C4 Process Operation and Control of the Miniplants

State of the art

During the first project period two miniplants were designed and constructed. The first plant is operated with thermomorphic solvent systems (TMS) at TU Dortmund, the second plant is operated using micellar solvent systems (MLS) at TU Berlin. The TMS plant is equipped with the typical laboratory automation system LabView (National Instruments). Stable and long term operation of the plant was achieved in continuous mode, the lab scale reaction conditions could be verified. The MLS plant is automated with an industrial automation system PCS7 (Siemens) and extensive online measurement instrumentation. For continuous plant operation an adequate control scheme is needed for the stabilization of the phase separation.

Research goals

The goal of this subproject is to develop strategies for the stabilization and economic online optimization of the operation of the mini plants situated in Berlin and Dortmund as well as a strategy for the time optimized plant start-up for the mini plant in Berlin. The main challenge is the inexact description of the behavior of the plants by the available process models. Despite these model uncertainties, an efficient operation of the plants should be achieved. The developed solutions will be of general interest for the operation of complex industrial process where key physico-chemical phenomena cannot de described accurately by rigorous process models.

Connected projects within Collaborative Research Centre/Transregio 63

A1 Transition Metal Catalysed Hydroformylation and Hydroesterification of Petro- and Oleochemical Starting Materials with Temperature Controlled Catalyst Separation in Gas/liquid/liquid Systems

A2 Catalytic Upgrading of Long Chain Olefins by Hydroformylation and Hydroesterification in Surfactant Modified Multi Phase Systems

B1 Optimal Reactor Design and Operation for Liquid Multiphase Systems

B4 Hydroformylation of Petrochemical- and Oleochemical Starting Materials in Micellar Solvent Systems in a Continuously Operated Miniplant with a Highly Efficient Catalyst Recycling

B8 Dispersion and Coalescence in Stirred Micellar Three-phase Systems

C1 Model-based Control of the Development of Novel Chemical Processes

Recent Publications

Müller, D.; Illner, M.; Esche, E.; Pogrzeba, T.; Schmidt, M.; Schomäcker, R.; Biegler, L. T.; Wozny, G.; Repke, J-U. Dynamic real-time optimization under uncertainty of a hydroformylation mini-plant. Comp. Chem. Eng., Advance Article, 2017. [doi: https://doi.org/10.1016/j.compchemeng.2017.01.041]

Esche, E.; Müller, D.; Werk, S.; Grossmann, I. E.; Wozny, G. Solution of Chance-Constrained Mixed-Integer Nonlinear Programming Problems. Comput.-Aided Chem. Eng., 38, 91-96, 2016. [doi: https://doi.org/10.1016/B978-0-444-63428-3.50020-5]

Gao, W.; Hernández, R.; Engell, S. A Study of Explorative Moves during Modifier Adaptation with Quadratic Approximation. Processes, 4(45), 2016. [doi:10.3390/pr4040045]

Hernández, R.; Engell, S. Modelling and iterative Real-time Optimization of a homogeneously catalyzed hydroformylation process. Comput.-Aided Chem. Eng., 38, 1-6, 2016. [doi: https://doi.org/10.1016/B978-0-444-63428-3.50005-9]

Hoffmann, C.; Illner, M.; Müller, D.; Esche, E.; Wozny, G.; Biegler, L. T.; Repke, J.-U. Moving-horizon State Estimation with Gross Error Detection for a Hydroformylation Mini-plant. Comput.-Aided Chem. Eng., 38, 1485-1490, 2016. [doi: https://doi.org/10.1016/B978-0-444-63428-3.50252-6]

López C., D.C.; Wozny, G.; Flores-Tlacuahuac, A.; Vasquez-Medrano, R.; Zavala, V. M. A Computational Framework for Identifiability and Ill-Conditioning Analysis of Lithium-Ion Battery Models. Ind. Eng. Chem. Res., 55, 3026-3042, 2016. [doi:10.1021/acs.iecr.5b03910]

Merchan, V. A.; Esche, E.; Fillinger, S.; Tolksdorf, G.; Wozny, G. Computer-Aided Process and Plant Development. A Review of Common Software Tools and Methods and Comparison against an Integrated Collaborative Approach. Chem. Ing. Tech., 88(1-2), 50–69, 2016. [doi: 10.1002/cite.201500099]

Merchan, V. A.; Wozny, G. Comparative evaluation of rigorous thermodynamic models for the description of the hydroformylation of 1-dodecene in a thermomorphic solvent system. Ind. Eng. Chem. Res., 55, 293-310, 2016. [doi:10.1021/acs.iecr.5b03328]

López C., D.C.; Barz, T.; Körkel, S.; Wozny, G. Nonlinear Ill-Posed Problem Analysis in Model-Based Parameter Estimation and Experimental Design. Comput. Chem. Eng., 77, 24-42, 2015. [doi:10.1016/j.compchemeng.2015.03.002]


López Cárdenas, D. C. Systematic evaluation of ill-posed problems in model-based parameter estimation and experimental design. Technische Universität Berlin, 2016. [More]

Müller, D. Development of operation trajectories under uncertainty for a hydroformylation mini plant. Technische Universität Berlin, 2015.



Zuletzt geändert am 04.04.2018