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1 Applications
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0.96 Minimum+ o,g5 Time, days
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FIG 11.25. Feedforward control can be expected to reduce variation in product quality by 4:l or
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greater.
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The value of consistent product quality is the combination of many effects. Slight variations in quality can be corrected by blending-an additional operation. Major variations call for reprocessing of the material and possible shutdown of the tower or of other connected units. The cost of such troubles is great, and difficult to assess. Only after a long period of operation can the effects of improved quality control be judged. In many plants, a certain minimum specification is placed on product quality. To ensure that the established minimum is not violated, even during times of severe load change, average product quality is often maintained at a safe margin above the minimum. Feedforward control can reduce the variation in quality during load changes, allowing average quality to be maintained closer to the minimum. In Fig. 11.25, product quality without feedforward control is seen to vary from 0.95 to 0.99, averaging 0.97, in order to respect the established minimum of 0.95. If feedforward were only to improve control by 4: 1, the average could be reduced to 0.955, a reduction of 0.015. Since distillate flow and composition are inversely proportional, a reduction of 0.015 in average composition represenk an increase in recovery by about tzhe same amount: 97 DZ = E = 95.5 = 1.016 o, Increasing t he flow of product by 1.6 percent with no additional operating costs can be quite attractive. Payout of the forward loop from this source alone could be only a few weeks. But suppose that the feedforward model were able to bring about perfect control. Average composition could then be reduced to 0.95, thereby improving recovery by g465 = 1.021: an increase of only 0.5
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Distillation
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percent more than before. The lessors to be learned from t his example is t hat even a crude feedforward model may be capable of recouping the lion s share of recaovcrable losses. Hence absolutely perfect control is seldom worth ut,taining. As far as savings in ut,ility co& are concerned, those programs which manipulate heat input as a function of feed rat e are obviously efficacious. Little else need be said in their behalf. The savings that may be realized in t,he way of reduced tankage requirements apply princ4pally to new installations. Since the prime function of the forward loop is to mainfain control despite variations in feed rate and composition, it can actually take the place of tankage which would be used to absorb these variations. In addition, control of product quality is generally so well improved through the use of feedforward loops, that, t,ankage used for smoothing and blending the product may also be unnecessary. In large installations, t hese savings alone could be worth several times the cost of the additional instruments. Further savings may be accrued from a number of interrelated processes in the plant. If one of the products from the column is feed stock for a reactor, minimizing its impurities may mean reduced catalyst consumption. Each plant will have its own peculiarities in this regard. BATCH DISTILLATION Although gradually diminishing in favor, batch distillation still is an interesting process to cont,rol, and deserves more than casual attention. Like most batch processes, its control system requires special consideration, ultimately bearing only faint resemblance to that of its continuous counterpart.
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The Material Balance
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A batch separation will require an amount of time inversely proportional t o the rate at which heat is introduced. Consequently, if processing time is to be minimized, heat input must be maintained at the maximum permissible level throughout distillation. This feature then fixes one of the variables which was subject to manipulation on a continuous tower. With vapor rate fixed, a material balance can be readily constructed for the batch still shown in Fig. 11.26. If distillate flow is selected as the variable to be manipulated for product-quality control, reflux is t,hen dependent. In the continuous system, product qu$lity was affected by both D,fF and V/F. But here, F = 0, so it follows that product quality is a function of the ratio of the remaining variables, that is, D/V. 1n.a sense, a batch still is similar to the enriching section of a continuous tower, part of whose vapor flow is feed. If, in the
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