Process Simulation and Control

Continuous chemical processes are inherently dynamic systems – process inputs and outputs change in time. To accommodate this, modern plants require some form of automatic control. This subject equips students with the skills to understand how and why key process variables change in time, and to then design and implement effective control strategies to accommodate this. Students are introduced to the concept of feedback control, with examples of control schemes for common unit operations. The development of dynamic process models is introduced, along with analytical and numerical techniques for process simulation. Process simulation is performed using linear ordinary differential equation models, Laplace transforms, transfer functions, and numerical methods. The response of complex process plants to common dynamic inputs is investigated. Students are introduced to frequency response analysis and Bode plots. The process control component of the subject introduces the concept of closed loop transfer functions and the PID controller. Dynamic process simulation is performed using analytical techniques and with the numerical simulation capabilities of software packages including MATLAB Simulink. The stability of closed loop systems is analysed using techniques such as Routh stability analysis, the Bode stability criterion, and gain and phase margins. The effect of controller tuning constants on control system response is investigated, along with various controller tuning methods. Advanced control strategies including cascade control, time-delay compensation, and feedforward control are developed, as well as techniques to simultaneously control multiple process variables in multiloop systems. The subject will cover feedback control schemes for common unit operations. Developing and using process simulators, including the application of Laplace transforms and transfer functions as well as the use of numerical simulation tools. Frequency response analysis and Bode plots. Simulation of closed-loop control systems and PID controllers. Closed-loop stability analysis and controller tuning. Advanced single-loop control strategies and multiloop control systems. Please view this video for further information: Process Simulation and Control

• 1Interpret how key process variables change in time for common chemical processes responding to typical dynamic inputs
• 2Simulate common unit operations, using analytical and numerical methods
• 3Analyse and implement effective and efficient control strategies for chemical processes
• 4Analyse and tune feedback controllers effectively
• 5Demonstrate mastery of the mathematical modelling of feedback and other control loops
• 6Appraise different methods of implementing advanced forms of process control and identify the optimum solutions particularly considering multi-loop control
• 7Appraise how regulatory control systems interact with safety systems to keep large scale chemical infrastructure operating in a reliable, safe, sustainable and profitable fashion.