Beruflich Dokumente
Kultur Dokumente
Chemical
E~ineerin@
0009-2509(94)=33-M
DEGREES
Department
OF FREEDOM
ANALYSIS
CONTROL
of Chemical Engineering
(Received
IN PROCESS
JACK W. PONTON
University of Edinburgh, Kings Buildings, EH9 3JL, U.K.
29 January
1994)
Abstract-In
developing the control system for a process it is desirable to know precisely the number of
process variables which the system designer is entitled to attempt to regulate, commonly known as the
degrees of freedom of the process. An extremely simple procedure is described; the maximum degrees of
freedom for any process is shown to be the total number of process streams, including streams of heating
and cooling media. If inventory in processing units is excluded unless, it affects some more significant
variabte, such as pressure or composition, then the effective degrees of freedom arc generally determined by
subtracting one from the total for every additional phase contained in a unit.
INTRODUaION
2089
JACK W. PONTON
2090
1) + C(P -
1)
=n,+Cn,+CP-1.
Subtracting
n, = n, - n, = ni + ne + n, - P + 1.
Note that this more general relationship does reduce
to the single phase expression when P is one, Checking the relationship for some specific examples confirms its applicability. A total vaporiser or condenser
has two material streams, one energy stream and two
phases. Thus n,, = 1 + 1 + 1 - 2 + 1 = 2 degrees of
freedom, e.g. feed rate and temperature or pressure,
but not both, which is correct. Note that the count is
correct where the product stream is not actually in
equilibrium with the vapour feed, or if it is subcooled.
Here there will still be a relationship between each of
the intensive properties of the two phases, i.e. equality
of phase compositions rather than an equilibrium
relation, and a rate equation relating temperatures
rather than an equality.
A three phase vapour-liquid-liquid
adiabatic flash
has one feed, three outputs and no energy streams.
Here n,, = 1 + 0 + 3 - 3 + 1 = 2 also. Typically feed
rate and pressure could be regulated.
An intuitive explanation for the reduction of degrees of freedom in multiphase systems is apparent
when a typical control system for this latter device is
considered, see Fig. 1.
The flexibility associated with the additional outputs is lost because these must be used to regulate
interface levels to maintain the correct number of
phases in the vessel. As noted earlier, these are not
degrees of freedom variables but inventories.
APPLICATION
TO
COMPLETE
PROCESSES
hl.4
seems worthwhile. Nonetheless it is sensible to confirm that units which do not simply contain lumped
phases in equilibrium are also correctly treated by this
approach. Two illustrations are given below.
Furthermore, the method gives the maximum number of degrees of freedom in a complex unit or process.
Standard practice for many types of equipment involves not using all available degrees of freedom. The
unused degrees of freedom are generally associated
with pressure.
F
(a) Using the approach above determine the degrees of freedom for each unit. Sum these, and then
subtract the number of shared streams to obtain the
final count.
(b) Count all the streams in the process. Separately
count the total number of extra phases, i.e. add up
all occurrences of phases greater than one in all units.
A convenient way of determining and illustrating
the process control degrees of freedom by the second
method is shown in the accompanying flowsheet,
Fig. 2. All streams represent potential degrees of freedom and possible adjustable variables, but beside
each unit is written the number lost as a result of the
presence of multiple phases in the unit. Total process
degrees of freedom is easily determined and their
localisation at particular points in the process
indicated.
COMPLEX
2091
UNITS
Total streams = 11
interchangers
A process-process heat exchanger or interchanger
can be thought of as a heater or condenser (if phase
change occurs) connected to a cooler or vaporiser by
an energy stream. The magnitude of the energy flow is
however not adjustable, being constrained by a rate
equation involving the stream temperatures, area and
heat transfer coefficient. In such an arrangement two
degrees of freedom are lost from the sum of those of
the two units, one for the connecting stream and one
for the rate equation. The energy interconnection
being hidden in the combined unit, the sum of the
visible streams, two inputs and two outputs, less any
deduction for two phases present, still gives the correct degrees of freedom. By analogy, a process heat
exchange bundle on any other type of unit should also
be correctly dealt with.
This can be thought of as a generalisation of the
rule for connecting
streams, so that units sharing a
material or energy stream lose one degree of freedom
from those of the individual units.
Countercurrent cascades
A single countercurrent equilibrium stage has three
degrees of freedom. A stack of N such units built into
a cascade, e.g. as in an absorber, will have (2N + 2)
streams, N two phase elements, and thus (IV + 2)
apparent degrees of freedom. These would never all be
Extra phases - -3
Total d. off. I 6
Fig. 2. Absorption processwith solvent recovery flash separator.
INVENTORY
2093
DEGREES
OF FREEDOM
IN DISTILLATION
2094
JACK W, PONTON
2
Fig. 3. Distillation
column, total
degrees of
freedom.
This is because the column and condenser are normally maintained at the same pressure. However, a
valve could be placed in the line between them. This
would actually be undesirable, as reducing the condenser pressure will decrease the temperature driving
force available from the cooling medium.
In practice, the whole of the system comprising
condenser, reflux drum and column is often kept at
the same nominal pressure with no valves other than
those shown in Fig. 4(a). Treating the condenser and
reboiler as a single unit, within the dotted envelope,
we can see that the degrees of freedom are accounted
for. There are four external streams and two phases,
hence three degrees of freedom for the subsystem. One
is deliberately unused by maintaining column and
condenser at the same pressure, one is used for pressure regulation, and one is occupied by setting the
flow of the reflux stream.
The alternative flooded condenser method of pressure regulation, Fig. 4(b), requires that there be liquid
in the condenser. The cooling water here is not adjusted, but acts as an implicit interface maintenance
control; it must be set so as to keep some liquid in the
condenser. It thus does not provide an additional
degree of freedom.
There appears to be no particular reason to maintain two phases in the reflux drum in this case; indeed
it will not be possible unless condensate flashes as a
result of a significant
pressure drop, which seems
undesirable, or the drum is vented in some way. The
reason for keeping an interface in the drum in the
previous scheme is that it is easier to measure it there
than in the condenser itself. However, if it is feasible to
measure an interface in the condenser, then it should
be possible to dispense with the reflux drum, saving an
item of equipment and improving safety and economy
by reducing inventory, as shown in (c).
Finally, experimenting with unusual overhead configurations led to the structure shown in (d). This
eliminates the reflux drum inventory, and while it
appears to add another heat exchanger, the partial
condenser Cl which provides reflux, could be built
into the same shell as the total condenser C2 which
@I
63
Fig. 4.
+_
--uQ
2095
CONCLUSIONS
REFERENCES
above confirms the approach implicit in (Ponton and Laing, 1993) that the
design of a control strategy can proceed by looking at
the number of potential adjustments, i.e. the total
number of streams, including energy inputs and outputs. The result is a trivially straightforward method
for counting degrees of freedom in which the effect of
The
procedure
inventory
developed
can be accounted
for explicitly,
and either