Chemical Engineering Commons^™

Responsive Economic Model Predictive Control For Next-Generation Manufacturing, Helen Durand

Chemical Engineering and Materials Science Faculty Research Publications

There is an increasing push to make automated systems capable of carrying out tasks which humans perform, such as driving, speech recognition, and anomaly detection. Automated systems, therefore, are increasingly required to respond to unexpected conditions. Two types of unexpected conditions of relevance in the chemical process industries are anomalous conditions and the responses of operators and engineers to controller behavior. Enhancing responsiveness of an advanced control design known as economic model predictive control (EMPC) (which uses predictions of future process behavior to determine an economically optimal manner in which to operate a process) to unexpected conditions of these types …

Modeling Of Rotary Packed Beds For Reactive And Non-Reactive Systems, Chinyere Evangeline Ezeobinwune

Graduate Theses, Dissertations, and Problem Reports (ETD)

Rotary packed beds (RPBs) are used in a wide range of reactive and non-reactive applications. In this research, a 2-d, first-principles, dynamic model of a non-reactive RPB that is used for heat exchange between the outgoing flue gas from a power plant and the incoming air to the boiler/pulverizer of the power plant is developed. A 2-d, first-principles model of a reactive RPB is developed where a functionalized metal-organic framework (MOF) is used for CO₂ capture.

For the non-reactive system, a Ljungstrom-type air preheater (APH) is considered. Existing models for these rotating heat exchangers are typically 1-d. There are …

Techno-Economic Analysis Of Acetaldehyde Production Via Partial Oxidative Dehydrogenation Of Ethanol, Sudarat Sompong

Chulalongkorn University Theses and Dissertations (Chula ETD)

Due to the increased attention regarding the battery electric vehicles, the demand for ethanol as a biofuel may be reduced in the future. Therefore, ethanol transformation towards acetaldehyde is conducted in this work, primarily because of the higher selling price and several advantages of acetaldehyde. Regarding the acetaldehyde preparation, acetaldehyde is produced by partial oxidative dehydrogenation of ethanol. According to the economic analysis results, at the same price of acetaldehyde, an annual production capacity of 120,000 tons is the most profitable production size. In addition, the potential process of producing acetaldehyde from ethanol is acetaldehyde production process at 200°C since …

Pharmaceutical Manufacturing In The 21st Century: Identification And Analysis Of Key Elements, Robert N. Mills

Honors Program: Senior Projects (Public)

The availability of quality pharmaceutical products impacts the lives of the global population on a daily basis. The importance of product availability and quality within pharmaceutical manufacturing requires that quality systems put into place are capable of accurately and robustly capturing the quality compliance, or lack thereof, of the various stages of production. This review intends to analyze current expert-recommended best practices within key elements of a pharmaceutical manufacturing quality control system and provide recommendations throughout. The quality elements discussed include Quality by Design method validation, necessary equipment determination, and equipment qualification, followed by documentation control and data flow.

Wastewater Treatment Fatty Acids For Biodiesel Production, Zachary Christman

Department of Agronomy and Horticulture: Dissertations, Theses, and Student Research

Wastewater scum is the thick oily substance that floats on top of the primary and secondary tanks within a wastewater treatment plant. Scum has a 30% to 60% lipid content making it an excellent resource for the biodiesel industry. Also the use of scum would reduce the cost of current management practices such as landfill disposal or incineration. In this article there is an overview of lipid byproducts currently being produced at wastewater treatment plants today. This is followed by a presentation showing a full length process for turning wastewater scum into biodiesel raw material.

