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Decoupling PID Control of A Reactive Packed Distillation Column
Decoupling PID Control of A Reactive Packed Distillation Column
ISSN: 2278-0181
Vol. 1 Issue 6, August - 2012
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International Journal of Engineering Research & Technology (IJERT)
ISSN: 2278-0181
Vol. 1 Issue 6, August - 2012
explicitly included the vapor-phase balances. They Loop decoupling can be realized by adding
developed a nonlinear controller that yielded good additional controllers called decouplers to a
performance with stability in the high-purity region conventional multi-loop configuration. In principle,
with the aid of a physical insight into the decoupling control schemes can provide two
nonminimum phase behaviour, and the superior important benefits [13]:
performance of the developed controller over linear (i) Elimination of control loop interactions which
PI controllers was demonstrated through result in the stability of the closed-loop system
simulations. Monroy-Loperena et al. (2000) also being determined solely by the stability
studied the control problem of an ethylene glycol characteristics of the individual feedback
reactive distillation column with the control control loops.
objective of regulating the ethylene glycol (ii) A set-point change for one controlled variable
composition in the product by manipulating the having no effect on the other controlled
reboiler boil-up ratio. They proposed a new idea for variables.
robust stabilization based on the analysis of the Considering the two points highlighted above, it
underlying input/output bifurcation diagram and on is expected that decoupling control should provide
modelling error compensation techniques. Al-Arfaj good performance in the control of chemical
and Luyben (2000) explored the closed-loop systems especially in the control of MIMO systems
control of a reactive distillation column with two like the reactive packed distillation process being
products and discovered that single-end considered in this work. Therefore, the aim of this
temperature control could keep both products at or work is to study the application of decoupling PID
above the specified purity values, even for large controllers for the control of some segment
disturbances, if reactive-zone holdup was temperatures of reactive packed distillation column
sufficiently large. Vora and Daoutidis (2001) using the production of ethyl acetate and water (by-
studied the dynamics and control of an ethyl acetate product) from the esterification reaction between
reactive distillation system and designed model- acetic acid and ethanol as the case study.
based linear and nonlinear state feedback
controllers, along with conventional SISO PI 2. Procedures
controllers. They demonstrated the superior 2.1. Experimental Procedure
performance of the nonlinear controller over both The process involved in this work was an
the linear controller and the conventional PI esterification reaction occurring simultaneously
controller. Khaledi and Young (2005) investigated with distillation operation that were carried out in
the nonlinearity of an ethyl tert-butyl ether reactive the experimental pilot plant of the reactive packed
distillation column and developed a 2 x 2 distillation column (RPDC) set up as in Figure 1a
unconstrained model predictive control scheme for (pictorially) and Figure 1b (schematically) and as
product purity and reactant conversion control by also shown in the work of Giwa and Karacan
using the process dynamics approximated by a (2012). The column, excluding the condenser and
first-order plus dead time model to estimate the the reboiler, had a height of 1.5 m and a diameter
process model for the model predictive controller. of 0.05 m. It consisted of a cylindrical condenser of
They found that the controller was very efficient a diameter and a height of 5 and 22.5 cm
for disturbance rejection and set-point tracking. respectively. The main column section of the plant
Völker et al. (2007) designed a multivariable was divided into three subsections of 0.5 m each.
