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Dr. AA
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T6
P1
T1
T2
T5
Feed
F1 Methane Ethane (LK) Propane Butane Pentane F2 T4 T3
F3 A1
L. Key
Liquid product
3
T6
P1
Vapor product
T1
T2
T5
Feed
F1 T4 T3 L1
F2
F3
Process fluid
Steam
A1
L. Key
Liquid product
T6
P1
Vapor product
T1
T2
T5
Feed
F1 T4 T3 L1
F2
F3
Process fluid
Steam
A1
L. Key
Liquid product
T6
P1
Vapor product
T1
T2
T5
Feed
F1 T4 T3 L1
F2
F3
Process fluid
Steam
A1
L. Key
Liquid product
T6
P1
Vapor product
T1
T2
T5
Feed
F1 T4 T3 L1
F2
F3
Process fluid
Steam
A1
L. Key
Liquid product
T6
P1
Vapor product
T1
T2
T5
Feed
F1 T4 T3 L1
F2
F3
Process fluid
Steam
A1
L. Key
Liquid product
T6
P1
Vapor product
T1
T2
T5
Feed
F1 T4 T3 L1
F2
F3
Process fluid
Steam
A1
L. Key
Liquid product
Quality System
99.73 %
0.135 %
-3s 2s -1s m +1s +2s +3s
0.135 %
Traditionally threesigma is acceptable, now, the industry is on six-sigma
m3s
99.9999998%
-6s -3s 2s -1s m +1s+2s+3s +6s
m6s
Control Benefits
When we control a process, we reduce the variability of key variables to achieve the seven objectives. Without feedback control
T P
Concentration
T A
Feed
F
outlet concentration
6 55 4 4 3 23
2 0 50
Composition (% H. Key)
50 100 150 200 250(min) time 300 350 400 450 500 Time (min)
100 150 200 250 300 350 400 450 500
0 51 50.5 50.5 50
50
51
valve position
49.5 49 49.5
49 0 50 100
A1
11
Control Benefits
When we control a process, we reduce the variability of key variables to achieve the seven objectives.
Composition (% H. Key)
2.5
2.5 0
50
50
100 150 200 250 300 350 400 450 500 time (min) Time (min)
100
150
200
250
300
350
400
450
500
valve position
60
60
40 20 40
20 0
100 80 80
100
Reflux valve
50
50
100 150 200 250 300 350 400 450 500 time (min) Time (min)
100
150
200
250
300
350
400
450
500
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Goal: Maximize conversion of feed ethane but do not exceed 864 o C Which operation, A or B, is better? Explain why.
Flue gas
FC AC Conversion
0.25 0.2
frequency
0.15 0.1 0.05 0 842 846 850 854 858 862 Temperature (C)
Ethane Feed
0.6 0.5
Temp. 864 C
frequency
0.4 0.3 0.2 0.1 0 842 846 850 854 858 862 Temperature
TC
Air
Fuel
13
88
Efficiency %
Ethane Feed
86 84 82 80 0 1 2 3 4 O2 mole % 5 6 7
14
TC
Air
Fuel
Flue gas
FC
AC
Ethane Feed
TC
Air
Fuel
A
0.25 0.2
frequency
B
Frequency Efficiency 88 86 84 82 80
0.5 0.4
Efficiency %
0.15 0.1 0.05 0 0.25 1.25 2.25 3.25 4.25 O2 mole % 5.25
15
Efficiency %
frequency
Operate the plant over a range of conditions, many operating points and transitions between them
Inconsistency!
Major disturbances
Class Workshop
What do the following words have in common?
Music
Love
Happiness
Operability
Class Workshop
Difficult to define exactly, but we know when we have achieved or fallen short!!
Music
Love
Happiness
Operability
From the simplest to most complex process, we must think about operability!
I need to regulate the flow, but how complex should the equipment be? Does the need for operability affect this decision?
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