Group of Chemical Process Modeling, Control and Simulation

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Group of Chemical Process Modeling,Control and
Simulation
University Babes-Bolyai Cluj-Napoca,
ROMANIA Faculty of Chemistry and Chemical
Engineering Department of Chemical Engineering
http//chem.ubbcluj.ro
http//chem.ubbcluj.ro/chemeng/HPteam.html
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Group of Chemical Process Modeling,Control and
Simulation

• Prof.dr.ing. Serban AGACHI control engineer
• Head of Department, vice-rector of UBB

• Lect.dr.ing. Árpád IMRE-LUCACI chemical engineer
• Lect.dr.ing. Mircea CRISTEA control engineer
• Lect.dr.ing. Zoltán NAGY chemical engineer
• Assit.drd. Anamaria CORMOS chemist

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Research Projects

• Modeling, Simulation and Advanced Control (Model
  Predictive) of Industrial Electrolysers (Ion
  Exchange Membrane and Amalgam Process)
• Controllability Analysis and Model Predictive
  Control of Chemical Reactors
• Model Predictive Control of PVC batch reactors
  and Fluid Catalytic Cracking Units
• Sensitivity studies of chemical processes
• Process control and virtual instrumentation using
  LabVIEW environment
• Modeling and Model Predictive Control of
  bioreactors
• Adaptive control algorithms
• Simulation of chemical processes using MATLAB,
  SIMULINK, FEMLAB, ASPEN, CHEMCAD, HYSYS, PRO/II,
• Direct digital control of chemical processes
  (CSTR, batch reactors)
• System for energy management in chemical industry
• Optimization of chemical processes (Pontryagin's
  maximum principle applied to fixed bed methanol
  reactor, nonlinear programming applied to
  industrial electrolysers)
• Multimedia applications in Computer Aided
  Education
• Modeling and control of recovering ammonia in the
  Ash Soda process
• Modeling and control of dryers in the ceramic
  industry
• Neural Networks in chemical kinetics and chemical
  engineering
• Environmental Pollution Mathematical Modeling and
  Simulation

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Main Projects

• Project supported by the World Bank and Romanian
  Government, No 70, Theme Computer Aided
  Chemical Engineering. Code 70. Director
  Prof.Dr.Ing. Serban Paul Agachi. Value 294,750
  USD.
• Institutional Partnership Project supported by
  the Swiss National Science Foundation, in
  collaboration with Eidgenössische Technische
  Hochschule Zürich. No. 7 IP 62643. Computer
  Aided Process Engineering. Director
  Prof.Dr.Ing.Serban Paul Agachi. Romanian
  Coordinator Lect.Dr.Ing. Cristea Vasile Mircea.
  Value 48,000 CHF.
• Project supported by the National Council of
  Scientific Research in High Education (CNCSIS),
  Theme 42, No. 349/2001. Dynamic Mathematical
  Model and Optimization of the Brine Electrolysis
  Process in Reactors with Ion Exchange Membrane.
  Optimization and optimal process control.
  Director Lect.Dr.Ing. Imre Arpad. Value
  80,000,000 lei.
• Project supported by the National Council of
  Scientific Research in High Education (CNCSIS),
  Theme B26, No. 7042/2001. Development and
  Practical Implementation of Model Predictive
  Techniques for the Distillation Column. Director
  Lect.Dr.Ing. Nagy Zoltan. Value 28,260,000 lei.
• Project supported by the National Council of
  Scientific Research in High Education (CNCSIS),
  Theme 12, No. 57/2001. Development of Advanced
  Control Algorithms for Chemical Process Control.
  Director Lect.Dr.Ing. Cristea Vasile Mircea.
  Value 45,000,000 lei.
• Project supported by the National Council of
  Scientific Research in High Education (CNCSIS),
  Themes 9/25, No. 1259/177, 2002/2003. Software
  for remote data acquisition and control, remote
  work and videoconference applied in chemical
  engineering research and education.
  Director Lect.Dr.Ing. Cristea Vasile Mircea.
  Value 113,000,000 lei.
• Project supported by the Ministry of Research and
  Education in the frame of Information Society
  Romanian Project, Project number 115/2003,
  Wireless monitoring system of industrial
  pollutant emissions. Director Prof.Dr.Ing.
  Serban Paul Agachi. Value 900,000,000 lei.

