Modelling in Process Systems Engineering

CAPE Centre, The University of Queensland Hungarian Academy of Sciences

Contents
Some modelling applications What is a model ? The key steps to real world modelling Where are models used ? What do models look like ? What form do models take ? Some modelling wisdom !
CAPE Centre, The University of Queensland Hungarian Academy of Sciences

Surge Control Design for a Hydrogen Compressor

Head (bar) versus flowrate (kg/s) during controlled shutdown

Model features: process model plus control elements considered complex nonlinear dynamics and potential discontinuous behaviour

CAPE Centre, The University of Queensland Hungarian Academy of Sciences

Rotary calciner for Na2CO3 production from trona

T m [k ] 451 450 449 448 447

P ID NLMPC N L M P C fe e d fo rw a rd

S q [% ] 1 .2 5 1 .2 1 .1 5 1 .1 1 .0 5 1
P ID NLMPC N L M P C fe e d fo rw a rd

2 3 T im e [h ]

0 .9 5 0

2 3 T im e [h ]

Solid temperature control and sesquicarbonate content dynamic response in the presence of the step increase of the solid inlet flowrate Qm=+500kg/h disturbance.
CAPE Centre, The University of Queensland Hungarian Academy of Sciences

Safety and Risk Assessment (BLEVE Radiation)

Boiling Liquid Expanding Vapour Explosion

3D surface showing percent first degree burns for a BLEVE

Model features: empirical model based on field trials and actual explosion effects BLEVE size and duration computed resource vulnerability based on stochastic (Probit) model
CAPE Centre, The University of Queensland Hungarian Academy of Sciences

Sugar Drying Control

0.025 0.02 (kg/s) Sugar flow 0.015 0.01 0.005 0

20

40 60 time (minute)

80

100

Sugar flowrate versus time under startup and airflow changes

Model features: grey-box model based on mass & heat transfer combined with particle transport validated model against pilot plant data provides basis for model-based control system design
CAPE Centre, The University of Queensland Hungarian Academy of Sciences

FCCU Control
MAIN FRACTIONATOR REACTOR Stack Gas

Tr

xO2sg
V14 REGENERATOR

Wr
6

Tcyc
Steam

V11

svsc
Air Vent

Treg
Wet Gas Compressor
1

V7

svrgc
2

Preheat Furnace F3

Fresh Feed

V6

Combustion Air Blower F4 F5

5

Atmospheric Air
1 2 3 4 5 6

F2 Diesel

F1

Slurry recycle

Furnace Fuel

PROCESS VARIABLES:

MODEL PREDICTIVE CONTROLLER

Reactor Temperature Regenerator Temperature Reactor Catalyst Inventory Cyclone Temperature Oxygen Content in Stack Gas

Model features: mechanistic model lumped kinetic model provides basis for model-based control system design
CAPE Centre, The University of Queensland Hungarian Academy of Sciences

Drying Electric Insulators

Model features: mechanistic/statistical model batch operation provides basis for model-based control system design
CAPE Centre, The University of Queensland Hungarian Academy of Sciences

Wastewater Treatment

Activated sludge process Clarification Process control

Model features: complex biological reactions within a mechanistic model validation against plant data challenging provides basis for model-based plant and control system design
CAPE Centre, The University of Queensland Hungarian Academy of Sciences

The Concept of a Model in PSE

What is a model ?
A model (M) for a system (S) and an experiment (E) is anything to which E can be applied in order to answer questions about S (Minsky, 1965)

Process engineering models

A mathematical representation (M) of a physical system (S) for a specific purpose (P) and experiment (E)

CAPE Centre, The University of Queensland Hungarian Academy of Sciences

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The Modelling Process

Real world problem 4 Interpretation 1 Mathematical problem 2 Mathematical 3 solution

CAPE Centre, The University of Queensland Hungarian Academy of Sciences

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The Modelling Process

Real world problem 4 Interpretation 1 Mathematical problem 2 Mathematical 3 solution

CAPE Centre, The University of Queensland Hungarian Academy of Sciences

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The Modelling Process

Real world problem 4 Interpretation 1 Mathematical problem 2 Mathematical 3 solution

CAPE Centre, The University of Queensland Hungarian Academy of Sciences

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The Modelling Process

Real world problem 4 Interpretation 1 Mathematical problem 2 Mathematical 3 solution

CAPE Centre, The University of Queensland Hungarian Academy of Sciences

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The Modelling Process

Real world problem 4 Interpretation 1 Mathematical problem 2 Mathematical 3 solution

CAPE Centre, The University of Queensland Hungarian Academy of Sciences

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Model Application Areas

Process design Process control and diagnosis Troubleshooting Process safety Operator training Environmental impact assessment

CAPE Centre, The University of Queensland Hungarian Academy of Sciences

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Model Classification
Mechanistic vs. Empirical (white/black/grey) Stochastic vs. Deterministic Lumped vs. Distributed Linear vs. Nonlinear Continuous vs. Discrete Dynamic vs. Steady state

CAPE Centre, The University of Queensland Hungarian Academy of Sciences

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Model Equation Forms

Deterministic Stochastic Lumped Distributed Linear Continuous Discrete NLAE/ODE/PDAEs NLAE/DE/Integral PDAEs NLAE/ODE Elliptic/Parabolic PDE linear AE/ODE NLAE/ODE -/DE

CAPE Centre, The University of Queensland Hungarian Academy of Sciences

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Modelling Wisdom
All models are wrong . . some are useful !

George Box

CAPE Centre, The University of Queensland Hungarian Academy of Sciences

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