Chemical process dynamics

and control
Flavio Manenti
CMIC Giulio Natta Dept.

Contacts
Flavio Manenti
Alexander von Humboldt Professor of Chemical Plants and Operations
POLITECNICO DI MILANO

Dipartimento di Chimica, Materiali e Ingegneria Chimica "Giulio Natta"

Centre for SuPER (Sustainable Process Engineering Research)
Piazza Leonardo da Vinci, 32 - I-20133 Milano, ITALY

TECHNISCHE UNIVERSITAT BERLIN

DBTA (Dynamic und Betrieb Technischer Anlagen) Faculty

Sekt. KWT 9, Strasse des 17.Juni, 135 - D-10623 Berlin, GERMANY

Phone IT +39.(0)2.2399.3273 - DE +49 (0)30 314 23418

Fax
IT +39.(0)2.2399.3280
Email
flavio.manenti@polimi.it
http://super.chem.polimi.it
Web
Excellence Cluster: www.reinforce.polimi.it
Students: Wednesday 10:15 11:15 (please, ask via email for)
MSc and PhD students and visiting: no limitations
Flavio Manenti Dipartimento CMIC Giulio Natta

People

Staff:

Claudia Bianchi, Giulia Bozzano, Flavio Manenti, Laura Piazza, Sauro Pierucci,
Carlo Pirola Guido Buzzi Ferraris, Eliseo Ranzi

Collaborators:

Andr Furtado Amaral, Brazil-Italy, Biorefinery (Plant)

Andrea Bassani, Italy, Sulfur & Coal Gasification (Process)
Lorenzo Cabianca, Belgium-Italy, Biomass gasification (Numerics)
Michele Corbetta, Italy-USA, Biorefinery downstream (Process)
Andres Ricardo Garzon-Leon, Colombia-Italy, Polymer Science (Kinetics)
Ergys Pahija, Hong Kong, Biorefinery (Plant)
Davide Papasidero, Italy-The Netherlands, Food Engineering (Kinetics)
Francesco Rossi, Italy-USA, Optimization (Process)
Mattia Vallerio, Belgium, Optimal Control (Process)
Anton Ochoa-Bike, Russian Fed., Nuclear (Process)
Zhaoli Zhang, China, Solar (Plant)
Muhammad Rizwan, South Korea (Plant)

Industrial Consultants:

Maria Grazia Grottoli, Lucio Molinari

Students: 22 ongoing thesis projects

Flavio Manenti Dipartimento CMIC Giulio Natta

Motivation to study process

control

Relevance

Manage chemical/power generation plants

Control-room/DCS operators
Needed everywhere
Driving license

Advanced skills

Process control means:

Numerical methods
Process modeling
Process simulation
Process optimization

Last call for you

Fun

Developing dynamic simulations, implementing every kind of

malfunctions, playing with the transients of the processes
Dynamic simulation of the chemical plants is become a 3D tool (also with
XBOX, 2012; see Eyesim by Invensys operations Management)

Flavio Manenti Dipartimento CMIC Giulio Natta

MS course program
Nonlinear Systems

Solvers

Optimizers
Differential systems

DCS, OTS, Plantwide control,

Soft sensing, process transients,
grade/load changes

Stiff systems
ODE,DAE,PDE,PDAE

Parallel
Computing

Dynamic
Simulation

Efficiency

Economy
Just in time
Market-driven
Logistics

Corporate
Supply Chain
Planning

Mathematical
Modeling

Data
Reconciliation

Scheduling

Optimization

Distributed predictive control

Model
Predictive
Control

Model
Reduction

Uncertainties
Optimal production

Outlier Detection
Robust methods
Linear/nonlinear Regressions

Dynamic optimization

Optimal grade changes

Raw Data

Performance Monitoring
Yield Accounting
Soft sensing

Flavio Manenti Dipartimento CMIC Giulio Natta

Decisions

Multi-objective
Real-time optimization
High accuracy
Reliable process control
Production improvement

MS course program
MAIN TOPICS
Brief history of and introduction to process control
Fundamentals of:

Process modeling

Numerical methods
Conservation principle

Process dynamics

Mass, energy, momentum balances

ODE/DAE systems
Open-loop dynamic simulation

Process control

Essentials of process control

P, PI, PID controllers
Closed-loop dynamic simulation

Data analysis

Data interpretation and correlation

Flavio Manenti Dipartimento CMIC Giulio Natta

MS course program

Data fitting
Data reconciliation
Outliers

Process modeling

Total continuity equation (mass balance)