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International scientific meetings attended in
1999-2003

• Artificial Intelligence in Industry, AIII'98,
  High Tatras, Slovakia, 1998
• 13th International Congress of Chemical and
  Process Engineering CHISA'98, Prague, Czech
  Republic, 1998
• 2nd Conference on Process Integration, Modeling
  and Optimization for Energy Saving and Pollution
  Reduction PRES'99, Budapest, Hungary, 1999
• 5th International Conference on Computer Aided
  Engineering Education, CAEE'99, Sofia, Bulgaria,
  1999
• XIth Romanian International Conference on
  Chemistry and Chemical Engineering, RICCE-11,
  Bucharest, Romania, 1999
• American Control Conference, ACC'2000, Chicago,
  Illinois, USA, 2000
• 14th International Congress of Chemical and
  Process Engineering CHISA'2000, Prague, Czech
  Republic, 2000
• European Symposium on Computer Aided Process
  Engineering, ESCAPE-11, Denmark, 2001
• 5th Italian Conference on Chemical and Process
  Engineering ICheaP-5 Congress, Florence, Italy,
  2001
• 4th Conference on Process Integration, Modeling
  and Optimization for Energy Saving and Pollution
  Reduction PRESS'01, Florence 20-23 May 2001
• International Conference and Exhibition Filtech
  Europa 2001, Düsseldorf, Germany, 2001
• European Symposium on Computer Aided Process
  Engineering, ESCAPE-12, Holland, 2002
• European Symposium on Computer Aided Process
  Engineering, ESCAPE-13, Finland, 2003

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Laboratory equipment

• HARDWARE
• Vapor-liquid equilibrium still (Siege  and Roeck
  Type, Normag Labor- und Verfahrenstechnik GmbH
  Co., Hofheim am Taunus, Germany),
• Pilot plant for studying the absorption
  processes,
• Pilot plant for three phase fluidization systems
• Separation modules
• Laboratory kit for chemical reaction engineering
  studies
• Laboratory kit for momentum, heat and mass
  transfer studies
• Independent data acquisition and control of the
  pilot plants by special National Instruments data
  acquisition and control cards
• Spectrophotometer Jasco V-530 UV-VIS, wave length
  190-1000 nm, accuracy 0.1 nm, spectrophotometer
  accessories
• Thermo balance MOM
• Gas chromatograph ITD (Axel Semrau Finnigan
  MAT)
• Reactor under pressure 100 bar
• Filtration pilot equipment
• Computers

• SOFTWARE
• LabVIEW 6.0,
• Matlab 6.5,
• Simulink 3.0,
• HYSYS,
• ChemCAD 5.0,
• Aspen Plus 12
• Cosmos M Designer,
• Hazoptimizer.

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• ILUDEST bubble cap tray column with the following
  characteristics

• 30 practical plates
• operation volume 10 liters
• reboiler with quartz heating rod 2 kW
• column head with solenoid controlled
  reflux-withdrawal divider and condenser
• distillate cooler (cooling agent water)
• feed heating system with quartz heating rod, 0.5
  kW
• product receivers 5 liters capacity each, to
  store the feed mixture respectively to collect
  the bottom and head product
• diaphragm pumps for feed and bottom product
  withdrawal
• 39 sampling valves on every tray, for feed,
  bottom, distillate flows.

The data acquisition and control system provided
with the system comprises the following
components

• sensors 18 temperature sensors places on every
  second tray, feed, reboiler and condenser
  measurement of absolute pressure at top and
  differential pressure between the top and bottom,
  level probes, flow sensors, etc.
• actuators in the plant solenoid valves, heating
  elements (described above) liquid and vacuum
  pumps
• Personal computer and accessories
• 19 ILUDEST-MOS unit as an interface between
  distillation plant and PC.

The ILLUDEST distillation column from the Process
Control Laboratory at UBB Cluj
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Mathematical models developed

• Dynamic model of the Fluid Catalytic Cracking Unit

• Models for two main industrial units the Model
  IV FCCU and the UOP FCCU.
• Number of equations 18 time dependent
  differential and 2 time and space dependent
  differential equations.
• Software implementation MatlabSimulink.
• Model fitted with industrial data for the UOP
  FCCU.
• Controllability analysis
• Decentralized PID Control and Model Predictive
  Control.

