating, cutting, and aerating in one unitTwin-screw is now becoming more common, as it is easier to manipulate a number of parameters
www.foodprocessing-technology.comScrew Speed manipulated
Moisture content manipulated
Motor torquemeasured
Product temperature measured
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Process Simulation (MATLAB/Simulink)
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Step Tests to Develop Model
Input 1 Input 2
Output 1 Output 2
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Step Tests to Develop ModelNoise and mismatch
Output 1 Output 2
Input 1 Input 2
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SS-MT SISO ControlEffect of tuning parameter values
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Relative Gain Analysis (RGA) for “Pairing”
Process Gain matrix =
λ11 & λ22 are closer to one, and therefore are the better control loop pairings.
This means the two control loops are:
SS (screw speed) controlling MT (motor torque)
MC (moisture content) controlling PT (product temperature)
⎥⎦
⎤⎢⎣
⎡=
⎥⎥⎦
⎤
⎢⎢⎣
⎡=⎥
⎦
⎤⎢⎣
⎡λλλλ
=Λ−−
−−
−−
88.12.
12.88.
21122211
2211
21122211
2112
21122211
2112
21122211
2211
kkkkkk
kkkkkk
kkkkkk
kkkkkk
2221
1211
⎥⎦
⎤⎢⎣
⎡−−−
=⎥⎦
⎤⎢⎣
⎡4.212.
87.32.
kk
kk
2221
1211
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Best “Pairing” based on RGA
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Simultaneous Setpoint Changes
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Simultaneous Setpoint Changes
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Disturbance Rejection(change in barrel temperature)
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RGA Validation: Opposite Pairing
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Textbook
Chapters1. Introduction 2. Fundamental Models3. Dynamic Behavior 4. Empirical Models5. Introduction to Feedback Control6. PID Controller Tuning7. Frequency-Response Analysis8. Internal Model Control 9. The IMC-Based PID Procedure10. Cascade and Feed-Forward Control11. PID Enhancements12. Ratio, Selective, and Split-Range Control13. Control-Loop Interaction14. Multivariable Control15. Plantwide Control16. Model Predictive Control17. Summary
Modules1. Introduction to MATLAB2. Introduction to Simulink3. Ordinary Differential Equations 4. MATLAB LTI Models 5. Isothermal Chemical Reactor 6. First-Order + Time-Delay Processes7. Biochemical Reactors8. Continuously Stirred Tank Reactor (CSTR)9. Steam Drum Level10. Surge Vessel Level11. Batch Reactor12. Biomedical Systems13. Distillation Control14. Case Study Problems15. Flow Control 16. Digital Control
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SummaryLaptop Studio-based Course
Lectures followed by simulation-based reinforcement of theory
Case Study ProjectsChoice of 5 projects, final 1/3 of course
Integrates concepts learned throughout course
Multivariable focus
Twin screw food extruder