Process Identification and PID Control

Offering a different approach to other textbooks in the area, this book is a comprehensive introduction to the subject divided in three broad parts. The first part deals with building physical models, the second part with developing empirical models and the final part discusses developing process control solutions. Theory is discussed where needed to ensure students have a full understanding of key techniques that are used to solve a modeling problem. Hallmark Features: Includes worked out examples of processes where the theory learned early on in the text can be applied. Uses MATLAB simulation examples of all processes and modeling techniques- further information on MATLAB can be obtained from www.mathworks.com Includes supplementary website to include further references, worked examples and figures from the book This book is structured and aimed at upper level undergraduate students within chemical engineering and other engineering disciplines looking for a comprehensive introduction to the subject. It is also of use to practitioners of process control where the integrated approach of physical and empirical modeling is particularly valuable.

Crystallization is an important technique for separation and purification of substances as well as for product design in chemical, pharmaceutical and biotechnological process industries. This ready reference and handbook draws on research work and industrial practice of a large group of experts in the various areas of industrial crystallization processes, capturing the essence of current trends, the markets, design tools and technologies in this key field. Along the way, it outlines trouble free production, provides laboratory controls, analyses case studies and discusses new challenges. First the instrumentation and techniques used to measure the crystal size distribution, the nucleation and solubility points, and the chemical composition of the solid and liquid phase are outlined. Then the main techniques adopted to control industrial crystallizers, starting from fundamental approaches to the most advanced ones, including the multivariable predictive control are described. An overview of the main crystallizer types is given with details of the main control schemes adopted in industry as well as the more suitable sensors and actuators.

This expanded new edition is specifically designed to meet the needs of the process industry, and closes the gap between theory and practice. Back-to-basics approach, with a focus on techniques that have an immediate practical application, and heavy maths relegated to the end of the book Written by an experienced practitioner, highly regarded by major corporations, with 25 years of teaching industry courses Supports the increasing expectations for Universities to teach more practical process control (supported by IChemE)

This book examines genotoxic impurities and their impact on the pharmaceutical industry. Specific sections examine this from both a toxicological and analytical perspective. Within these sections, the book defines appropriate strategies to both assess and ultimately control genotoxic impurities, thus aiding the reader to develop effective control measures. An opening section covers the development of guidelines and the threshold of toxicological concern (TTC) and is followed by a section on safety aspects, including safety tests in vivo and vitro, and data interpretation. The second section addresses the risk posed by genotoxic impurities from outside sources and from mutagens within DNA. In the final section, the book deals with the quality perspective of genotoxic impurities focused on two critical aspects, the first being the analysis and the second how to practically evaluate the impurities.

This book focuses on plastics process analysis, instrumentation for modern manufacturing in the plastics industry. Process analysis is the starting point since plastics processing is different from processing of metals, ceramics, and other materials. Plastics materials show unique behavior in terms of heat transfer, fluid flow, viscoelastic behavior, and a dependence of the previous time, temperature and shear history which determines how the material responds during processing and its end use. Many of the manufacturing processes are continuous or cyclical in nature. The systems are flow systems in which the process variables, such as time, temperature, position, melt and hydraulic pressure, must be controlled to achieve a satisfactory product which is typically specified by critical dimensions and physical properties which vary with the processing conditions.  Instrumentation has to be selected so that it survives the harsh manufacturing environment of high pressures, temperatures and shear rates, and yet it has to have a fast response to measure the process dynamics. At many times the measurements have to be in a non-contact mode so as not to disturb the melt or the finished product. Plastics resins are reactive systems. The resins will degrade if the process conditions are not controlled. Analysis of the process allows one to strategize how to minimize degradation and optimize end-use properties.

Practical Process Control (loop tuning and troubleshooting). This book differs from others on the market in several respects. First, the presentation is totally in the time domain (the word «LaPlace» is nowhere to be found). The focus of the book is actually troubleshooting, not tuning. If a controller is «tunable», the tuning procedure will be straightforward and uneventful. But if a loop is «untunable», difficulties will be experienced, usually early in the tuning effort. The nature of any difficulty provides valuable clues to what is rendering the loop «untunable». For example, if reducing the controller gain leads to increased oscillations, one should look for possible interaction with one or more other loops. Tuning difficulties are always symptoms of other problems; effective troubleshooting involves recognizing the clues, identifying the root cause of the problem, and making corrections. Furthermore, most loops are rendered «untunable» due to some aspect of the steady-state behavior of the process. Consequently, the book focuses more on the relationship of process control to steady-state process characteristics than to dynamic process characteristics. One prerequisite to effective troubleshooting is to «demystify» some of the characteristics of the PID control equations. One unique aspect of this book is that it explains in the time domain all aspects of the PID control equation (including as the difference between the parallel and series forms of the PID, the reset feedback form of the PID equation, reset windup protection, etc.) The book stresses an appropriate P&I (process and instrumentation) diagram as critical to successful tuning. If the P&I is not right, tuning difficulties are inevitable. Developing and analyzing P&I diagrams is a critical aspect of troubleshooting.

