Process Dynamics and Digital Control

by
Dr. Héctor Arturo Ruiz Leza

Universidad Autónoma de Coahuila

Dr. Héctor A. Ruiz

- Chemical Engineering, Autonomous University of Coahuila. Mexico, 2004.

- Lead Operations Engineer, Magnelec Industries. Subsidiary of Peñoles Group, 2007.

-
- Ph.D. in Chemical and Biological Engineering, University of Minho, Portugal, 2011

2
 Biorefinery Research Group| Autonomous University of Coahuila

The Biorefinery Group is active in various aspects of biorefinery processes using lignocellulosic
and aquatic (micro and macro – algae) biomass for the production of biofuels and compounds
with high added-value through the integration of clean processes as Hydrothermal Processing
taking into consideration environmental aspects, based today in the context of Bioeconomy.

www.biorefinerygroup.com

Source: www.biorefinerygroup.com
Pilot plant at UAdeC-Mexico
Planta Piloto de Biorrefinería -UADEC
Planta Piloto de Biorrefinería –UADEC – Bagazo de caña
Planta Piloto de Biorrefinería -UADEC
Fundamentals of Process Dynamics and Control

Control systems are essential:

- A good process operation
- Process security
- Quality in products
- Minimize environmental impacts

The objective of a control system

It is to maintain the most important characteristics of the process, in the desired

objectives in spite of the disturbances.

What parts are important in a control system?

It is a combination of sensors, actuators and computer systems tuned to orchestrate and

profitably carry out the operation of the process.
Fundamentals of Process Dynamics and Control

Industry 4.0

Industry 4.0 refers to a new phase in the

industrial revolution that focuses heavily
on interconnectivity, automation, machine
learning, and real-time data.
Fundamentals of Process Dynamics and Control

Sustainable processes

Sustainable industrial chemical processes or processes sustainable industrial processes, are

also processes by stages that are unitary activities, but that enhance the use of materials
and energy for the production of goods (or useful products) and minimize or eliminate the
presence of residues and waste –or evils– (since Depending on the type of waste, these can
contribute to the environmental pollution and its effects).
Fundamentals of Process Dynamics and Control

What industrial processes do you know?

Fundamentals of Process Dynamics and Control
Beer Process Video -9
Fundamentals of Process Dynamics and Control
Beer Process
 Fundamentals of Process Dynamics and Control
Beer Process – Letra - PORTUGAL
 Fundamentals of Process Dynamics and Control
Beer Process – Letra - PORTUGAL
 Fundamentals of Process Dynamics and Control
Beer Process – Letra - PORTUGAL
 Fundamentals of Process Dynamics and Control
Beer Process – Spaten-Franziskaner-Bräu GmbH
 Fundamentals of Process Dynamics and Control
Beer Process – Spaten-Franziskaner-Bräu GmbH
 Fundamentals of Process Dynamics and Control
Beer Process – Spaten-Franziskaner-Bräu GmbH
Fundamentals of Process Dynamics and Control

Critical stage of the Beer process to establish process control

Fundamentals of Process Dynamics and Control
Peñoles is a subsidiary company owned by Grupo BAL. Peñoles is the second largest Mexican mining company,
the first Mexican producer of gold, zinc and lead and the world leader in silver production. Peñoles is a company
with active mines within Mexico and with some prospection projects in South America. Holdings includes
the Fresnillo Silver Mine / Mina Proaño, the Met-Mex Peñoles metallurgical complex and Química del Rey; a
Chemical facility; three operations. Peñoles produces about 80,500,000 troy ounces (2,500,000 kg) of silver and
756,100 troy ounces (23,520 kg) of gold annually. Other metals that the company produces
are zinc, lead, copper, bismuth, and cadmium.

Video -11
Fundamentals of Process Dynamics and Control
Peñoles

- Metallurgical Group (located in Torreón,

Coahuila: The lead-silver circuit, that includes
a Lead Smelter, which processes lead-silver
concentrates to produce lead bullion, and the
Lead-Silver Refinery that produces refined
gold, lead, silver and bismuth,
principally. The zinc circuit, that includes the
Electrolytic Zinc Refinery to produce refined
zinc. Met-Mex operates other plants, Aleazin
(located in Ramos Arizpe,
Coahuila), that produces zinc alloys, and
Bermejillo (in the .state of Durango) produces
copper sulfate, zinc sulfate and antimony
trioxide.

