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Plantwide Control of Chemical Processes

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)

Lecture 03 - PID Control

Topics covered in this lecture: The PID algorithm, Purpose of proportional, integral and derivative action, Instability due to too much feedback, PID controller tuning, First-order plus dead time model identification, Controller modes and action.


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