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Abstract - The aim of this work is to compare several of the commercial dynamic models for batch
distillation available worldwide. In this context, BATCHFRAC, CHEMCAD BATCH, and
HYSYS.Plant software performances are compared to experimental data. The software can be used as soft
sensors, playing the roll of ad-hoc observers or estimators for control objectives. Rigorous models were used
as an alternative to predict the concentration profile and to specify the optimal switching time from products
to slop cuts. The performance of a nonlinear model obtained using a novel identification algorithm was also
studied. In addition, the strategy for continuous separation was revised with residue curve map analysis using
Aspen SPLIT.
Keywords: batch distillation, residue curve map, soft sensor, inferential control, nonlinear identification.
batch distillation. The work by Henson and Seborg simulation (the interactions are computed from
(1997) lists a number of simulation and experimental average values and do not consider the effect of
cases in which feedback controllers were used. groups that are not directly linked), the UNIQUAC
In this work, a nonlinear model-based strategy (short for UNIversal QUAsi Chemical) method was
was developed with commercial software selected (Abrams and Prausnitz, 1975). In this
specifically suitable for modeling batch distillation model, the liquid-phase activity coefficients can be
operation. BATCHFRAC (Aspen Technology Inc, individually differentiated in the combinatorial part,
Cambridge, MA, USA), HYSYS.Plant® (AEA which includes the geometric significance for
Technology, Calgary, Canada), and CHEMCAD combining molecules of different shapes and sizes,
BATCH (Chemstations Inc., Houston, TX, USA) and the residual part, which includes the energy
performances were tested to evaluate whether their parameters (Equations 1-3).
potentialities in other applications such as inferential
control structure and/or soft sensor could be ln γ i = ln γ iComb + ln γ iRes (1)
attractive.
Φi Φi
ln γ iComb = ln + 1 − −
PROBLEM STATEMENT xi xi
(2)
The process considered in this paper corresponds
to a distillation column described in Nad and Spiegel z Φ Φ
− qi ln i + 1 − i
(1987), from which the experimental data have been 2 θi θi
taken. The column has an internal diameter of 162
mm packed with Sulzer Mellapak 250Y. A packing
height of 8.0 m was used, and the number of
θk τik
∑ ∑∑
theoretical stages was measured with a standard
ln γ iRes = qi 1 − ln θ jτ ji − (3)
method (chlorobenzene + ethylbenzene at total θ jτ jk
reflux). The column, including the reboiler and the j k
condenser, has 20 theoretical stages. The j
volumetrically measured liquid hold ups of the
column and the condenser were 0.015 m3 and 0.005 where γi is the liquid-phase activity coefficient, xi is
m3, respectively. The system was tested with a the liquid-phase molar fraction, and z is the
ternary mixture of n-heptane + cyclohexane + coordination number (usually 10). The molecular
toluene. The initial charge, on a molar basis, was volume fractions, Φi, and the molecular surface
39.40% for n-heptane, 40.70% for cyclohexane, and fractions, θi, are computed based on Equations 4 and 5.
19.90% for toluene. After 2.78 hours of operation,
the steady state conditions of the column were x i ri
Φi ≡ (4)
reached. Then, the reflux ratio sequence and the
switching time recommended by the authors were
∑ rjx j
j
followed in order to compare the performance of the
different software packages.
x i qi
θi ≡ (5)
∑ q jx j
CLASSICAL APPROACH j
Vapor-Liquid Equilibrium The molecular size (ri) and the molecular shape
(qi) are computed from the group volume parameter
A check of the accuracy of the estimation model (Rk) and the group surface area (Qk), as stated in
of the physical properties is the key factor in
Equations 6 and 7. υik is the number of groups of
succeeding in process simulation, and thus obtaining
realistic equipment behavior (Carlson, 1996; the kth type in the ith molecule
Agarwall et al., 2001). The pure component vapor
pressures were derived from the Antoine equation
(Antoine, 1888). To avoid problems inherent in
ri = ∑ υik R k (6)
k
group contribution methods like UNIFAC in process
Brazilian Journal of Chemical Engineering
Nonlinear Dynamic Modeling 309
System
Parameter n-heptane n-heptane cyclohexane
cyclohexane toluene toluene
aij -0.8744 0.7788 -0.0238
aji 0.6985 -0.8597 0.1775
bij/K 90.41 -192.14 -30.49
bji/K -80.76 178.89 -54.66
Tlower/K 298.1 303.1 293.1
Tupper/K 371.6 383.9 383.7
Brazilian Journal of Chemical Engineering, Vol. 19, No. 03, pp. 307 - 317, July - September 2002
310 L.Jiménez, M.S.Basualdo, J.C.Gómez, L.Toselli, and M.Rosa
Cyclohexane
Distillation
boundary nC7 cC6
Binary
azeotrope
Figure 1: Residue curve map for n-heptane + cyclohexane + toluene at 101.3 kPa.