A practical guide to semiconductor manufacturing from process control to yield modeling and experimental design Fundamentals of Semiconductor Manufacturing and Process Control covers all issues involved in manufacturing microelectronic devices and circuits, including fabrication sequences, process control, experimental design, process modeling, yield modeling, and CIM/CAM systems. Readers are introduced to both the theory and practice of all basic manufacturing concepts. Following an overview of manufacturing and technology, the text explores process monitoring methods, including those that focus on product wafers and those that focus on the equipment used to produce wafers. Next, the text sets forth some fundamentals of statistics and yield modeling, which set the foundation for a detailed discussion of how statistical process control is used to analyze quality and improve yields. The discussion of statistical experimental design offers readers a powerful approach for systematically varying controllable process conditions and determining their impact on output parameters that measure quality. The authors introduce process modeling concepts, including several advanced process control topics such as run-by-run, supervisory control, and process and equipment diagnosis. Critical coverage includes the following: * Combines process control and semiconductor manufacturing * Unique treatment of system and software technology and management of overall manufacturing systems * Chapters include case studies, sample problems, and suggested exercises * Instructor support includes electronic copies of the figures and an instructor's manual Graduate-level students and industrial practitioners will benefit from the detailed exami?nation of how electronic materials and supplies are converted into finished integrated circuits and electronic products in a high-volume manufacturing environment. An Instructor's Manual presenting detailed solutions to all the problems in the book is available from the Wiley editorial department. An Instructor Support FTP site is also available.

Covers PID control systems from the very basics to the advanced topics This book covers the design, implementation and automatic tuning of PID control systems with operational constraints. It provides students, researchers, and industrial practitioners with everything they need to know about PID control systems—from classical tuning rules and model-based design to constraints, automatic tuning, cascade control, and gain scheduled control.  PID Control System Design and Automatic Tuning using MATLAB /Simulink introduces PID control system structures, sensitivity analysis, PID control design, implementation with constraints, disturbance observer-based PID control, gain scheduled PID control systems, cascade PID control systems, PID control design for complex systems, automatic tuning and applications of PID control to unmanned aerial vehicles. It also presents resonant control systems relevant to many engineering applications. The implementation of PID control and resonant control highlights how to deal with operational constraints. Provides unique coverage of PID Control of unmanned aerial vehicles (UAVs), including mathematical models of multi-rotor UAVs, control strategies of UAVs, and automatic tuning of PID controllers for UAVs Provides detailed descriptions of automatic tuning of PID control systems, including relay feedback control systems, frequency response estimation, Monte-Carlo simulation studies, PID controller design using frequency domain information, and MATLAB/Simulink simulation and implementation programs for automatic tuning Includes 15 MATLAB/Simulink tutorials, in a step-by-step manner, to illustrate the design, simulation, implementation and automatic tuning of PID control systems Assists lecturers, teaching assistants, students, and other readers to learn PID control with constraints and apply the control theory to various areas. Accompanying website includes lecture slides and MATLAB/ Simulink programs PID Control System Design and Automatic Tuning using MATLAB/Simulink is intended for undergraduate electrical, chemical, mechanical, and aerospace engineering students, and will greatly benefit postgraduate students, researchers, and industrial personnel who work with control systems and their applications.

This book surveys methods, problems, and tools used in process control engineering. Its scope has been purposely made broad in order to permit an overall view of this subject. This book is intended both for interested nonspecialists who wish to become acquainted with the discipline of process control engineering and for process control engineers, who should find it helpful in identifying individual tasks and organizing them into a coherent whole. A central concern of this treatment is to arrive at a consistent and comprehensive way of thinking about process control engineering and to show how the several specialities can be organically fitted into this total view.

Focusing on the practical implementation of the methods of process modelling and control, this book provides readers with rapid access to the methods described, while including the theoretical background necessary. Throughout, the essential knowledge is built up from chapter to chapter, starting with laying the foundations in plant instrumentation and control. Modelling abilities are then developed by starting from simple time-loop algorithms and passing on to discrete methods, Laplace transforms, automata and fuzzy logic. In the end, readers have the means to design simple controllers on the basis of their own models, and to use more detailed models to test them. With its clarity and simplicity of presentation, and illustrated by more than 200 diagrams, this book supports self-study and teaches readers how to apply the appropriate method for the application required, and how to handle problems in process control. Bridging theory and practice, over 200 exercises and solutions can be found in the accompanying «Applied Process Control: Efficient Problem Solving», to develop the problem-solving abilities of process engineers.