Process Dynamics and Control of Petrochemical plants

At the end of this course, the students should be able to: 1. evaluate models and do an appreciation of their use in chemical engineering; 2. create mathematical models for processes governed by equilibrium, conservation (e.g., mass, momentum, and energy), transport, and kinetic; 3. develop models of representative chemical and/or physical processes from the first principle; 4. discern the difference between steady-state and non-steady-state behavior; 5. demonstrate an appreciation of the importance of dynamics in process design and operation; 6. analyse feed-forward, feed-back, and PID control of systems; 7. analyse the behaviour of linear dynamic systems; 8. show how block diagrams may be used and manipulated to represent relatively complex systems; and 9. use appropriate software tools (e.g., MATLAB Control Toolbox & Simulink) for the modeling of plant dynamics and the design of well-tuned control loops. * It is expected that 2hrs every week should be used by students to learn how to use software for simple calculations based on the content of this course.

Introduction to process dynamics and control; review of mathematical tools needed for modeling and simulation. Process dynamics: review of Laplace transforms. Transient behavior of I5', 2nd, and higher-order systems. Components of a control system; operation and design. Basic control actions, valves. Transfer functions. Use of block diagrams. Systems response to the impulse. Step and sinusoidal inputs. Derivation of dynamics equations for simple instruments-thermometers, liquid level, and manometer. Dynamic equations for control of simple models-mixing vessels, single CSTR and CSTR in series, PFR. Distillation and absorbers columns; Stability analysis/frequency response analysis; design of feedback controllers based on transient response criteria; design of feedback controllers- based on frequency response criteria. Design of model-based controllers such as IMC, DMC etc. Applications of control to petrochemical plants PREG. Minimum Academic Standards Equipment List of Laboratories/Workshops and Some Equipment/ Instruments/ Tools Expected in them Unit Operation Laboratory Batch Drying Unit, liquid-solid Rotary Filtration Unit; Spray Dryer, Wetted Disc Absorption Column, Apex Drier, Vacuum Distillation Unit, Double Effect Evaporator, Drying Ovens, Tray Drier Unit, Packed Tower Gas/Liquid Unit. Fluidized Bed Unit Distillation Unit Solid/Liquid Extraction Unit, Batch Reactor Assembly, Starch Hydrolyzing and Distillation Unit Process Development /Petroleum testing Laboratory Analytical equipment: viscosimeters, hydrometers, colorimeter, moisture balance, refractometer, pH meter, conductivity meter, flash and cloud point apparatus, fluid bed dryer, autoclave, cutting mill, vacuum pump, weighing balance, bomb and colorimeter, Soxhlet extractor, automated pressure, automated pH control process, automated temperature. Process rig, gas chromatograph, atomic absorption spectroscopy AAS, scanning electron microscope. Reaction, catalysis, and petrochemical analysis laboratory Gyratory shaker, stuart with accessory, laboratory oven, water bath, rotary evaporator, autoclave, centrifuge, liquid chemical reactor reaction vessel with pressure gauge, vacuum pump, batch reactors, reaction distillation unit, electric heating mantle and electromagnetic stirrer, burettes, pipette, beakers, laboratory chemicals. Computer/Animation Laboratory The computer laboratory should have at least 50 PCs and at least three petrochemical engineering software (ASPEN HYSYS packages, CHEMCAD, POYMATH, MATLAB) plus AutoCAD installed. Animation videos on several petrochemical plants such as the production of polymers. Fuel blending, pyrolysis of seeds to fuel oil. Ethylene glycol, ethylene acetate, production of sulphuric, phosphoric fertilizers. Production of gasoline, naphtha, kerosene, fuel, and lubricating oils, paraffin wax, asphalt etc. Inclusion of LabView software on the PCs. (LABVIEW Stands for Laboratory Virtual Instrumentation Engineering Workbench). It is mostly used for automating the usage of processing and measuring equipment in all the laboratory setup. It is used in the field of industrial automation, instrument control, data acquisition and more). Inclusion of SCILAB software (SCILAB is a numerical computation package that is very important in instrumentation and control engineering. It is also used in data analysis, signal processing, simulation of fluid dynamics and image enhancement). Staffing Academic Staff The NUC guidelines on staff/student ratio of 1:15 for Engineering and Technology departments shall apply. However, there should be a minimum of six full-time equivalents of Staff in the department. There is need to have a reasonable number of Staff with doctoral degrees as well as sufficient industrial experience. With a minimum load of 15 Units per semester for students and a minimum of six full-time equivalent of staff in each programme, staff should have a maximum of 15 contact hours per week for lectures, tutorials, practical’s and supervision of projects. NUC requirement encourages all academic staff to have PhD degrees; hence appointment of academic staff is preferably to the Lecturer cadre. Only in exceptional cases are candidates with great promise appointed to Graduate Assistant and Assistant Lecturer positions for the purpose of being developed to the Lecturer cadre as registered PhD candidates. Academic Support Personnel Teaching Assistant/Demonstrators to help lecturers in the conduct of tutorials, practical’s and field work. This category of personnel is not expected to be regular staff as they are to be paid on the basis of approved hourly rate. Administrative Support Staff The services of the administrative support staff are indispensable in the proper administration of the departments and faculty offices. It is important to recruit very competent senior staff that are computer literate. Technical Support Personnel The services of technical support staff, which are indispensable in the proper running of laboratories and workshop/studios are required. It is important to recruit very competent senior technical staff to maintain teaching and research equipment. They are also to undergo regular training to keep them abreast of developments in equipment operation and maintenance. The minimum of academic staff to technical staff ratio of 5:1 should be maintained. Minimum Number of Staff Subject to the general standards specified by NUC: 1. there should be a minimum of two PhDs and four M.Eng degree holders full-time academic staff to mount the programme; 2. each workshop or laboratory should have an adequate number of staff with the right mix, such that each unit or section in that workshop or laboratory can run efficiently; and 3. there should be an adequate number of administrative staff of the appropriate caliber for the office of the Head of Department to run. Student/Staff Ratio The minimum staff-to-student ratio should be 1:15 from 200 level to 500 level. Library There must be adequate library facilities to cater for the interest of all the programmes in the faculty. These include current journals, handbooks, textbooks, manuals, codes of practice, standards and specifications in sufficient numbers. Classrooms, Laboratories, Workshops, Clinics and Offices The following are the NUC requirements for various physical spaces: Academic m2 Professor’s office 18.50 Head of Department’s office 18.50 Tutorial teaching staff space 13.50 Other teaching staff space 7.00 Technical staff space 7.00 Science staff research laboratory 16.50 Engineering staff research laboratory 14.50 Seminar space per student 1.85 Drawing office space (A.O. Board) (per student) 4.60 Drawing office space (A.I. Board) (per student) 3.70 Laboratory space 7.50 Non-academic Secretarial space 7.00 Office Facilities S/No Office No in Room Facilities 1. HOD 1 Table, chairs, A/C, filing cabinet, bookshelves, computer unit, Secretary and facilities. 2. Professor 1 Table, chairs, A/C, filing cabinet, bookshelves, computer unit, Secretary and facilities. 3. Reader 1 Table, chairs, A/C, filing cabinet, bookshelves, computer unit. 4. Senior 1 Table, chairs, A/C, filing cabinet, bookshelves, Lecturer computer unit. 5. Lecturer I 2 Table, chairs, fan, filing cabinet, bookshelves. 6. Lecturer II 3 Table, chairs, fan, filing cabinet, bookshelves