The Potentials Of Faecal Sludge Treatment Using Local Conditioners In Tanzania: A Review, Doglas Benjamin1

Tanzania Journal of Engineering and Technology (TJET)

Worldwide, every day human beings generate millions of tons of Faecal Sludge (FS), which is rich in water, nutrients, energy, and organic compounds. Yet FS is not being managed in a way that permits us to derive value from its reuse, while at the same time, millions of farmers struggle with depleted soils and lack of water. In most of the developing countries, energy for cooking is mainly derived from cutting of trees, either as wood or charcoal. Resource recovery and reuse from FS can create livelihoods, enhance food security, support green economies, reduce waste and contribute to cost recovery …

Process/Equipment Design Implications For Control System Cybersecurity, Helen Durand

Chemical Engineering and Materials Science Faculty Research Publications

An emerging challenge for process safety is process control system cybersecurity. An attacker could gain control of the process actuators through the control system or communication policies within control loops and potentially drive the process state to unsafe conditions. Cybersecurity has traditionally been handled as an information technology (IT) problem in the process industries. In the literature for cybersecurity specifically of control systems, there has been work aimed at developing control designs that seek to fight cyberattacks by either giving the system appropriate response mechanisms once attacks are detected or seeking to make the attacks difficult to perform. In this …

A Model-Based Framework For The Smart Manufacturing Of Polymers, Santiago D. Salas Ortiz

LSU Doctoral Dissertations

It is hard to point a daily activity in which polymeric materials or plastics are not involved. The synthesis of polymers occurs by reacting small molecules together to form, under certain conditions, long molecules. In polymer synthesis, it is mandatory to assure uniformity between batches, high-quality of end-products, efficiency, minimum environmental impact, and safety. It remains as a major challenge the establishment of operational conditions capable of achieving all objectives together. In this dissertation, different model-centric strategies are combined, assessed, and tested for two polymerization systems.

The first system is the synthesis of polyacrylamide in aqueous solution using potassium persulfate …

Design And Cost Analysis Of Acrylic Acid Plant, Adam Ferrier

Chemical Engineering Undergraduate Honors Theses

The purpose of this project was to model and design a plant to produce 75,000 tons per year of acrylic acid. Using the design in section B.9 of Richard Turton’s Analysis, Synthesis, and Design of Chemical Processes as a starting point, a plant was designed based around the partial oxidation of propylene to acrylic acid. The final plant design produces about 86,000 tons per year of acrylic acid. Using an interest rate of 10%, the plant has a discounted cash flow rate of return of 32% over 2 years of startup and 10 years of operation. Attached is an executive …

Stability Analysis Of A More General Class Of Systems With Delay-Dependent Coefficients, Chi Jin, Keqin Gu, Islam Boussaada, Silviu-Iulian Niculescu

SIUE Faculty Research, Scholarship, and Creative Activity

This paper presents a systematic method to analyse the stability of systems with single delay in which the coefficient polynomials of the characteristic equation depend on the delay. Such systems often arise in, for example, life science and engineering systems. A method to analyze such systems was presented by Beretta and Kuang in a 2002 paper, but with some very restrictive assumptions. This work extends their results to the general case with the exception of some degenerate cases. It is found that a much richer behavior is possible when the restrictive assumptions are removed. The interval of interest for the …

Recovery Of Water And Salt From Hyper-Saline Mine Water Using Freeze Crystallization, Gabrielle Casey

Chemical Engineering Undergraduate Honors Theses

The Freezerbacks researched, designed, and economically evaluated a full-scale freeze crystallization process as well as two alternative full-scale processes: 5 stage multiple effect evaporation and reverse osmosis. All three processes were designed to treat hyper-saline mine water that was sent into evaporation pond systems. These systems were designed for Freeport-McMoRan’s mines that need to treat impacted water.

The Freeport-McMoRan copper mine in Miami, Arizona was visited in order to gain insight about the problem. The mine is no longer actively mining copper and is in the process of reclaiming land used. An essential part of restoring the land is treating …

Desalination: Freeze Crystallization, Ibrahim Guiga

Chemical Engineering Undergraduate Honors Theses

The Freezerbacks researched, designed, and economically evaluated a full-scale freeze crystallization process as well as two alternative full-scale processes: 5 stage multiple effect evaporation and reverse osmosis. All three processes were designed to treat hyper-saline mine water that was sent into evaporation pond systems. These systems were designed for Freeport-McMoRan’s mines that need to treat impacted water.