controller for a medium-scale semi-batch reactive The upper, middle and lower sections were the
distillation column and showed experimentally that rectifying, the reaction and the stripping sections
the controller performed well for large set-point respectively. The rectifying and the stripping
changes and in the face of process disturbances. sections were packed with raschig rings while the
Grüner et al. (2003) applied asymptotically exact reaction section was filled with Amberlyst 15 solid
input/output-linearization to an industrial reactive catalyst that had a surface area of 5300 m2/kg, a
distillation column and found through simulation total pore volume of 0.4 cc/g and a density of 610
studies that, in comparison with a well-tuned linear kg/m3. The reboiler was spherical in shape with a
controller, the controller showed a superior volume of 3 Litre. The column was fed with acetic
performance with respect to set-point changes and acid at the top (between the rectifying and the
disturbances, even in the presence of unknown reaction sections) while ethanol was fed at the
input delays. bottom (between the reaction and the stripping
Reactive distillation is a multi-input multi- sections) with the aid of peristaltic pumps which
output (MIMO) system and, based on that, the were operated with the aid of a computer via
system is expected to be controlled as a MIMO MATLAB/Simulink program. All the signal inputs
type or using one of the early approaches to (reflux ratio (R), feed ratio (F) and reboiler duty
multivariable control which is “loop decoupling”. (Q)) to the column and the measured outputs (top
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International Journal of Engineering Research & Technology (IJERT)
ISSN: 2278-0181
Vol. 1 Issue 6, August - 2012
K eq
CH 3COOH C2 H 5OH CH 3COOC2 H 5 H 2O (1)
the controllers. The conditions used in carrying out EtOH Tank AcH Tank
Level
THERMOCOUPLE
CONVERTE
MODULE
INPUT
INPUT
MODULE
1 R Step 3 5
Reaction Section
2 F PRBS 0.5 2
3 Q (kJ/s) PRBS 0.595 0.63
Stripping Section
Level
S/N Parameter Signal
Initial Final
Figure 1. Reactive packed distillation column. (a)
1 R PRBS 1 5
Pictorial view; (b) Sketch view
2 F PRBS 1 2
3 Q (kJ/s) PRBS 0.49 0.63 2.2. Control Configuration and Simulation
In the control aspect of this work, the
temperatures of three segments of the reactive
packed distillation column were considered and the
process was tested for both set-point tracking and
disturbance rejection. For the set-point tracking
study, the system, being a MIMO type, comprised
three controlled variables (top segment
temperature, reaction segment temperature and
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International Journal of Engineering Research & Technology (IJERT)
ISSN: 2278-0181
Vol. 1 Issue 6, August - 2012
bottom segment temperature) and three reaction segment temperature and the bottom
manipulated variables (reflux ratio, feed ratio and segment temperature respectively. As can be
reboiler duty) while for the disturbance rejection observed from the results, the application of the
study, chosen the reboiler duty as the disturbance inputs resulted in changes in the dynamic responses
variable, in this case, there were two controlled of the segment temperatures. This is an indication
variables (top segment temperature and reaction that the segment temperatures were functions of the
segment temperature) and two manipulated inputs. This is, of course, the reason for choosing
variables (reflux ratio and feed ratio). The MIMO the inputs as the manipulated variables of the
system was decoupled and controlled like a SISO control of this process.
type by the application of decouplers that were
estimated from the MIMO transfer function models 75.4
of the system. After the decoupling, the reflux 75.2
ratio, feed ratio and reboiler duty were used as the
75
Ttop ( oC)
manipulated variables of top segment temperature,
74.8
reaction segment temperature and bottom segment
74.6
temperature respectively for the set-point tracking
study. In the disturbance rejection study, the reflux 74.4
76.4
2.3. Tuning of Controllers
The controllers designed for the reactive packed 76.3
D Pu 4
td Furthermore, the application of the inputs of
8 11 2t d experiment 2 given in Table 2 resulted in the
responses given in Figures 5, 6 and 7 respectively
3. Results and Discussions for the top segment temperature, the reaction
segment temperature and the bottom segment
3.1. Experimental Studies
temperature. As was observed in the case of
In the experimental studies, after applying the
experiment 1, there were significant dynamic
inputs shown in Table 1, the response obtained
responses towards the individual inputs for each of
from experiment 1 are as shown in Figures 2, 3 and
the segment temperatures.