Distillation Design Methods studying the effect on the number of rectifying and
stripping stages. The last method is only applicable
In general, it is not possible to cross boundaries for separations in which one of the products is a node
with distillation and recycle streams. It may be (stable or unstable).
possible to cross distillation boundaries if unit The results from BV and Ω methods for both
operations other than distillation (i.e., liquid-liquid approaches (remove first the light or the heavy
extraction, reactor, membrane, etc.) are considered or component) are very similar, recovering pure
if the boundary is strongly curved. For all practical cyclohexane, pure toluene, and the azeotrope. Figure
purposes it can be stated that, for homogeneous 2 shows the concentration profiles for the second
distillation, the whole separation sequence lies in the strategy, in which the second column is very close to
same distillation region. Computing a distillation the n-heptane + toluene axis.
column on a RCM is not difficult because the feed
and the top and bottom products must lie in a straight
line to satisfy the mass balance. The exact position of PROCESS MODELING
each point depends on its relative flowrate. In
addition, both products must be on the same residue A model for the system described by Nad and
curve line. Spiegel (1987) was developed. HYSYS.Plant® and
Two preliminary design methods were used. The BATCHFRAC use rigorous calculations, with
boundary value procedure (BV) was computed to several methods available to integrate the differential
assess the separation feasibility and to calculate the equations, while CHEMCAD BATCH uses a
minimum reflux/reboil ratio for a fixed component pseudostationary model.
recovery (99 mol %). BV performs calculations by
starting at both ends of the column and computing Initialization with HYSYS.Plant
towards the middle; a separation is feasible if the
lines that illustrate the rectifying and the stripping Two feeds are introduced into the reboiler and
concentration profiles intersect. The omega design condenser at the same temperature and
procedure (Ω) optimizes the feed stage location by concentration. Once the condenser is filled, the
reflux valve is opened until the stages have the fractions was continuous, and cut time switches were
experimental holdup; hence, the initial conditions introduced between two operational steps.
can be reproduced. To model the start-up period, the
reflux ratio is set to infinity, the heat duty is fixed, The Pseudostationary Model of CHEMCAD
and the feed and product flowrates are set to zero. BATCH
The predicted start-up period is 2.66 hours, a value
with only a 4.3% deviation. CHEMCAD BATCH models the discontinuous
operation with the CC-BATCH module. The
Initialization using BATCHFRAC simulation of batch unit operations is performed as a
sequence of pseudostationary states, in which each
Initial conditions were fixed as the total reflux step begins with the final conditions of the previous
stationary values. Due to software limitations, no one, and the calculations are performed linking a
time considerations were implemented for the start- series of steady states. The option of having the same
up period, and therefore it was reached concentration in the still pot, plates, and condenser is
instantaneously. To model the whole production adopted for the initialization period. During start-up,
period in a single run, the accumulator type, the the conditions were set to total reflux. To calculate
feed-loading time, and the operational procedure the production period, a set of thirty independent
(sequence of operational steps linked by the so- operating steps were necessary. Batch distillation
called stop criteria) were fixed. In this case, the was integrated with continuous operation with the
reflux ratio was modified according to time use of tanks and time switches between certain
considerations. Dump action for the different operational steps.
Cyclohexane Cyclohexane
Toluene
nC7 cC6
Feed
Figure 2: Column profiles with removal of the light component in the first column.
Brazilian Journal of Chemical Engineering, Vol. 19, No. 03, pp. 307 - 317, July - September 2002
312 L.Jiménez, M.S.Basualdo, J.C.Gómez, L.Toselli, and M.Rosa
1.0 1.0
nC7, Nad&Spiegel (1987)
CHEMCAD-BATCH
0.2 0.2
0.0 0.0
0 2 4 6 8 0 2 4 6 8
Time/h Time/h
BATCHFRAC BATCHFRAC
o
Top temperature/ C
105
o
CHEMCAD-BATCH CHEMCAD-BATCH
95
100
85
95
75 90
2 4 6 8 2 4 6 8
Time/h Time/h
υ k
u k
N (• )
B q −1 ( )
A q −1 ( ) yk
NONLINEAR IDENTIFICATION METHODS with q-1 denoting the unit time-delay operator.