The Freeport-McMoRan copper mine in Miami, Arizona was visited in order to gain insight about the problem. The mine is no longer actively mining copper and is in the process of reclaiming land used. An essential part of restoring the land is treating …

A Comprehensive Techno-Economic Framework For Shale Gas Exploitation And Distribution In The United States, Jorge Asis Charbel Chebeir

LSU Doctoral Dissertations

Over the past years, shale gas has turned into one of the most significant sources of energy in the United States. Technological advancements have provided the energy industry with the necessary tools to allow the economic exploitation of an enormous volume of natural gas trapped in shale formations. This has boosted the domestic gas production and generated a boom in other sectors of the economy in the country. However, major challenges are involved in the development of shale gas resources. A drastic decline of wells’ productivity, the costs involved in the gas production and distribution facets, and the volatile behavior …

On Accounting For Equipment-Control Interactions In Economic Model Predictive Control Via Process State Constraints, Helen Durand

Chemical Engineering and Materials Science Faculty Research Publications

Traditionally, chemical processes have been operated at steady-state; however, recent work on economic model predictive control (EMPC) has indicated that some processes may be operated in a more economically-optimal fashion under a time-varying operating policy. It is unclear how time-varying operating policies may impact process equipment, which must be investigated for safety and profit reasons. It has traditionally been considered that constraints on process states can be added to EMPC design to prevent the controller from computing control actions which create problematic operating conditions for process equipment. However, no rigorous investigation has yet been performed to analyze whether, when a …

Operation And Process Control Development For A Pilot-Scale Leaching And Solvent Extraction Circuit Recovering Rare Earth Elements From Coal-Based Sources, Douglas Kweku Addo

Theses and Dissertations--Mining Engineering

The US Department of Energy in 2010 has identified several rare earth elements as critical materials to enable clean technologies. As part of ongoing research in REEs (rare earth elements) recovery from coal sources, the University of Kentucky has designed, developed and is demonstrating a ¼ ton/hour pilot-scale processing plant to produce high-grade REEs from coal sources. Due to the need to control critical variables (e.g. pH, tank level, etc.), process control is required. To ensure adequate process control, a study was conducted on leaching and solvent extraction control to evaluate the potential of achieving low-cost REE recovery in addition …

Online Model Predictive Control Of A Nonisothermal And Nonisobaric Membrane Reactor For Water-Gas Shift Reaction Applications, Jacob Martin Douglas

Graduate Theses, Dissertations, and Problem Reports (ETD)

Online Model Predictive Control of a Nonisothermal and Nonisobaric Membrane Reactor for Water-Gas Shift Reaction Applications Jacob M. Douglas Modern hydrogen production units are tasked with producing the most hydrogen possible while dealing with flow variations caused by changing power demands. Classical methods for hydrogen production employing the water-gas shift reaction are governed by equilibrium limitations that take effect at high temperatures and high concentrations of H2 (Georgis, et al., 2014). The implementation of a membrane reactor with temperature control enables the hydrogen concentration and temperature to reach an equilibrium at a higher concentration of H2. Another challenge that is …

Development Of A Sustainability Evaluation And Control Framework For Chemical Processes, Shuyun Li

Graduate Theses, Dissertations, and Problem Reports (ETD)

Industry, government, and society have begun to shift from economic stand-alone focus to the inclusion of sustainability in the decision-making process. This shift can be attributed to the growing environmental and social awareness that makes consumers and stakeholders not only care about product quality and cost, but also products and processes that minimize the environmental impact and conserve natural resources. As a result, some progress has been made in recognizing and understanding the challenges of sustainable development, which helps evaluating the sustainability performance of a specific process/product. In particular, sustainability assessment tools and methodologies have been developed to help the …

Design And Implementation Of Model Predictive Control Strategies For Improved Power Plant Cycling, Xin He

Graduate Theses, Dissertations, and Problem Reports (ETD)

Design and Implementation of Model Predictive Control Strategies for Improved Power Plant Cycling

Xin He

With the increasing focus on renewable energy sources, traditional power plants such as coal-fired power plants will have to cycle their load to accommodate the penetration of renewables into the power grid. Significant overshooting and oscillatory performance may occur during cycling operations if classical feedback control strategies are employed for plantwide control. To minimize the impact when power plants are operating away from their designed conditions, model-based optimal control strategies would need to be developed for improved power plant performance during cycling.