4 below for the top segment temperature, the
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International Journal of Engineering Research & Technology (IJERT)
ISSN: 2278-0181
Vol. 1 Issue 6, August - 2012
68
The values of the model parameters shown in
Ttop ( oC)
66
Equations (3 - 5) above are as given in Table 4. It
64 can be seen from the model parameters that while
62 some static gains (Kp) were positive, others were
negative. The static-gain sign change is one of the
60
0 500 1000 1500 2000 2500 3000 3500 4000 phenomena occurring as a result of the complex
t (s) nature of the reactive packed distillation process.
Figure 5. Experimental dynamic response of top Also, it was observed that the maximum static gain
segment temperature to the inputs of experiment 2 occurred between input 2 and output 2 (that is,
between the feed ratio and the reaction segment
temperature).
74
73
G(s) Kp (min) Td (min)
72
g11(s) -79.321 5.503516 0.00092
71 g12(s) -1.3652 5.184786 0.495887
0 500 1000 1500 2000 2500 3000 3500 4000 g13(s) -89.1061 5.169331 0.001784
t (s)
Figure 6: Experimental dynamic response of g21(s) 31.94718 8.465251 0.489046
reaction segment temperature to the inputs of g22(s) 427.8996 5.266308 0.009036
experiment 2
g23(s) -18434.9 5.290776 0.009019
87.8 g31(s) -739.469 35.64333 8.59E-06
87.6 g32(s) 6.791428 1.005618 0.499407
g33(s) -231.189 0.790481 0.5
Tbot ( oC)
87.4
87.2
87
Considering the time constant ( ) of the process,
the transfer function of the relationship between the
86.8
reflux ratio and the bottom segment temperature
0 500 1000 1500 2000 2500 3000 3500 4000
t (s) was found to possess the highest value. This is an
Figure 7: Experimental dynamic response of indication of the fact that when the same input unit
bottom segment temperature to the inputs of is applied to the process, this part of the process is
experiment 2 likely to have the highest effect on the time
required for the process to get to the steady state.
3.2. System Identification Studies As can be seen from the values of the delay time
With the three (3) inputs (reflux ratio, feed ratio (Td) also shown in Table 4, the maximum delay
and reboiler duty) and three (3) outputs (top time possessed by the system was found to be 0.5
segment temperature, reaction segment temperature min. This means that the output variables of the
and bottom segment temperature) chosen as the reactive packed distillation studied in this work
variables of this process, the results (Figures 2 - 4) were responding quickly to the changes in the input
obtained from experiment 1 were used to develop variables.
the MIMO transfer function models of the process The results of experiment 2 were similarly used
with the aid of System Identification Toolbox of to develop the SISO transfer function models that
MATLAB. The forms of the process models were used to calculate the tuning parameters of the
developed are as given in Equations (3 - 5) below. controllers. Also, the three SISO transfer function
models between the individual input and the
k p1,1 e
-Td 1,1 s
k p1,2 e
-Td 1,2 s
k p1,3 e
-Td 1,3 s corresponding output are as outlined in Equations
Ttop s Rs Fs Qs (3) 6, 7 and 8 below respectively for the top segment
1,1s 1 1,2 s 1 1,3 s 1
-Td 2,1 s -Td 2,2 s -Td 2,3 s
temperature, the reaction segment temperature and
k p2,1 e k p2,2 e k p2,3 e the bottom segment temperature.
Trxn s Rs Fs Qs (4)
2,1s 1 2,2 s 1 2,3 s 1
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ISSN: 2278-0181
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-Td1 s
k p1 e PIDC2 2.8790 0.2543 0.0636
Ttop s Rs (6)
1s 1 PIDC3 14.6186 0.4234 0.1059
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International Journal of Engineering Research & Technology (IJERT)
ISSN: 2278-0181
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Trxn ( oC)
responses of the top segment temperatures obtained
0.4
using the two tuning techniques were able to reach
the set point at almost the same time (that is, their 0.2 Ziegler-Nichols
response or settling times were almost the same) Cohen-Coon
Set point
and with very close rise time. However, the 0
0 5 10 15 20 25 30 35 40
overshoot observed from Ziegler-Nichols tuning t (min)
technique was found to be higher than that of
Cohen-Coon tuning technique.
