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September 23, 2023


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Plantwide Control of Chemical Processes. Instructor: Prof. Nitin Kaistha, Department of Chemical Engineering, IIT Kanpur.

The issue of control structure selection, where the control system designer must make decisions as to what variables need to be controlled and the corresponding manipulated variables, is usually treated in a very perfunctory manner in courses on control theory. In practical chemical process operation, it is this choice of the control structure that turns out to be crucial towards effective disturbance rejection and maximizing process profitability. Given the large number of control degrees-of-freedom even for the simplest of chemical processes with material/energy recycle, how does one systematically design an effective plant-wide control system? This course addresses the same using an engineering common sense approach. Essential process control theory fundamentals are very briefly covered followed by control structure design for common unit operations such as reactors, distillation columns, heat exchangers and miscellaneous operations (furnaces, refrigeration systems etc). Issues in plantwide control such as proper inventory management and effect of material/energy recycle are then highlighted followed by comprehensive plant-wide control system design case-studies on example processes. Control structure design considerations for maximizing plant profitability are explicitly covered. (from nptel.ac.in)

Course Curriculum

  • Lecture 01 – Introduction Unlimited
  • Lecture 02 – Process Dynamics and Negative Feedback Unlimited
  • Lecture 03 – PID Control Unlimited
  • Lecture 04 – Common Industrial Control Loops and Advanced Loops Unlimited
  • Lecture 05 – Advanced Loops (cont.), Multivariable Systems Unlimited
  • Lecture 06 – Systematic Tuning using Frequency Domain Analysis Unlimited
  • Lecture 07 – Frequency Domain Analysis Unlimited
  • Lecture 08 – Multivariable Systems Unlimited
  • Lecture 09 – RGA and Dynamic Decoupling Unlimited
  • Lecture 10 – Model based Control Unlimited
  • Lecture 11 – Dynamic Matrix Control Unlimited
  • Lecture 12 – Control of Distillation Columns Unlimited
  • Lecture 13 – Temperature Inferential Distillation Control Unlimited
  • Lecture 14 – Considerations in Temperature Inferential Control Unlimited
  • Lecture 15 – Control of Complex Column Configurations Unlimited
  • Lecture 16 – Control of Heat Integrated Columns Unlimited
  • Lecture 17 – Homogenous Extractive Distillation Unlimited
  • Lecture 18 – More on Complex Columns and Reactive Distillation Unlimited
  • Lecture 19 – Control of Reactors Unlimited
  • Lecture 20 – PFR Controls (cont.) and CSTRs Unlimited
  • Lecture 21 – CSTR Heat Management Unlimited
  • Lecture 22 – Heat Exchangers and Miscellaneous Systems Unlimited
  • Lecture 23 – Degrees of Freedom Analysis Unlimited
  • Lecture 24 – Degrees of Freedom Analysis (cont.) Unlimited
  • Lecture 25 – Illustration of Considerations in Control Structure Synthesis Unlimited
  • Lecture 26 – Two Column Recycle Process Unlimited
  • Lecture 27 – Throughput Manipulator Selection: Illustration of the Radiation Rule Unlimited
  • Lecture 28 – Plantwide Control Structure Design Unlimited
  • Lecture 29 – Systematizing Plantwide Control Design Unlimited
  • Lecture 30 – The Luyben Design Procedure Unlimited
  • Lecture 31 – Role of Equipment Capacity Constraints Unlimited
  • Lecture 32 – Recycle Process Case Study Unlimited
  • Lecture 33 – Recycle Process Case Study (cont.) Unlimited
  • Lecture 34 – C4 Isomerization Process Case Study Unlimited
  • Lecture 35 – C4 Isomerization Process Case Study (cont.) Unlimited
  • Lecture 36 – C4 Isomerization Process Case Study (cont.) Unlimited
  • Lecture 37 – Systematic Economic Plantwide Control Design Procedure Unlimited
  • Lecture 38 – Ethylbenzene Process Case Study Unlimited
  • Lecture 39 – C4 Isomerization Process Revisited Unlimited
  • Lecture 40 – Contrasting Conventional and Top-Down Approach Unlimited
  • Lecture 41 – Cumene Process Plantwide Control Unlimited

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