It is assumed that the orders n, m, and s and the
A Brief Review nonlinear functions gi(*) are known and that the goal
is to estimate the parameters of the linear (a1,···, an,
In contrast to linear models that approximate the b1,···, bm) and nonlinear (c1,···, cr) subsystems from
system around a given operating point, nonlinear input-output data. A typical choice is to represent the
models are able to describe the global behavior of nonlinear subsystem by a polynomial expansion.
the system over the entire operating range. One of Equation (9) can be written as a (nonlinear)
the most frequently studied classes of nonlinear difference equation of the form
models is the Hammerstein models, which consists
of the cascade connection of a static (zero-memory) n r m
nonlinearity and a linear time invariant (LTI) system yk = − ∑ a jyk − j + ∑∑ b jci uik − j + υk (11)
(Ljung, 1999; Eskinat et al., 1991). j=1 i =1 j=1
In this section, a noniterative algorithm for the
estimation of Hammerstein models, which is based Now defining the vectors
only on least square estimation, and singular value
decomposition, is presented. The algorithm is then
θ = (a1,,a n , b1c1,, bm c1,, b1cr ,, b m cr ) (12)
T
used to estimate a nonlinear model of the process.
The data used for the identification are generated via
simulation of a rigorous model of the column based φk = (− y k −1, , − y k − n , u k −1, , u k − m ,
on first principles, implemented with the commercial (13)
package HYSYS.Plant®, tuned to match the u2 k −1 , , u 2 r r
k − m , , u k −1, , u k − m )
T
experimental data. As a result of the identification
process, a reduced-order nonlinear model that is
equation (11) can be written in linear regressor form
suitable for control design is obtained. For the
as
purposes of comparison, the same data are used to
estimate a state-space (linear) model of the column,
using a subspace identification method (Viberg, 1995). y k = φ k T θ + υk (14)
yk =
( ) N (u ) + υ =
B q −1 YN = Φ N T θ + VN (15)
A (q −1 )
k k
where
(9)
B (q −1 ) r YN=(y1,···, yN)T, VN=(υ1,···, υN)T,
∑ cigi (u k ) + υk
A (q −1 ) i =1
=
and ΦN=(φ1,···, φN)T.
( )
A q −1 = 1 + a1q −1 + + a n q − n
provided the indicated inverse exists. Now defining
(10)
B (q −1 ) = b1q −1 + + b m q − m
the vectors a=(a1,···, an)T, b=(b1,···, bm)T, and c=(c1,···,
cr)T and the matrix
Brazilian Journal of Chemical Engineering, Vol. 19, No. 03, pp. 307 - 317, July - September 2002
314 L.Jiménez, M.S.Basualdo, J.C.Gómez, L.Toselli, and M.Rosa
and vk are the process noise and the output Overschee and de Moor (1994) was used for the
measurement noise vectors, respectively, and where estimation. The N4SID algorithm chooses
A, B, C, and D are the system matrices of automatically the best (in the mean-square sense)
appropriate dimensions to be estimated. model order (default range is from 1 to 10). The
In this case, the N4SID algorithm by Van resulting system matrix estimates are
−1.036·10−3
5.314·10−4 0
B= , D= (23)
4.207·10−5 0
1.696·10−4
The simulation results are also shown in Figure 6 the outputs of the identified system. Here again,
(as dash-dotted lines). For the purposes of validation, there was very good agreement between the
a different data set was used to compute estimates of measured and the estimated outputs.
15
Reflux ratio
.8
10
.6
ycC6
.4
5
.2
0
1 2 3 4 1 2 3 4
t/s·104 t/s·104
.5
.8 .4
ynC7
.6 .3
ytol
.4 .2
.2 .1
1 2 3 4 1 2 3 4
t/s·104 t/s·104
Figure 6: Clockwise from top left: reflux ratio, experimental (solid line), nonlinear estimate (dotted line),
and 4SID estimate (dash-dotted line) of cyclohexane, toluene, and n-heptane concentrations.
Brazilian Journal of Chemical Engineering, Vol. 19, No. 03, pp. 307 - 317, July - September 2002
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