Plantwide Control - case studies considering biodiesel and formic acid processes

Dipesh S Patle

Chemical Engineering Department, Motilal Nehru National Institute of Technology,

Allahabad, 211 004, Uttar Pradesh, India.
dipesh-patle@mnnit.ac.in

1. Introduction

Plantwide control (PWC) design is the development of a control system for interconnected operations in

chemical processes with material and/or energy recycles. Process design has direct influence on the process

controllability. Therefore, it is a good idea to address process design and control aspects in an integrated

framework. However, this enhances the complexity, especially when dealing with a large complex processes.

Mansouri et al [1] studied an integrated process design and control of reactive distillation processes through a

computer‐aided framework. They proved that designing the reactive distillation process at the maximum driving

force results in a feasible and reliable process design as well as the control system. Same authors in another

study [2] studied the integrated process design and control of RD unit involving multi-elements through a

computer-aided hierarchical decomposition-based framework. They showed that the design at the maximum

driving force can be controlled using conventional controllers as well as advanced controllers. The recycles may

affect the process dynamics due to the introduction of an integrating effect, which may result in the snowball

effect that consequently makes the process control a challenging task. PWC methodologies can be classified as

heuristics, optimization, mathematical and mixed approaches; Please refer to Vasudevan et al. [3] for a review of

methodologies and applications. Rigorous mathematical and optimisation based methodologies demand

substantial computations, particularly when dealing with intricate processes, and their solution depends on the

extent of details considered. On the other hand, heuristic-based methodologies involve fewer computations and

are easy to apply.

One of the widely used heuristic-based PWC methods is the nine-step PWC procedure proposed by Luyben et

al. [4], which considers the significance of control and the operational objectives. In general, limitations of

heuristic-based methods are that they depend only on user's experience. Process simulators can assist in deciding

the suitable controller pairings from PWC perspective. One such method that uses heuristics and simulators is
the integrated framework of simulation and heuristics (IFSH) methodology, [5] which is easy to apply and

requires fewer computations.

In this article, the two of our own PWC studies are discussed. First is the PWC of biodiesel production from

waste cooking oil (WCO) and the second process is the PWC of formic acid (FA) production. Both processes

are commercially important process and their PWC studies in the open literature are limited. IFSH methodology

was used to develop a PWC mechanism for both processes. Following section describes the process design of

the two processes.

2. Process design and simulation

2.1 Biodiesel production from waste cooking oil

Based on potential WCO availability in Malaysia, biodiesel plant capacity was taken as 120 kt/year. For reliable

biodiesel process modeling, it is crucial to capture the non-ideal phase equilibrium as the biodiesel process

involves highly non-ideal components. Main attributes of this process were: (1) one reactor for esterification, (2)

three reactors for transesterification with intermediate phase separators and (3) biodiesel and glycerol are

separated first followed by methanol separation and washing of biodiesel. This scheme prevents backward

reactions as methanol is present until biodiesel and glycerol are separated and the recovered methanol contains

very small amount of water, which avoids energy intensive methanol-water separation and facilitates methanol

re-use in the process [6]. Dortmund modified UNIFAC was used in this study to predict the physical properties

of the considered components. Aspen Plus V8.0 was used for the simulation purpose. Please refer to our study

[6] for more about the process.

2.2 Formic acid

Please refer to our study [7] for more about the FA process. This process includes of a reactor (where a carbonyl

reaction occurs), one RD column for MF hydrolysis and two distillation columns for separation of the products.

The merit of this process is that it combines hydrolysis and separation units into a RD column to produce FA,

thereby reducing the footprint of equipments. The UNIQUAC-HOC model was selected for thermodynamic

calculations. Aspen Plus V8.8 was used for the simulating the process.
3. Plantwide control

PWC structure for these processes was designed using the IFSH method that was developed by Konda et al. [5].

IFSH methodology is methodical and hierarchical having a total of eight levels that utilizes rigorous process

simulator in conjunction with the heuristics in PWC structure design. Length to diameter ratio for CSTR and

reflux drum & sump in distillation columns was considered as 2:1. For CSTR, the volume was determined based

on the residence time. The volumetric flow rate (cum/min) was multiplied with 10 (for 10 min inventory) to get

a total volume of reflux drum and sump in distillation columns.