Dynamic model of brine electrolysis in IEM
reactors

• Model of the industrial process for brine
  electrolysis in IEM reactors
• Number of equations 70 time dependent
  differential and 350 non-linear algebraic
  equations.
• Software implementation MatlabSimulink.
• Model fitted with industrial data.
• Process optimization.
• Decentralized PID Control and Model Predictive
  Control.

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Mathematical models developed

• Dynamic model of a binary distillation column

• Model for continuous separation of
  n-propanol/water mixture
• Number of equations 42 time dependent
  differential and 122 algebraic equations.
• Software implementation MatlabSimulink, C
• Model fitted with experimental data
• Simulation and Model Predictive Control.

Dynamic model of PVC reactor

• Model for industrial batch process for
  polymerization of vinyl chloride
• Number of equations 10 ODE and 150 non-linear
  algebraic equations.
• Software implementation MatlabSimulink.
• Model fitted with industrial data.
• Process optimization.
• PID Control and Model Predictive Control.

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Mathematical models developed

• Dynamic model of a continuous fermentation
  bioreactor

• Model of a yeast fermentation bioreactor
• Number of equations 8 time dependent
  differential and 20 algebraic equations
• Software implementation MatlabSimulink, C
• Model fitted with experimental data
• Simulation and Model Predictive Control..

Artificial Neural Network based dynamic model of
a bioreactor

• Software implementation Matlab
• Model fitted with experimental data.
• Nonlinear Model Predictive Control.

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Mathematical models developed
Dynamic model of the Drying Process of Electric
Insulators

• Dynamic model of the Drying Process of Electric
  Insulators.
• Number of equations 6 time dependent
  differential equations and 5 algebraic equations.
  
• Model fitted with industrial data for the drying
  chamber of electric insulators.
• Software implementation MatlabSimulink.
• Controllability analysis.
• PID Control of the gases temperature and moisture
  content of the drying product.
• Model Predictive Control of the gases temperature
  and moisture content of the drying product.
• Fuzzy Logic Control of the gases temperature and
  moisture content of the drying product.
• Neural Networks Model Based Control of the gases
  temperature and moisture content of the drying
  product.

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Mathematical models developed
Dynamic model of brine electrolysis in amalgam
cathode reactor

• Number of equations 154 time dependent
  differential equations and more than 500
  non-linear algebraic non-linear equations
• Software implementation MatlabSimulink.
• Decentralized PID Control and Model Predictive
  Control.

Dynamic model of the Rotary Calcium Soda Ash
Production

• Number of equations 7 time and space dependent
  differential equations and 2 algebraic equations
• Software implementation MatlabSimulink.
• Controllability analysis.
• PID Model Predictive Control of the product
  sodium carbonate content

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Mathematical models developed
Mathematical model of river pollution

• Steady state and dynamic mechanistic model
• Time and space dependent differential equations
• Software implementation MatlabFemlab
• Simulation of propagation along the rivers for
  water soluble pollutants

Dynamic and steady-state model for
ethanol-water continuous distillation

• Software implementation ChemCAD, HYSYS, Pro/II,
  AspenPlus, Aspen Dynamics
• Design, control
• Comparison of simulation results with real pilot
  plant data

Mathematical modeling and Simulation of Racemic
Calcium Panthothenate Synthesis

• Steady state and dynamic models developed in
  ChemCAd, HySys, Aspen Plus, PRO/II - models
  fitted with industrial data

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Industrial Data Acquisition System
Steam production and management in a
thermo-electric station

• Natural gas, water consumption and steam
  production monitoring for 6 networked industrial
  boilers
• Steam consumption management for 20 industrial
  consumers
• Provides water, natural gas and steam flow, both
  instant and integrated values on different time
  intervals
• Generates graphic charts and printable reports
  with the measured values
• 96 transducers for temperature, pressure and flow
  measurements for gas, water and steam
• National Instruments SCXI components and LabView
  software development system

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Industrial Data Acquisition System