CHAPTER 2 : CONTROL OBJECTIVES

AND BENEFITS
When I complete this chapter, I want to be
able to do the following.

• Recognize examples of the seven (7)

control objectives in chemical processes
• Calculate indicators of variability in a
process variable
• Be able to calculate the economic impact
of variability
CHAPTER 2 : CONTROL OBJECTIVES
AND BENEFITS
Outline of the lesson.

• Seven (7) Control Objectives

1. Safety
2. Environmental protection
3. Equipment protection
4. Smooth operation
5. Product quality
6. Profit
7. Monitoring and diagnosis

• Variability measures
• Economic impact of variability
• Workshop
 EXAMPLE PROCESS: FLASH SEPARATION

Let’s discuss
this process
T6 P1
Vapor
product

Feed T1 T2
T5 P ≈ 1000 kPa
Methane T ≈ 298 K
Ethane (LK)
Propane F1 T4 T3 L1
Butane
Pentane

F2 F3

A1
Liquid
Process Steam product
L. Key
fluid
 SEVEN CONTROL OBJECTIVES

Give example
1. Safety

2. Environmental T6 P1
Vapor
Protection product

3. Equipment T5
T1 T2
protection
Feed
4. Smooth operation F1 T4 T3 L1
production rate

5. Product quality
F2 F3
6. High profit A1
Liquid
Process Steam product
L. Key
fluid
7. Monitoring &
diagnosis
 SEVEN CONTROL OBJECTIVES

High pressure
1. Safety in drum is
dangerous Vapor
2. Environmental T6 PC
Protection product

3. Equipment T5
T1 T2
protection
Feed
4. Smooth operation F1 T4 T3 L1
production rate

5. Product quality
F2 F3
6. High profit A1
Liquid
Process Steam product
L. Key
fluid
7. Monitoring &
diagnosis
 SEVEN CONTROL OBJECTIVES

1. Safety Give example

2. Environmental T6 P1
Vapor
Protection product

3. Equipment T5
T1 T2
protection
Feed
4. Smooth operation F1 T4 T3 L1
production rate

5. Product quality
F2 F3
6. High profit A1
Liquid
Process Steam product
L. Key
fluid
7. Monitoring &
diagnosis
 SEVEN CONTROL OBJECTIVES
To flare
1. Safety Never release
hydrocarbons
Vapor
2. Environmental to atmosphere T6 P1
Protection product

3. Equipment T5
T1 T2
protection
Feed
4. Smooth operation F1 T4 T3 L1
production rate

5. Product quality
F2 F3
6. High profit A1
Liquid
Process Steam product
L. Key
fluid
7. Monitoring &
diagnosis
 SEVEN CONTROL OBJECTIVES

1. Safety Give example

2. Environmental T6 P1
Vapor
Protection product

3. Equipment T5
T1 T2
protection
Feed
4. Smooth operation F1 T4 T3 L1
production rate

5. Product quality
F2 F3
6. High profit A1
Liquid
Process Steam product
L. Key
fluid
7. Monitoring &
diagnosis
 SEVEN CONTROL OBJECTIVES

1. Safety No flow could

damage the
2. Environmental
Vapor
pump T6 P1
product
Protection

3. Equipment T5
T1 T2
protection
Feed
4. Smooth operation F1 T4
T3 LC
production rate

5. Product quality
F2 F3

6. High profit A1
Liquid
Process Steam product
L. Key
fluid
7. Monitoring &
diagnosis
 SEVEN CONTROL OBJECTIVES

1. Safety Give example

2. Environmental T6 P1
Vapor
Protection product

3. Equipment T5
T1 T2
protection
Feed
4. Smooth operation F1 T4 T3 L1
production rate

5. Product quality
F2 F3
6. High profit A1
Liquid
Process Steam product
L. Key
fluid
7. Monitoring &
diagnosis
 SEVEN CONTROL OBJECTIVES

Always keep
1. Safety the production
rate smooth Vapor
2. Environmental T6 P1
Protection product

3. Equipment T5
T1 T2
protection
Feed
4. Smooth operation FC T4 T3 L1
production rate

5. Product quality
F2 F3

6. High profit A1
Liquid
Process Steam product
L. Key
fluid
7. Monitoring &
diagnosis
 SEVEN CONTROL OBJECTIVES

1. Safety Give example

2. Environmental T6 P1
Vapor
Protection product

3. Equipment T5
T1 T2
protection
Feed
4. Smooth operation F1 T4 T3 L1
production rate

5. Product quality
F2 F3
6. High profit A1
Liquid
Process Steam product
L. Key
fluid
7. Monitoring &
diagnosis
 SEVEN CONTROL OBJECTIVES
Achieve L.Key
1. Safety by adjusting
the heating Vapor
2. Environmental T6 P1
Protection product

3. Equipment T5
T1 T2
protection
Feed
4. Smooth operation F1 T4
T3 L1
production rate

5. Product quality
F2 F3

6. High profit AC
Liquid
Process Steam product
L. Key
fluid
7. Monitoring &
diagnosis
 SEVEN CONTROL OBJECTIVES

1. Safety Give example

2. Environmental T6 P1
Vapor
Protection product

3. Equipment T5
T1 T2
protection
Feed
4. Smooth operation F1 T4 T3 L1
production rate

5. Product quality
F2 F3
6. High profit A1
Liquid
Process Steam product
L. Key
fluid
7. Monitoring &
diagnosis
 SEVEN CONTROL OBJECTIVES