Tray/pack sizing option in Aspen Plus was used to obtain the column diameter, where the diameter of a

distillation column was determined based on the maximum vapor velocity. Levels of IFSH methodology (as

presented in Konda et al. [5]) were then implemented step by step to obtain a PWC structure for both processes.

These levels are mentioned below:

Level 1.1: Define PWC Objectives

Level 1.2: Determine CDOF

Level 2.1: Identify and Analyze Plant-Wide Disturbances

Level 3.1: Production Rate Manipulator Selection

Level 3.2: Product Quality Manipulator Selection

Level 4.1: Selection of Manipulators for More Severe Controlled Variables

Level 4.2: Selection of Manipulators for Less Severe Controlled Variables.

Level 5: Control of Unit Operations

Level 6: Check Component Material Balances

Level 7: Effects due to Integration

Level 8: Enhance Control System Performance

Figure 1 and figure 2 present the developed PWC structure for the biodiesel process and FA process,
respectively.
 MEOH V-1 RC100 PC101

PC100 V-4
H2SO4 FRAC-2
V-2 LC103 FRAC-2-1
N2-IN V-49 1
RC101 N2-OUT
V-50
TC101
P-3
OIL 10
V-14 H-1 P-1 P-5
LC104
RFFA TC100
V-42
FC100 RFFA1
PC102
LC105
V-8
LC100
1
LC101 V-3
GLY-IN V-5 FRAC-1
P-4 H-2
W-1-1 V-6 FRAC-1-1
W-1 LC102
6 TC102

W-1-2 FRAC-1-2
V-7 P-6-1
FC101 ME-WAT-1 P-6
V-12 S-1-1 V-9
LC106
V-10 R-CAO-1
PC103

LC108 V-11 S-1 CAO

F-1 R-CAO V-15
LC107
GLY-2
F-1-2
CASO4 pH100
V-13
P-7
PC200
N2-OUT
V-43 CC200
N2-IN V-44

LC213

V-16 LC200 WATER

V-38 BIO-D
RTRANS1 V-39
R-1
V-20
LC202 LC201
V-46 N2-OUT WASH-2 V-40 WASTE
D-1-1 TC200
D-1-2 (organic)
V-19
D-1 PC201
V-17 N2-IN V-45 V-51 LC214

V-23 V-21
SP200
R-2 RTRANS2
LC205 S-2
LC204
LC203 NA3PO4
D-2 TC201
SP201
D-2-2
V-18 N2-OUT
PC203 D-2-1 V-24
PC202
V-48 V-22
V-37
pH201
LC207
N2-IN LC212

1 V-36 H3PO4
ME-WAT-2
V-47
P-8 RTRANS3
FRAC-4 V-29 R-CAT-1
LC206
10 H3PO4-2 TC202 R-CAT
V-25 V-35
V-26 PC204 P-12
LC208

FRAC-4-2 R-3

V-30
P-11 R-CAT2 pH200
H-3 H-4
TC203
1
LC209 FRAC-3-1
R-CAT2-1 FRAC-3
V-32
V-41 LC211
V-27 V-34
GLY-OUT P-9 11
P-10 NAOH
LC210
FRAC-3-2
S-3 V-33 MEOH-2
NA3PO4-2 RC201
V-31 TC204

RC200

Figure 1: PWC for a biodiesel process [6].

 Figure 2: PWC for a FA process.

4. Results and Discussion

4.1. Biodiesel process

Table 1 presents the performance of the control system for the disturbances (D1 to D7). For the complete

biodiesel plant, having a capacity of 120 kt/annum, settling time of the biodiesel production rate of about 10 h

for disturbances D1 to D6. The merits of the control system can be evaluated from the values of DPT and TV.

Table 1. Performance of PWC system designed for the complete biodiesel process [6].

