BATCH PROCESS

CONTROL(SEQUENTIAL
AND LOGIC CONTROL)

PRESENTED BY-
VIJAY PRATAP SINGH
2009 EE05(C&I)
MNNIT,ALLAHABD
A processes in which sequence of operation is carried out
to produce a quantity of product(the batch) and in which
the sequence is repeated to produce further batches is called
batch or sequential process
Batch processing typically involves raw materials that are
combined to mix or react in a certain sequence over a
period of time to produce the completed output.
A sequence of one more steps (recipe) usually carried out
in more than one vessel and in a defined order, yielding a
finished product.
 BATCH PROCESSING USE IN
MANUFACTURING
Electronic materials
Specialty chemicals
Metals
Ceramics
Polymers
Food and agricultural materials
Biochemical's

Batch process are widely use in chemical industry and

food processing. where the operation carried out
frequently involves raw material carrying out reaction of
two other chemicals at specified temperature
In a batch reactor the reactants and the catalyst are
placed in the reactor which is then closed to transport
of matter and the reaction is allowed to proceed for a
given time whereupon the mixture of unreacted
material together with the products is withdrawn.
A chemical is produced by the reaction of two other
chemicals at specified temperature. The two chemical
are mixed together in a reactor and feeding hot or cold
water through water jacket, which surround the
vessel, control the temperature of reaction. the flow of
chemical into reactor and flow of product mix out of
reactor are controlled by adjusting the respective
valves.
 
Batch Mixing Tank-Operations
Sequence
1. Introduce liquid A until level reaches LH2
2. Close A valve, open B valve and start mixer
3. When level reaches LXH2, stop flow of B and the
mixer and open discharge valve (VN9)
4. Discharge product until level reaches LL2, then
close the discharge valve.

8
9
INFORMATION FLOW
DIAGRAM

10
CLASSIFICATION OF BATCH
PROCESSING
ON THE BASIS OF NUMBER OF PRODUCT
Single -product batch process
Multi-grade batch process
Multi-product batch process

ON THE BASIS OF STRUCTURE

Series (single –stream)
Parallel (multi- stream)
 A Single -product batch process produces the same
product in each batch and same operation are performed in
each batch using the same amount of raw material.

.
A Multi-grade batch process product that are similar but
differ only in formula quantities. The same operation are
performed in each batch but the quantity of raw material
and processing condition are varied.
 A Multi-product batch process produces product utilizing
different methods of production are control. In this both
the procedure and formula changed
 Series (single –stream) Batch Process

A series-structure batch process is a group of unit

through which batch passes sequentially as shown in
figure. It can be a single unit such as a reactor or
overall process unit in a sequence.
 PRALLEL BATCH PROCESS
A parallel batch process structure is that in which several batches
may be executing at same time as shown in figure (b). And they
could be performing the same operation
 SERIES PARALLEL
BATCH PROCESSES
Multi-Product Processing Overview
Fab Tool

A B B A A B Process 1

Fab Tool

Process 1
A A A A

Process 2

Fab Tool

Process 1

A B B A A B
Process 2

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MATRIX STRUCTURE OF
BATCH PROCESSES
Control of batch processes differs from control of continuous
processes in two main ways.
Since batch processes have no steady-state operating point,
the set point and control signals correspond to time-varying
profiles.
batch processes are repeated over time and are
characterized by two independent variables, the run time t
and the run counter k.
xk(t ) = F(xk(t ), uk(t )), xk(0) = x(0)k
 Yk(t ) = H(xk(t ), uk(t)), 
Zk = Z(xk[0, tf ], uk[0, tf]),
 where  
T denotes the run time
K denotes the run index
X represents the state vector
U is the input vector
There are two types of control objectives.
Online implementation.
1.Online control of run-time outputs
2. Online control of run-end outputs
 run-to-run implementation.
3. Run-to-run control of run-time outputs
4. Run-to-run control of run-end outputs
 ONLINE CONTROL OF RUN TIME
OUTPUTS

This control approach is similar to that used in

continuous processing. However, although some
controlled variables, such as temperature in isothermal
operation, remain constant, the key process
characteristics, such as process gain and time
constants, can vary considerably because operation
occurs along state trajectories rather than at a steady
state operating point.
uk(t ) = K(Yk(t ), Yref(t ))
 ONLINE CONTROL OF RUN END
OUTPUTS
it is necessary to predict the run-end outputs z based on
measurements of the run-time outputs y. Model
predictive control (MPC) is well suited to this task
The controller can be written as
Uk(t ) = P(Zpred,k(t ), Zref), (2)
where P is the online control law for run-end outputs and
Zpred, k(t ) is the prediction of z available at time t for
batch k.
 