Use the least

1. Safety
costly heating
2. Environmental T6 P1
Vapor
Protection product

3. Equipment T5
T1 T2
protection
Feed
4. Smooth operation F1 T4
T3 L1
production rate

5. Product quality
F2 F3

6. High profit AC
Liquid
Process Steam product
L. Key
fluid
7. Monitoring &
diagnosis
 SEVEN CONTROL OBJECTIVES

1. Safety Give example

2. Environmental T6 P1
Vapor
Protection product

3. Equipment T5
T1 T2
protection
Feed
4. Smooth operation F1 T4 T3 L1
production rate

5. Product quality
F2 F3
6. High profit A1
Liquid
Process Steam product
L. Key
fluid
7. Monitoring &
diagnosis
 SEVEN CONTROL OBJECTIVES

1. Safety Calculate & plot

key parameters,
Vapor
2. Environmental e.g., UA. T6 P1
Protection product

3. Equipment T5
T1 T2
protection
Feed
4. Smooth operation F1 T4 T3 L1
production rate

5. Product quality
F2 F3
6. High profit A1
Liquid
Process Steam product
L. Key
fluid
7. Monitoring &
diagnosis UA
time
 SEVEN CONTROL OBJECTIVES

1. Safety
All seven must be achieved. Failure to do so
will lead to operation that is
2. Environmental unprofitable or worse, unsafe.
Protection

3. Equipment T6 P1
Vapor
protection product

4. Smooth operation T5
T1 T2
production rate
Feed
5. Product quality F1 T4 T3 L1

6. High profit

7. Monitoring & F2 F3
diagnosis A1
Liquid
Process Steam product
L. Key
fluid
 BENEFITS FROM PROCESS CONTROL
When we control a process, we reduce the variability of
key variables to achieve the seven objectives.

Without feedback control

Composition (% H. Key)
6

outlet concentration
5

2
0 50 100 150 200 250 300 350 400 450 500
time (min)

51
valve position (% open)

50.5 Reflux valve

50

49.5

49
0 50 100 150 200 250 300 350 400 450 500
time (min)
 BENEFITS FROM PROCESS CONTROL
When we control a process, we reduce the variability of
key variables to achieve the seven objectives.

With feedback control

3.5
Composition (% H. Key)

outlet concentration
3

2.5
0 50 100 150 200 250 300 350 400 450 500
time (min)

100

valve position (% open)

80 Reflux valve
60

40

20
0 50 100 150 200 250 300 350 400 450 500
time (min)

Variability is moved from controlled to manipulated variable!

 BENEFITS FROM PROCESS CONTROL

When we control a process, we reduce the variability of

key variables to achieve the seven objectives.

What statistics
can we calculate
from this data?

How do we relate
variability to
process performance?
BENEFITS FROM PROCESS CONTROL

Process performance =
efficiency, yield, production
rate, etc. It measures
performance for a control
objective.

Calculate the process

performance using the
distribution, not the
average value of the key
variable!
Example of Benefits of reduced
variability for chemical reactor
A
Goal: Maximize conversion of
feed ethane but do not exceed
864C
Which operation, A or B, is better
B
and explain why.
Example of Benefits of reduced A
variability for chemical reactor

Goal: Maximize efficiency and

prevent fuel-rich flue gas
Which operation, A or B, is better
B
and explain why.
 CHAPTER 2: GOALS AND BENEFITS WORKSHOP 1
Determine one example for each of the seven control objective categories.

PIC Flue
1
gas The feed flows
AT
1
PI
4 through a pipe and
FT
1 TI
1
PI
is heated by the
5
TI combustion of fuel
feed TI
5

TI
6
PT
1 product
TI
3
TI
7 TI TI
TI 9 10
4

FT TI
FI
2 8 TI
3
air 11

PI
2
PI
3
PI
6
fuel
CHAPTER 2 : CONTROL OBJECTIVES & BENEFITS

When I complete this chapter, I want to be

able to do the following.

• Recognize examples of the seven (7)

control objectives in chemical processes
• Calculate indicators of variability in a
process variable
• Be able to calculate the economic impact
of variability

Lot’s of improvement, but we need some more study!

• Read the textbook
• Review the notes, especially learning goals and workshop
• Try out the self-study suggestions
• Naturally, we’ll have an assignment!
 CHAPTER 2: GOALS AND BENEFITS WORKSHOP 2

Two process examples show the benefit of reduced variability,

the fired heater reactor and the boiler. Discuss the difference
between the two examples. Can you think of another example
that shows the principle of each?

Squeeze down the variability

0.4
frequency of occurrence

0.3

0.2

0.1

0
-3 -2 -1 0 1 2 3
deviation from mean
 CHAPTER 2: GOALS AND BENEFITS WORKSHOP 3

In both the flash drum and the fired heater examples,

temperature measurement is very important. Describe
several methods for measuring temperature and recommend
the most appropriate for the flash drum example.

How hot is it? T6 P1

Vapor
product

T1 T5
T2

Feed
F1 T4 T3 L1

F2 F3

A1
Liquid
Process Steam product
L. Key
fluid