Figure 9. Dynamic responses of reaction segment
temperature to a 0.5 unit set-point change
0.3
1
Also observed from the responses of the top
0.8
Tbot ( oC)
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6
and the bottom segment temperatures. Similarly,
the ISE values of Cohen-Coon tuning technique 4
were discovered to be lower than those of the
2
Trxn ( oC)
Ziegler-Nichols tuning technique except in the case
of the top segment temperature where they (the two 0
tuning techniques) had the same ISE values, as Ziegler-Nichols
-2
seen in Table 8. These results of the IAE and ISE Cohen-Coon
Set point
values were found to be in support of the -4
0 50 100 150
observations obtained from the graphical responses t (min)
of the temperatures.
Figure 12. Dynamic responses of reaction segment
3.5.2. Disturbance Rejection temperature to a unit step change in disturbance
As said earlier, the temperature control of this variable
process was tested not only for set-point tracking
but also for disturbance rejection. As such, the The differences between the two control tuning
control simulation of this study was also carried out techniques were also shown clearly and
for disturbance rejection (the disturbance variable numerically by calculating the IAE and ISE values
was chosen to be the reboiler duty) and the results and the results of the calculations are as tabulated
of the simulations are as shown in Figures 11 and below (Table 8). From the table, it was observed
12. that the IAE and ISE values of Cohen-Coon tuning
Figure 11 shows the responses of the top technique were lower than those of the Ziegler-
segment temperatures for a unit step change in the Nichols for both the top segment temperature and
reboiler duty for the two tuning techniques studied the reaction segment temperature.
in this work. As can be seen from the figure, the
response of the Cohen-Coon tuning technique was Table 9. Performance criteria of disturbance
observed to be a little bit, though not much, faster rejection control system
in reaching the set-point of the process than that of
IAE ISE
the Ziegler-Nichols technique. Method
Ttop Trxn Ttop Trxn
1
Z-N 26.06 16.14 21.05 37.86
0
C-C 22.19 11.65 13.76 23.73
Ttop ( oC)
-1
This smaller natures of the IAE and ISE values
-2
for the responses of the segment temperatures of
Ziegler-Nichols
-3 Cohen-Coon
the Cohen-Coon tuning technique than those of the
Set point Ziegler-Nichols tuning technique were also in
-4
0 50 100 150 support of what were observed from the graphical
t (min)
responses of the segment temperatures.
Figure 11. Dynamic responses of top segment
temperature to a unit step change in disturbance 4. Conclusions
variable The good results obtained from the simulations
of decoupling PID set-point tracking and
Shown in Figure 12 are the dynamic responses disturbance rejection control studies of reactive
of the reaction segment temperature to the packed distillation column using Ziegler-Nichols
disturbance variable. Just as it was observed in the and Cohen-Coon tuning techniques have shown
case of the set-point tracking, the overshoot of the that decoupling PID control can be successfully
Ziegler-Nichols tuning technique was found to be applied to the system. In addition, due to its
higher than that of the Cohen-Coon tuning relatively lower values of IAE and ISE, Cohen-
technique but the responses of the two PID control Coon tuning technique was discovered to be better
tuning techniques were discovered to settle almost than Ziegler-Nichols tuning technique for this
at the same time. process.
5. Acknowledgements
Abdulwahab Giwa wishes to acknowledge the
support received from the Scientific and
Technological Research Council of Turkey
(Türkiye Bilimsel ve Teknolojik Araştırma
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International Journal of Engineering Research & Technology (IJERT)
ISSN: 2278-0181
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Kurumu - TÜBİTAK) for his Ph.D. Programme. In Chemical Engineering and Processing, 36:
addition, this research was supported by the 101- 09.
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D
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