- Chemical Group (Química del Rey), located in

Laguna del Rey): is the largest plant producing
Sodium Sulfate in the Americas.
Fundamentals of Process Dynamics and Control
Peñoles Magnelec-Process
Visit to the plant - Química del Rey, May 2014
Fundamentals of Process Dynamics and Control
Peñoles

-https://www.elsiglodetorreon.com.mx/noticia/1201904.una-industria-en-medio-del-desierto.html
- https://www.milenio.com/negocios/magnelec-con-la-mas-alta-tecnologia
Fundamentals of Process Dynamics and Control
Peñoles

- https://www.elsiglodetorreon.com.mx/noticia/1201904.una-industria-en-medio-del-desierto.html
- https://www.milenio.com/negocios/magnelec-con-la-mas-alta-tecnologia
- https://www.milenio.com/negocios/de-la-sal-hasta-la-tecnologia-penoles-en-quimica-del-rey
Fundamentals of Process Dynamics and Control
Fundamentals of Process Dynamics and Control
Peñoles - Electric power generation

Sustainable processes

AES - Applied Energy Services TAMUÍN (San

Luis Potosí, Mexico): Thermal power station-
132 hectares for Thermal power station
Golfo (TEG) and with 5.60 hectares for
Thermal power station Peñoles (TEP) having
a total gross capacity of 560MW and a total
net capacity of 490MW, which provide
energy to the industrial groups Cementos
Mexicanos (Cemex) and Peñoles.
2007. AES Corporation (NYSE: AES)
announced today that it has acquired two
230 megawatt generating plants burning
petroleum coke and circulating fluidized bed
(CFB) in Tamuin, Mexico.
 Fundamentals of Process Dynamics and Control
Peñoles - Electric power generation - Sustainable processes - Wind power

https://energiahoy.com/2017/04/08/el-recien-inaugurado-parque-eolico-de-coahuila-producira-780-mil-mega-wats-anuales/
https://www.elfinanciero.com.mx/empresas/penoles-generara-497-mw-de-electricidad-en-2017
 Fundamentals of Process Dynamics and Control

Peñoles - Naica Mine (The crystal mine)

Video -20

https://www.eluniversal.com.mx/articulo/cartera/negocios/2015/10/13/penoles-cierra-la-mina-naica-en-chihuahua
Fundamentals of Process Dynamics and Control
Peñoles Magnelec-Process
Fundamentals of Process Dynamics and Control
Peñoles Magnelec-Process
Raw material MgO - Química del Rey
Fundamentals of Process Dynamics and Control
Peñoles Magnelec-Process
Raw material MgO - Química del Rey
Fundamentals of Process Dynamics and Control
Peñoles Magnelec-Process - Electric grade process
Fundamentals of Process Dynamics and Control
Peñoles Magnelec-Process - Electric grade process
 Fundamentals of Process Dynamics and Control
2) Peñoles Magnelec-Process – MgO (The MRA, MEGR & MEGE family of Sized Magnesium Oxides, is
specifically designed for Refractory and Ceramics Industries to enhance the mechanical & thermal properties of
shaped refractories and ceramic applications, among others).
Fundamentals of Process Dynamics and Control
Peñoles Magnelec- Process – Electrofused process
Fundamentals of Process Dynamics and Control
Peñoles Magnelec- Process – Electrofused process
Fundamentals of Process Dynamics and Control
3) Peñoles Magnelec- Process – Special grinds (Inaugurated 2006)
Fundamentals of Process Dynamics and Control
Manual control
Fundamentals of Process Dynamics and Control
Manual control
Fundamentals of Process Dynamics and Control
Industrial Control Rooms
 Fundamentals of Process Dynamics and Control
Industrial Control Rooms
Production / Process Control Rooms are vital for operations and help to ensure the safety,
security, and controls across the plant are at the forefront of the plant's operators and
employees
 Fundamentals of Process Dynamics and Control
Industrial Control Rooms
Production / Process Control Rooms are vital for operations and help to ensure the safety,
security, and controls across the plant are at the forefront of the plant's operators and
employees
Fundamentals of Process Dynamics and Control
Holcim Control Rooms
Fundamentals of Process Dynamics and Control
Fundamentals of Process Dynamics and Control
Biorefinery Pilot plant at UAdeC-Mexico
Biorefinery Pilot plant at UAdeC-Mexico
Biorefinery Pilot plant at UAdeC-Mexico
Fundamentals of Process Dynamics and Control