 RUN TO RUN CONTROL OF
RUN TIMES OUTPUT
The manipulated variable profiles can be generated using
iterative learning control (ILC), which exploits
information from previous runs. This strategy exhibits
the limitations of open-loop control with respect to the
current run, in particular, the fact that there is no
feedback correction for run-time disturbance
Uk+1[0, tf ] = I(yk[0, tf ], yref [0, tf ])
where I is the iterative-learning control law for runtime outputs.
ILC uses the entire profile of the previous run to generate the input
profile for the next run.
 
 RUN TO RUN CONTROL OF RUN
END OUTPUT
In this case the input profiles are parameterized as uk[0,
tf ] = U(πk) using the input parameters πk. The batch
process is thus seen as a static map between the input
parameters πk and the run-end outputs Zk.
The controller is written as
Uk+1 [0, tf ] = U(πk+1)
πk+1 = R(Zk, Zref)
where U represents the input parameterization and R is
the run-to-run control law for run-end outputs.
BATCH CONTROL SYSTEM
 CHARACTERSTICS
OF BATCH PROCESS

Absence of steady state and presence of constraints.

In batch processing, operations proceed from an initial state to

a very different final state. Hence, there exists no single
operating point around which the control system can be
designed. Consequently, for control design and optimization, it
is not possible to use approximate models by linearization
around a single Operating point  .
Repetitive nature
 SEQUENTIAL CONTROL
Sequential control is crucial in many control
applications, as in chemical batch processes
A sequential control procedure can be represented
graphically by one of the following two method.

1. A State diagram, also denoted a State machine

2. A Sequential function chart (SFC)

 STATE DIGRAM

 
A state diagram represents a state machine. A state machine has
a number of states. Each state is either active or passive. Only
one state is active at a time. The state machine always starts in a
particular state defined as the initial state, and it ends (stops)
after the final state.
 SEQUENTIAL FUNCTION
CHART
Sequential function charts (SFCs) are similar to State
diagrams. One small difference is that a transition condition is
indicated by a small line in the transition path from one state
to another. And, typically, the states are denoted steps, which
are represented by rectangles.
Production amounts are usually smaller than for
continuous processing.
Requires reduced inventories and shorter response
times.
Final product quality must be satisfied with each batch
(no blending).
More emphasis on production scheduling in batch
processing.
Batch processing is suitable for production system
where product are made in low volume.
Batches or product are transferred from one
processes equipment or unit to another.

It can be used concurrently or sequentially to

produce different products.
Automation is used in batch processing to
precisely control quantities, times and
sequences resulting in superior consistency of
the output.
Batch time can be adjusted to meet quality of
product.
 REFERENCES

1. COMPUETR AIDED PROCESS CONTROL BY S.K. SINGH

2. IEEE CONTROL SYSTEMS MAGAZINE 2006
3. Control of Batch Processing Systems BY Haresh Gurnmi, Ravi
Anupindi and Ram Akella Graduate Scliool of Industrial
Administration, Carnegie Mellon Universit.y, Pittsburgh, PA 15213
4. Instrument Engineers' Handbook: Process control and
optimization By Bela G. Liptak, Béla G. Lipták, page no.1535
5. BATCH PROCESS CONTROL STRATEGIES BY S. Macchietto,
Centre for Process Systems Engineering, Imperial College, London
6. 2008 10th Intl. Conf. on Control, Automation, Robotics and Vision
Hanoi, Vietnam, 17–20 December 2008 by Jie Zhang, Jerome
Nguyan, Newcastle University
7. Issues Surrounding Supervisory Control of Batch Manufacturing
Systems Mohsen A. Jafari Department of Industrial Engineering
Rutgers University