Atmospheric tank, Pipeline

Component continuity equations (component mass balances)

Continuous stirred tank reactor, Consecutive reactions, Plug flow reactor

Energy equation

Continuous stirred tank reactor with exothermic reactions, Cooled two-phase

continuous stirred tank reactor, Jacketed tubular reactor

Equation of motion

Gravity tank, Pipeline and pig for oil operations

Transport equations

Flavio Manenti Dipartimento CMIC Giulio Natta

MS course program
Equation of state
Equilibrium

Chemical, Physical

Chemical kinetics

Arrhenius, Reaction rate

Reactors and unit operations

Series of isothermal constant-holdup CSTRs

CSTRs with variable holdups
Two heated tanks
Gas-phase CSTR
Nonisothermal CSTR

Perfectly mixed cooling jacket

Plug flow cooling jacket
Lumped cooling jacket
Metal wall capacitance

Flavio Manenti Dipartimento CMIC Giulio Natta

MS course program

Single-component vaporizer

Steady-state model
Liquid-phase dynamics
Liquid and vapor dynamics
Thermal equilibrium model

Multicomponent flash drum

Steady-state model
Rigorous model
Practical model

Batch reactor

Heating phase
Cooling phase

Reactor with mass transfer

Ideal binary distillation column
Multicomponent nonideal distillation column
Batch distillation with holdup
pH system

Flavio Manenti Dipartimento CMIC Giulio Natta

MS course program

10

Energy storage

Concentrating solar plant, Archimede plant

Advanced process control

Ratio, cascade
Plantwide process control

Complex units, Gas processing, Industrial processes

Optimal (predictive) process control

DMC (dynamic matrix control)

Nonlinear model predictive control
Dynamic real-time optimization
Ringing, stability, numerical methods

Essentials of strategic levels (process optimization)

Production scheduling, planning (business-wide process control)

Enterprise-wide process control
Essential of mixed-integer optimization

CAPE industrial applications

Flavio Manenti Dipartimento CMIC Giulio Natta

MS course program
Essential of C++

11

LABORATORIES

Grammar & syntax

Numerical methods, BzzMath library
ODE and DAE systems (C++)

Dynamic simulation and conventional control

Gravity-flow tank
Series of isothermal CSTRs
Nonisothermal CSTR

Nonlinear model predictive control (C++)

Dynamic optimization (C++)
Commercial dynamic simulators (e.g. DYNSIM, ASPENHYSYS)
Tutorial, overview
Ideal flash separator and related control scheme

Flavio Manenti Dipartimento CMIC Giulio Natta

MS course program

12

Gas processing (refrigeration and/or separation sections)

Process simulation
Plantwide control
Conditions, scenarios, grade changes, OTS

Exam

Pre-test (optional)
Oral (mandatory)

Flavio Manenti Dipartimento CMIC Giulio Natta

References

13

Some names for process dynamics and control (books):

G. Stephanopoulos - Chemical process control: an introduction to theory and

practice, Prentice-Hall, 1984
D. Seborg, T. Edgar, D. Mellicamp - Process Dynamics and Control, J. Wiley, 2003
S. Skogestad, I. Postlethwaite - Multivariable Feedback Control -Analysis and design, Wiley,
1996; 2005
S. Skogestad - Chemical and Energy Process Engineering, CRC Press, Taylor&Francis, 2008
J. Romagnoli, A. Palazoglu - Introduction to Process Control, CRC Press, Taylor&Francis, 2005
M. Luyben, W. Luyben - Essentials of process control, McGraw-Hill, Chemical Engineering
Series, 1997
W. Bequette - Process Control: Modeling, Design, and Simulation, Prentice Hall Professional,
2003
T. Marlin - Process control: designing processes and control systems for dynamic performance,
McGraw-Hill, 2000
G. Buzzi-Ferraris, F. Manenti Interpolation and Regression Models for the Chemical
Engineering: Solving Numerical Problems, Wiley-VCH (Vol. 2), 2010
G. Buzzi-Ferraris, F. Manenti Nonlinear Systems and Optimization for the Chemical
Engineering: Solving Numerical Problems, Wiley-VCH (Vol. 3), 2013
G. Buzzi-Ferraris, F. Manenti - Differential and Differential-Algebraic Systems for the Chemical
Engineering: Solving Numerical Problems, Wiley-VCH (Vol. 4), 2014

Use database/library, ISI Web of Knowledge, Scopus for papers

Flavio Manenti Dipartimento CMIC Giulio Natta