Important parts of an automatic control system:

1) Process: it is the set of unit operations necessary to modify the characteristics of the
raw materials.
Fundamentals of Process Dynamics and Control

Important parts of an automatic control system:

2) Primary element/sensor: Sensors are the first element in the control loop which
measures the change in the process and reporting the process variable so they are also
called as the primary element. Sensors are devices which cause change when affected by
a change in the process variable. There are different types of sensors for measuring
variables like Pressure, Temperature, Flow, Level, pH, Vibration, etc.,

There are different types of sensors available for various process variable:

- Thermocouples, RTD for Temperature measurement

- Strain gauge, Pressure sensing diaphragm, capacitive cells for pressure measurement
- Orifice plate, Pitot tube, Magnetic flow tube etc., for flow measurement

Source: automationforum.co
Fundamentals of Process Dynamics and Control
Fundamentals of Process Dynamics and Control
Fundamentals of Process Dynamics and Control

Important parts of an automatic control system:

3) Transmitters (secondary element): Transmitters are devices that convert the signal into
a standard signal that can be transmittable through the control loop and the parameters
can be monitored remotely.

- Pressure transmitters
- Flow transmitters
- Temperature transmitters
- Level transmitters
- Analytic transmitters

Source: automationforum.co
Fundamentals of Process Dynamics and Control

Important parts of an automatic control system:

4) Controllers: Controllers are the centre of process control, which receives process
variable then compare with setpoint stored in the controller and sends a feedback as the
controller output to control the final control element. There are pneumatic and electronic
or programmable such as DCS, PLC uses a complex mathematical algorithm to perform
the control action.

- PLC (Programmable Logic Controller): PLCs are usually computers connected to a set of
input/output (I/O) devices. The computers are programmed to respond to inputs by
sending outputs to maintain all processes at setpoint.

- DCS (Distributed Control Signal): DCSs are controllers that, in addition to performing
control functions, provide readings of the status of the process, maintain databases and
advanced man-machine-interface.
Source: automationforum.co
Fundamentals of Process Dynamics and Control
Important parts of an automatic control system:

4) Controllers:

It is a pneumatic, hydraulic or electronic device that receives the average value of the
variable and compares it with the desired value (set-point) and acts to correct the
deviation of the controlled variable, sending a corrective signal to the final control
element.

Source: automationforum.co
Fundamentals of Process Dynamics and Control

Important parts of an automatic control system:

5) Final control element: Final control elements are the correcting elements that receives
signal from the controller and make a change in process to adjust the process variable at
the desired parameter. In any control loop, the speed with which a final control element
reacts to correct a variable that is out of setpoint is very important. Many of the
technological improvements in final control elements are related to improving their
response time.

- Pumbs and Control valves – Final control devices of Flow control system

- Heaters and Boilers – Final control devices of temperature control system

- Compressor and Valves: Final control devices of pressure control system

Source: automationforum.co
Fundamentals of Process Dynamics and Control
Identification letters of instruments
Fundamentals of Process Dynamics and Control

Identification letters of instruments

Fundamentals of Process Dynamics and Control

Identification letters of instruments

Fundamentals of Process Dynamics and Control
Identification letters of instruments
Fundamentals of Process Dynamics and Control

Control Terminology

Controlled variables is the process variable that is maintained at a specified value

or within a specified range.

Manipulated variables is the process variable that is acted on by the control

system to maintain the controlled variable at the specified value or within the
specified range.

Disturbance variables is an undesirable input signal that upsets the value of the
controlled output of the plant.