NPTEL Syllabus
Plantwide Control of Chemical Processes -
Web course
COURSE OUTLINE
This course addresses the dynamic modeling, simulation and plant-wide control of
complex chemical processes with material and energy recycle using commercial
NPTEL
process simulators (Aspen Plus and Hysys). http://nptel.iitm.ac.in
T h e steps necessary in moving from steady state to dynamic simulation are
presented in detail.
Chemical Engineering
These include proper equipment sizing, correct plumbing, developing a basic
regulatory control structure and proper tuning of the control loops.
Dynamic simulation and control of common unit operations such as reactors,
distillation columns and multi-unit operations such as heterogenous azeotropic Pre-requisites:
distillation is covered first followed by elaborate case-studies on complex plant-
wide processes. UG level course on process control.
The material effectively complements the video counterpart of this course. Coordinators:
Contents: Dr. Nitin Kaistha
Department of Chemical Engineering IIT
Essentials: Kanpur
Proper plumbing and equipment sizing for moving to dynamics, tuning controllers.
Single Unit Dynamic Simulations:
Tank, CSTR, cooled packed bed reactor, simple distillation. column.
Multi-unit Dynamic Simulations:
Heat integrated distillation columns, heterogenous, azeotropic distillation, reactive
distillation.
Complex Plant-wide Case-studies:
Recycle process with side reaction, hydro-dealkylation process, cumene process.
COURSE DETAIL
S.No Topics No. of
Hours
Essentials for Smooth Transition from Steady State to Dynamics
1 Flow-driven vs pressure driven dynamic simulations. 2
Equipment sizing:
Surge tanks, distillation columns, heat exchangers.
Plumbing guidelines:
Liquid pumping systems, gas compression systems.Control
valve and pump sizing.
2 PID Controllers: 1
Direct/reverse action, manual/automatic/cascade mode,
tuning for typical flow, level and pressure loops.
Systematic tuning: relay feedback and step test.
Dynamic Simulation and Control of Single Unit Systems
1 Simple tank process. 1
2 CSTR: 3
Steady state and dynamic model equations and their
solution, typical control structure, Matlab case study, Aspen
Plus and Hysys case study.
3 Cooled packed bed reactor: 4
Steady state and dynamic model equations and their
solution, typical control structure, Matlab case study, Aspen
Plus and Hysys case study.
4 Simple distillation column: 6
Steady state and dynamic model equations and their
solution, single ended vs dual-ended temperature inferential
control, control tray selection using steady state
sensitivity/SVD analysis, steady state disturbance rejection
evaluation using flexibility in specifications, Aspen Plus and
Hysys case study.
Dynamic Simulation and Control of Multi-Unit Systems
1 Heat-integrated distillation system: 2
Control structure design using steady state analyses,
dynamic control performance evaluation in Hysys.
2 Heterogenous azeotropic distillation: 3
Example process, temperature inferential control structure
design using steady state analyses and dynamic control
performance evaluation in Aspen Plus.
3 Reactive distillation: 3
The methyl acetate RD column, example control structure,
steady state and dynamic simulation in Aspen plus.
Case-studies on Plant-wide Control of Complex Plants
1 Recycle process with side reaction: 6
Base case, alternative regulatory control structures, dynamic
simulation in Hysys. Linking Hysys with Matlab. Steady state
operating conditions for maximum operating profit using
optimizer in Matlab.
2 Hydrodealkylation process: 6
Base case design, plant-wide control structure, dynamic
simulation in Hysys and Aspen Plus.
3 Cumene alkylation process: 4
Base case design, plant-wide control structure, dynamic
simulation in Hysys.
Total 41
References:
Luyben, W.L., Tyreus, B.D. and Luyben, M.L. (1998) Plantwide Process
Control.McGraw Hill: New York.
A joint venture by IISc and IITs, funded by MHRD, Govt of India http://nptel.iitm.ac.in