In this thesis, …

Fluid Agitation Studies For Drug Product Containers Using Computational Fluid Dynamics, Matthew Hiroki Ichinose

Master's Theses

At Amgen, the Automated Vision Inspection (AVI) systems capture the movement of unwanted particles in Amgen's drug product containers. For quality inspection, the AVI system must detect these undesired particles using a high speed spin-stop agitation process. To better understand the fluid movements to swirl the particles away from the walls, Computational Fluid Dynamics (CFD) is used to analyze the nature of the two phase flow of air and a liquid solution.

Several 2-D and 3-D models were developed using Fluent to create simulations of Amgen's drug product containers for a 1 mL syringe, 2.25 mL syringe, and a 5 …

Experimentation And Modeling Of The Effects Of Along-Wind Dispersion On Cloud Characteristics Of Finite-Duration Contaminant Releases In The Atmosphere, Jessica M. Morris

Graduate Theses and Dissertations

Along-wind dispersion, or stretching of the cloud in the direction of the wind, plays an important role in the concentration and modeling of contaminant releases in the atmosphere. Theoretical and empirical derivations were compared for appropriate parameterization of along-wind dispersion. Available field data were analyzed to evaluate and improve previous parameterizations of the along-wind dispersion coefficient, σ_x. An experimental test program was developed and executed in an ultra-low speed wind tunnel at the Chemical Hazards Research Center to determine the effects of the time distribution coefficient on true finite-duration releases from an original area source. Multiple wind speeds, release durations, …

A Nonlinear Systems Framework For Cyberattack Prevention For Chemical Process Control Systems, Helen Durand

Chemical Engineering and Materials Science Faculty Research Publications

Recent cyberattacks against industrial control systems highlight the criticality of preventing future attacks from disrupting plants economically or, more critically, from impacting plant safety. This work develops a nonlinear systems framework for understanding cyberattack-resilience of process and control designs and indicates through an analysis of three control designs how control laws can be inspected for this property. A chemical process example illustrates that control approaches intended for cyberattack prevention which seem intuitive are not cyberattack-resilient unless they meet the requirements of a nonlinear systems description of this property.

Economic Model Predictive Control Design Via Nonlinear Model Identification, Laura Giuliani, Helen Durand

Chemical Engineering and Materials Science Faculty Research Publications

Increasing pushes toward next-generation/smart manufacturing motivate the development of economic model predictive control (EMPC) designs which can be practically deployed. For EMPC, the constraints, objective function, and accuracy of the state predictions would benefit from process models that describe the process physics. However, obtaining first- principles models of chemical process systems can be time-consuming or challenging such that it is preferable to develop physics-based process models automatically from process operating data. In this work, we take initial steps in this direction by suggesting that because experiments that are used to characterize first-principles models often target specific types of data, an …

State Measurement Spoofing Prevention Through Model Predictive Control Design, Helen Durand

Chemical Engineering and Materials Science Faculty Research Publications

Security of chemical process control systems against cyberattacks is critical due to the potential for injuries and loss of life when chemical process systems fail. A potential means by which process control systems may be attacked is through the manipulation of the measurements received by the controller. One approach for addressing this is to design controllers that make manipulating the measurements received by the controller in any meaningful fashion very difficult, making the controllers a less attractive target for a cyberattack of this type. In this work, we develop a model predictive control (MPC) implementation strategy that incorporates Lyapunov-based stability …

Data-Based Nonlinear Model Identification In Economic Model Predictive Control, Laura Giuliani, Helen Durand

