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

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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

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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

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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

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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

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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

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Testing Procedure

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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

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AI

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PID

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PID with Cascade

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Heat Exchanger

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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

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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

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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

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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

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Thanks to Dr. Terry Tolliver for assisting with the simulation of the SIUE pilot plant.

The End

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QUESTIONS???