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This project has received funding from the European Union’s Horizon 2020 research and innovationprogrammeunder grant agreement N° 636!2
Integrated Control and Sensingfor Sustainable Operation of
Flexible Intensied Processes
June 29, 201
Prof! "r! Sebastian #ngell
$% "ort&und
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$'e Partners in t'e Consortiu&
Universit"deg#i $tudidi %ag#iari
$upp#ier forinstrumentation& $'Es
(esearch institutes& academia)rocess industr*
+enera# %,N$EN$ )resentation - 'anue# )ereira (eme#he - %ag#iari -20.6-06-2!
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/dvance the production of high-va#ue products thatmeet high ua#it* demands in (exible intensiedcontinuous plants 1* introducing nove# on#ine
sensors & c#osed-#oop contro# methods
+enera# %,N$EN$ )resentation - 'anue# )ereira (eme#he - %ag#iari -20.6-06-2!
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)ission
'iniaturizedeuipment
ntensi4edheat & mass
transfer
)ossi1#*modu#ar
setup
)roductuniformit*
$ustaina1i#it*
5ast adaption tomaret demand
nnovativeproducts
C'aracteristics *enets
Containerized modular plant from F³ Factory project
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Co&pared to batc' processes7 there are signicant benets of 8e9i1#e intensi4ed continuous processes in man* cases
$peci4c cha##enges:
• $ma## dimensions fast sensors & c#osed-#oop contro# needed
• Higher ua#it* #eve#s more accurate sensors needed
•
%omp#e9 phenomena )/T and mode#-1ased contro# necessar*• nnovative products fast design7 engineering and optimization
• 5ou#ing and c#ogging needs specia# attention
ntegrated )/T-1ased )rocess %ontro# copes ;ith these cha##enges:
• 5ast and accurate on#ine sensing of e* product and process
parameters• )/T and mode# 1ased c#osed-#oop contro# and on#ine optimization
• Too#s for design7 monitoring7 and optimization of the process and of itscontro# s*stem
+enera# %,N$EN$ )resentation - 'anue# )ereira (eme#he - %ag#iari -20.6-06-2!
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)oti+ation
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+enera# %,N$EN$ )resentation - 'anue# )ereira (eme#he - %ag#iari -20.6-06-2!
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pproac'
"e+elop ne- tec'nologies for Integrated ProcessControl
,n#ine $ensors%#osed-#oop
%ontro#$oft;are Too#s
ntegrated va#idation in8e9i1#e intensi4ed continuous
p#ants
High quality products
Sustainabl
e processes
Competitiv
e prices Flexibility
%ross-sectoria#
dissemination & e9p#oitation
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Intensied
s.nt'esisof organicco£s
Intensied
production of'ig'/+iscouspol.&ers
Continuous
for&ulationof co&plex liuids
Setup
Tu1u#ar reactor cu#t to contro# =isruptions ? ;aste
o+el
sensors
on#ine N'( sensor
on#ine fou#ing sensor
on#ine rheo#og*
sensor for po#*merme#ts
on#ine rheo#og*
sensor ;ith air-1u11#e detection+enera# %,N$EN$ )resentation - 'anue# )ereira (eme#he - %ag#iari -20.6-06-2!
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Case Studies o+el $ec'nologies
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Online r'eolog.
sensors
Online fouling
sensor
Online )3
sensor
)rocessparameter
@iscosit* vs shearrate7 non-Ne;tonian 8uids7po#*mer me#ts
Thicness offou#ing #a*er in atu1u#ar reactor
%ompositions andratios of su1stances
5eatures n#ine7 non-invasive7 measureacross pipe7mu#ti-phase-use7fast
n#ine7 non-invasive7 possi1#*space-reso#ved
/t-#ine7 fast7accurate7 possi1#*ca#i1ration free7high #inearit*
)rincip#e U#trasoundAacross pipeB
U#trasoundAa#ong pipeB
'(-N'(spectroscop*ApermanentmagnetB
+enera# %,N$EN$ )resentation - 'anue# )ereira (eme#he - %ag#iari -20.6-06-2!
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o+el sensing tec'nologies
$
N
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$ec'nolog. Features
'ode#-1ased c#osed-#oopcontro# -
Using simp#e rigorous mode#s ;ithon#ine adaptation of parameters
- terative optimization- )#ant-;ide contro#
=ata-1ased c#osed-#oopcontro#
- =ata-1ased mode#s for comp#e9phenomena
-%#osed-#oop contro# 1ased upon thesemode#s
Too# for sensor fai#uredetection
- nterna# mode# is trained using processdata
- ,n#ine correction of fa#se sensor data
Too# for data-mining-
Using Cdata cu1esD ;hich com1ineprocess7 contro#7 and design data
- denti4es #ong-term deviations- Ena1#es process optimization
Too# for design eva#uation - Eva#uation of the integrated contro#s*stem in an ear#* design stage
-Using rea#istic production scenarios+enera# %,N$EN$ )resentation - 'anue# )ereira (eme#he - %ag#iari -
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o+el Control $ec'nologies $ools
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Integrated 4alidation of $ec'nologies
ProcessA8e9i1#e7 intensi4ed7
continuousB
d+anced P$5composition ? rheo#og* ? fou#ing
6 sensors a+ailable on t'e &ar7
)onitoring$ensor fai#ures ? performance
$ based adapti+e control(igorous and data-1ased contro#
)#ant-;ide contro#
Design valuation
+enera# %,N$EN$ )resentation - 'anue# )ereira (eme#he - %ag#iari -20.6-06-2!
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+enera# %,N$EN$ )resentation - 'anue# )ereira (eme#he - %ag#iari -20.6-06-2!
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#xa&ple for integrated +alidation5
Intensied s.nt'esis of organic co£s
'i9ing
(eactorsection .
(eactorsection 2
=os
=os/2
=os/.=os
N'(
5ou#ing$ensor
Sensors
,n#ine state& parameter
estimation
'ode#-1asedcontro#
Control
,ther sensors
$ensor fai#uredetection &
correction
,n#ineperformancemonitoring
Monitoring
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%,N$EN$ focuses on 8e9i1#e intensi4ed continuousprocesses
Nove# on#ine-sensors7 advanced contro# methodsand monitoring too#s are deve#oped and integrated
to ena1#e to e9p#oit the 1ene4ts of these processes
The sensing and contro# techno#ogies can a#so 1eused for conventiona# processes
%ross-sectoria# dissemination and e9p#oitation ;i##;iden the impact of %,N$EN$ on the processindustries
+enera# %,N$EN$ )resentation - 'anue# )ereira (eme#he - %ag#iari -20.6-06-2!
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Conclusions
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$'an7 .ou8
12
Emai#: manue#reme#heF1a*ercom
Coordinator5 )anuel Pereira 3e&el'e
+enera# %,N$EN$ )resentation - 'anue# )ereira (eme#he - %ag#iari -20.6-06-2!
mailto:[email protected]:[email protected]