Performance Criterion
Disturbances
Settling time (h) DPT (kg) TV

D1 (+10% in WCO flow rate) 9.2 1641 449

D2 (-10% in WCO flow rate) 10.2 1621 413

D3 (-10% in pre-exponential factor of transesterification 64

3.1 117
reactions, due to catalyst deactivation)

D4 (+5% in WCO flow rate and D3 simultaneously) 403

9.4 1663
 Performance Criterion
Disturbances
Settling time (h) DPT (kg) TV

D5 (D2 and D3 simultaneously) 10.6 1982 453

D6 (+20% in WCO flow rate) 12.6 2308 565

D7 (-30% in WCO flow rate) 18.7 4690 1454

Figure 3 shows the dynamic profile of biodiesel production rate for the disturbances D1, D2, D6 and D7. It is

clear from the figure that the plant settles down smoothly to a new throughput. In general, the change in WCO

produces a proportionate change in the biodiesel production rate.

20000
D6

D1
Biodiesel (kg/h)

16000

D2

12000

D7

8000
0 10 20 30
Time (h)

Figure 3. Transient profile of biodiesel production rate for selected disturbances [6].

Figure 4 depicts that the accumulation is more for greater throughput changes. Accumulation of WCO for all

disturbances (except for D7) reaches to zero in some time, which is of vital importance for safe and stable

operation of the plant. D7 took more than 30 h to settle down.

0.020 D1
D2
Accumulation (kmol/h)

D6
0.015 D7

0.010

0.005

0.000

0 5 10 15 20 25 30
Time (h)

Figure 4. WCO accumulation due to disturbances D1, D2, D6 and D7 [6].

4.2. Formic acid process

PWC structure developed for the FA process also worked satisfactorily in the presence of the several

disturbances. Figure 5 depicts the profiles of the process for ± 20% change in the TPM. The figure indicates that

the developed control system is able to control the process in due time. Remaining results are not shown here for

brevity.

144 -20%
Formic Acid

128
(kmol/h)

112

96 +20%

0 5 10 15 20
Time (h)

Figure 5. Transients of FA for the tested disturbances.

5. Conclusions

A complete PWC scheme using IFSH for two complex processes was discussed. The CV-MV pairings were

found considering heuristics, simulations and/or RGA analysis. Pressure driven simulation was used in Aspen

Plus Dynamics for obtaining more realistic results. The designed PWC system was assessed for settling time,

DPT (which impacts economics), TV (which indicates control moves required to reject a disturbance), and DDS

(which quantifies accumulation of components) for various disturbances. Results show that the designed control

systems controlled the processes despite several disturbances.

6. References

1. Sharma, S., Patle, D. S., Gadhamsetti, A. P., Pandit, S., Manca, D. and Nirmala, G. “Intensification and
performance assessment of the formic acid production process through a dividing wall reactive
distillation column with vapour recompression”, Chem. Eng. Process. Process Intensif., 123, pp. 204–
213 (2017).
2. Mansouri, S.S., Huusom, J.K.; Gani, R.; Sales-Cruz, M. “Systematic integrated process design and
control of binary element reactive distillation processes”, AIChE J., 62 (9), pp. 3137–3154 (2016).
3. Mansouri, S.S., Sales-Cruz, M., Huusom, J.K. and Gani, R., “Systematic integrated process design and
control of reactive distillation processes involving multi-elements”, Chem. Eng. Res. Des., 115, pp.
348–364 (2016).
4. Vasudevan S. and Rangaiah G.P., A Review of Plant-Wide Control Methodologies and Applications in
“Plant-Wide Control: Recent Developments and Applications” edited by G.P. Rangaiah and V.
Kariwala, John Wiley, Chichester, 2012.
5. Luyben, M. L., Tyreus, B. D. And Luyben, W. L. “Plantwide control design procedure”, AIChE J., 43,
pp. 3161-3174 (1997).
6. Murthy Konda, N. V. S. N., Rangaiah, G. P. and Krishnaswamy, P. R., “Plantwide control of industrial
processes: An integrated framework of simulation and heuristics”, Ind. Eng. Chem. Res., 44, pp.
8300−8313 (2005).
7. Patle, D. S., Ahmad, Z. and Rangaiah, G. P., “Plantwide control of biodiesel production from waste
cooking oil using integrated framework of simulation and heuristics”, Ind. Eng. Chem. Res., 53, pp.
14408-14418 (2014).