System Modeling Coursework

Class 30: Modeling of Batch reactor

P.R. VENKATESWARAN
Faculty, Instrumentation and Control Engineering,
Manipal Institute of Technology, Manipal
Karnataka 576 104 INDIA
Ph: 0820 2925154, 2925152
Fax: 0820 2571071
Email: pr.venkat@manipal.edu, prv_i@yahoo.com
Web address: http://www.esnips.com/web/SystemModelingClassNotes
 WARNING!

• I claim no originality in all these notes. These are the

compilation from various sources for the purpose of
delivering lectures. I humbly acknowledge the wonderful
help provided by the original sources in this compilation.
• For best results, it is always suggested you read the source
material.
• Refer to Class 14: Modeling of Chemical Systems for more
material and proper perspective

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 Contents

• Batch process definition

• Batch process nomenclature
• Batch formalism
• Batch Procedure
• Control loop suggested
• References

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 Introduction

• Prior to the late 1930s practically all chemical and petroleum

production processes essentially were of the batch mode.
• When crude oil, for example, was first cracked into lighter
hydrocarbon fractions, thermal cracking was of the batch
mode.
• Where inherently suited (chemically or physically) andwhere
a large and continuous market demand for a single product
existed, manufacturers found that continuous production
warranted the costs of scaling up equipment and integrating
the flow to and from various unit operations in a
continuous production system.
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 What could be a batch process?

• Every process is a batch process; the difference is how long the

process runs between startup and shutdown. (While this may be true
theoretically, it is indeed an oversimplification.)
• A batch process is discontinuous, in which ingredients are sequentially
prepared, mixed, reacted, cooked, heated, or cooled, finished, and
packed—all in accordance with a time-sequenced schedule worked
out by a process engineer.
• A batch process seldom is purely batch; a continuous process seldom
is purely continuous. Most batch processes require continuous control
over one or more variables throughout the entire schedule, and thus
the overall batch control system must be a form of hybrid. Many
products made continuously will, at the end of the line, require batch
packaging, inspection, handling, storing, and shipping.

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 Speaking in general…

• A batch process usually is completed within a matter of

minutes to a few hours, as contrasted with a few seconds
for what may be termed a discrete operation or weeks or
months for a continuous process from start-up to
shutdown.
• However, in the latter case, for any given molecule of
substance entering the process, the interval of time within
the process (residence time or throughput rate) before it
exits as part of a finished product usually can be measured
in seconds to very few minutes.

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 Batch Nomenclature

• Recipe: A list of ingredients, amounts, or proportions of

each ingredient. Depending on the product, the recipe may
be created by a chemist or other specialist as the result of
formulating the desired product in a laboratory (possibly
pilot plant) environment.
• Grade: A variation in a recipe or formula, usually achieved
through the use of different product data parameters such
as temperature, times, and amounts. This may constitute a
new recipe.
• Unit: A vessel and its associated process equipment that
acts independently of other process units
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 Batch Nomenclature

• Operation: A time- and event-based sequence that defines

the actions of a process unit in performing a process
function. A typical operation may be the sequence to
charge, heat, or dump a given unit.
• Procedure: A sequence of unit operations with specific
product data that constitutes the batch cycle; also
commonly referred to as a recipe or formula.
• Discrete Control Device: An on-off device, such as a
solenoid valve, pump, or motor.
• Regulatory Control: A general term encompassing PID
(proportional plus integral plus derivative) loops and
continuous control functionality.

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 Batch Nomenclature
• Sequenced Batch: The most basic type of batching control. This can
become quite complex because of the large number of operations in
some cases. It may be considered as logic planning and incorporates
all on–off functions and control of other discrete devices. In the pure
form, sequence control involves no process feedback or regulatory
control. It is quite amenable to ladder-logic-based programmable logic
controllers (PLCs).
• Programmed Batch: Elements of sequenced batch plus the addition
of some regulatory control. This system requires little operator
intervention. Sophisticated regulatory controls (beyond PID) seldom
are needed.
• High-Level Batch: Elements of programmed batching with external
and process feedback. Optimization routines may be used as, for
example, in the production of polyvinylchloride (PVC) and other
polymeric emulsions.
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 Process type characteristics

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 Batch formalism

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 Step 1.

• The starting point is that of defining the control

elements from the piping and instrumentation
drawings (P&IDs).
• Using the P&ID, an equipment tag list can be
constructed, including various regulatory and
discrete devices

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 Step 2.

• Following the identification of the control elements, the

individual strategies must be defined.
• Regulatory control strategies may be specified, using ISA
symbology, or, for complex interactive loops, the Scientific
Apparatus Makers Association (SAMA) standard RC22-11
may be useful.
• Due to the nature of batch control processes, attention
should be given to loop mode changes, alarm status
changes, and adaptive tuning requirements.

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 Step 3.

• Individual sets of time and event sequences are

called operations. The actions within an operation
include sequencing, interlocking, profiling, failure
monitoring with emergency shutdown, calculations,
integrators and timers, and parallel operations in
addition to the discrete and regulatory functions.
• In addition the operation provides for manual
operator entry and convenient entry and reentry
points, all for coordinated control of the total unit

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 Step 4: Procedure Definition

• The procedure consists of a sequence of operations

and sets of product parameters, because most batch
processes are characterized by a series of small
batches flowing sequentially through multiple units.
• Each batch follows some path, using some or all of
the units or operations along that path.
• By treating each operation as a single control action
in the procedure, a time-sequence-type diagram can
be designed for the procedure

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 Step 5: Defining Failure Conditions.

• After the first four steps of the formalism are complete, the
designer should pass through the hierarchy once again to
establish an analysis of the failure conditions of the process.
Time sequences should then be defined for the application-
dependent failure steps.
• These failure sequences should be incorporated by
operation and should allow for reentry into the operation at
a position that does not jeopardize personnel, equipment, or
product.

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 Step 6: Optimization and Reports.

• Finally, once all phases of the definition are

complete, optimization of the performance of
equipment and data measurement should be done
and the determination of end report and batch
history data completed.
• The format of batch end data should also be
considered for printed reports.

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 Batch reactor and associated Instrumentation

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 Model Proposed

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 To complete the picture …

• Refer to class 14: modeling of chemical process

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 References

• Handbook of Process Control – Liptak

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 And, before we break…

I laugh not at another’s loss;

I grudge not at another’s gain;
No worldly waves my mind can toss;
My state at one doth still remain.
I fear no foe, I fawn no friend;
I loathe not life, nor dread my end.
- Sir Edward Dyer

Thanks for listening…

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