Chemical Engineering and Materials Science Faculty Research Publications

Many chemical/petrochemical processes in industry are not completely modeled from a first-principles perspective because of the complexity of the underlying physico-chemical phenomena and the cost of obtaining more accurate, physically relevant models. System identification methods have been utilized successfully for developing empirical, though not necessarily physical, models for advanced model-based control designs such as model predictive control (MPC) for decades. However, a fairly recent development in MPC is economic model predictive control (EMPC), which is an MPC formulated with an economics-based objective function that may operate a process in a dynamic (i.e., off steady-state) fashion, in which case the details …

Process Intervention For Water Recovery In Food Manufacture, Christian Michael Wisniewski

Theses and Dissertations

A case study has been conducted for the recovery of water from complex wastewater at a soluble coffee manufacturing factory. The study has evaluated separation methods for process intervention based on environmental and economic assessments. Water recovery was identified in two possible wastewater streams at the factory: the overall plant effluent and an intermediate stream before it enters on-site pre-treatment. A novel vibratory field membrane separation was tested at the laboratory scale using real factory wastewater and scaled-up using appropriate design protocols. Recovery of water from the intermediate stream proved the most effective, both environmentally and economically. The full-scale vibratory …

Modeling Pharmaceutical Inhibition Of Glucose-Stimulated Renin-Angiotensin System In Kidneys, Ashlee N. Ford Versypt, Minu R. Pilvankar, Hui Ling Yong

Biology and Medicine Through Mathematics Conference

No abstract provided.

Pid Algorithm Design For Automation Of Eukaryote Fermentation, Madison Mann

Chemical Engineering Undergraduate Honors Theses

Single celled eukaryotic organisms are advantageous in the production of proteins for use in biopharmaceuticals due to their ease of cultivation and manipulation. Because of high cell density during fermentation and an ability to allow post-translational protein modifications, yeast is particularly well-suited. To maximize the specific formation rate of the desired proteins, an optimum specific growth rate of the yeast should be found and maintained. This rate is dependent upon pH, temperature, dissolved oxygen content, and carbon feed rate. Fermentation can be done in a fed batch reactor system, and it is possible to use a Buglab (online biomss) sensor …

A Proposed Process And Economic Analysis For A Manufacturing Facility For Nylon 6,6, Perry Doles

Chemical Engineering Undergraduate Honors Theses

The global nylon market is a multi-billion-dollar industry that has been thriving in recent years due to advances in the process technology and its flexibility as a material. Nylon 6,6 is a versatile material with uses in many industries because of its ability manipulated into many forms. It is commonly used in applications that require heat resistance, chemical resistance, and high mechanical strength. It is commonly used in luggage, car parts, carpets, and many other plastic products that require the properties that nylon 6,6 exhibits. The versatility and demand for nylon 6,6 make it an attractive process for many potential …

Some Insights Into The Migration Of Double Imaginary Roots Under Small Deviation Of Two Parameters, Dina Alina Irofti, Keqin Gu, Islam Boussaada, Silviu-Iulian Niculescu

SIUE Faculty Research, Scholarship, and Creative Activity

This paper studies the migration of double imaginary roots of the systems’ characteristic equation when two parameters are subjected to small deviations. The proposed approach covers a wide range of models. Under the least degeneracy assumptions, we found that the local stability crossing curve has a cusp at the point that corresponds to the double root, and it divides the neighborhood of this point into an S-sector and a G-sector. When the parameters move into the G-sector, one of the roots moves to the right halfplane, and the other moves to the left half-plane. When the parameters move into the …

Cfd/Fea Of A Steam Methane Reforming Tube, Matthew Wegener

Research Opportunities for Engineering Undergraduates (ROEU) Program 2017-18

Steam methane reforming is the primary method by which hydrogen is produced; increased efficiency in hydrogen production could enable hydrogen’s usage as an alternative fuel. The objectives of this project are to construct a robust CFD/FEA model of a steam methane reforming tube, and to perform CFD/FEA analysis in both steady and transient operational states, comparing thermal stresses/strains in the tube wall in the two states and relating tube stresses/strains to properties of the process controller.