Process Dynamics and Control Fourth Edition Dale E. Seborg University of California, Santa Barbara Thomas F. Edgar University of Texas at Austin Duncan A. Mellichamp University of California, Santa Barbara Francis J.
Doyle III Harvard University VICE PRESIDENT & DIRECTOR Laurie Rosatone SENIOR DIRECTOR Don Fowley EXECUTIVE EDITOR Linda Ratts SENIOR MARKET SOLUTIONS ASSISTANT Courtney Jordan PROJECT MANAGER Gladys Soto PROJECT EDITOR Nichole Urban PROJECT ASSISTANT Wauntao Matthews SENIOR MARKETING MANAGER Daniel Sayre DIRECTOR, PRODUCTION Lisa Wojcik SENIOR CONTENT SPECIALIST Nicole Repasky PRODUCTION EDITOR Loganathan Kandan COVER PHOTO CREDIT Courtesy of ABB This book was set in 10/12 TimesTenLTStd by SPi Global, Chennai, India and printed and bound by Strategic Content Imaging. The cover was printed by Strategic Content Imaging. This book is printed on acid free paper. Founded in 1807, John Wiley & Sons, Inc.
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Title: Process dynamics and control / Dale E. Seborg, University of California, Santa Barbara, Thomas F. Edgar, University of Texas at Austin, Duncan A. Mellichamp, University of California, Santa Barbara, Francis J.
Doyle III, Harvard University. Description: Fourth edition. | Hoboken, NJ : John Wiley & Sons, Inc., [2016] | Includes bibliographical references and index. Identifiers: LCCN 2016019965 (print) | LCCN 2016020936 (ebook) | ISBN 9781119285915 (pbk.: acid-free paper) | ISBN 9781119298489 (pdf) | ISBN 9781119285953 (epub) Subjects: LCSH: Chemical process control—Data processing.
Classification: LCC TP155 .2815—dc23 LC record available at https://lccn.gov/2016019965 Printing identification and country of origin will either be included on this page and/or the end of the book. In addition, if the ISBN on this page and the back cover do not match, the ISBN on the back cover should be considered the correct ISBN. Printed in the United States of America About the Authors To our families Dale E. Seborg is a Professor Emeritus and Research Duncan A.
Mellichamp is a founding faculty member Professor in the Department of Chemical Engineering of the Department of Chemical Engineering of the at the University of California, Santa Barbara. He University of California, Santa Barbara. He is edi- received his B. degree from the University of Wis- tor of an early book on data acquisition and control consin and his Ph.
degree from Princeton University. computing and has published more than 100 papers Before joining UCSB, he taught at the University of on process modeling, large scale/plantwide systems Alberta for nine years. Seborg has published over analysis, and computer control. degree 230 articles and co-edited three books on process con- from Georgia Tech and a Ph.
from Purdue University trol and related topics. He has received the American with intermediate studies at the Technische Universität Statistical Association’s Statistics in Chemistry Award, Stuttgart (Germany). He worked for four years with the American Automatic Control Council’s Education the Textile Fibers Department of the DuPont Company Award, and the ASEE Meriam-Wiley Award. He was before joining UCSB.
Mellichamp has headed sev- elected to the Process Automation Hall of Fame in eral organizations, including the CACHE Corporation 2008. Seborg has served on the Editorial Advisory (1977), the UCSB Academic Senate (1990–1992), and Boards for several journals and a book series. He has the University of California Systemwide Academic also been a co-organizer of several major national and Senate (1995–1997), where he served on the UC Board international control engineering conferences. He presently serves on the governing boards of several nonprofit organizations and as president of Thomas F.
Edgar holds the Abell Chair in chemical Opera Santa Barbara. Emeritus Professor since 2003, he engineering at the University of Texas at Austin and still guest lectures and publishes in the areas of process is Director of the UT Energy Institute. He earned a profitability and plantwide control. degree in chemical engineering from the University of Kansas and his Ph.
from Princeton University. Doyle III is the Dean of the Harvard Paulson Before receiving his doctorate, he was employed by School of Engineering and Applied Sciences. He is also Continental Oil Company. His professional honors the John A.
Armstrong Professor of Engi- include the AIChE Colburn and Lewis Awards, ASEE neering & Applied Sciences at Harvard University. He Meriam-Wiley and Chemical Engineering Division received his B. from Cam- Awards, ISA and AACC Education Awards, AACC bridge, and Ph. from Caltech, all in Chemical Engi- Bellman Control Heritage Award, and AIChE Comput- neering.
Prior to his appointment at Harvard, Dr. Doyle ing in Chemical Engineering Award. He has published held faculty appointments at Purdue University, the over 500 papers in the field of process control, optimiza- University of Delaware, and UCSB. He also held vis- tion, and mathematical modeling of processes such as iting positions at DuPont, Weyerhaeuser, and Stuttgart separations, combustion, microelectronics processing, University.
He is a Fellow of IEEE, IFAC, AAAS, and and energy systems. He is a co-author of Optimization AIMBE; he is also the recipient of multiple research of Chemical Processes, published by McGraw-Hill in awards (including the AIChE Computing in Chemical 2001. Edgar was the president of AIChE in 1997, Engineering Award) as well as teaching awards (includ- President of the American Automatic Control Council ing the ASEE Ray Fahien Award). He is the Vice in 1989–1991 and is a member of the National Academy President of the Technical Board of IFAC and is the of Engineering.
President of the IEEE Control Systems Society in 2016. iii Preface Global competition, rapidly changing economic condi- it is essential for understanding the material. Key theo- tions, faster product development, and more stringent retical concepts are illustrated with numerous examples, environmental and safety regulations have made process exercises, and simulations. control increasingly important in the process industries.
Initially, the textbook material was developed for an Process control and its allied fields of process modeling industrial short course. But over the past 40 years, it and optimization are critical in the development of has significantly evolved at the University of California, more flexible and complex processes for manufacturing Santa Barbara, and the University of Texas at Austin. high-value-added products. Furthermore, the continu- The first edition was published in 1989 and adopted ing development of improved and less-expensive digital by over 80 universities worldwide.
In the second edi- technology has enabled high-performance measure- tion (2004), we added new chapters on the important ment and control systems to become an essential part topics of process monitoring, batch process control, of industrial plants. and plantwide control. For the third edition (2011), we Overall, it is clear that the scope and importance were very pleased to add a fourth co-author, Professor of process control technology will continue to expand Frank Doyle (then at UCSB) and made major changes during the 21st century. Consequently, chemical engi- that reflect the evolving field of chemical and biolog- neers need to master this subject in order to be able ical engineering.
These previous editions have been to develop, design, and operate modern processing very successful and translated into Japanese, Chinese, plants. The concepts of dynamic behavior, feedback, Korean, and Turkish. and stability are important for understanding many General revisions for the fourth edition include complex systems of interest to chemical engineers, reducing the emphasis on lengthy theoretical deriva- such as bioengineering and advanced materials. An tions and increasing the emphasis on analysis using introductory process control course should provide an widely available software: MATLAB® , Simulink® , and appropriate balance of theory and practice.
In partic- Mathematica. We have also significantly revised mate- ular, the course should emphasize dynamic behavior, rial on major topics including control system design, physical and empirical modeling, computer simulation, instrumentation, and troubleshooting to include new measurement and control technology, fundamental con- developments. In addition, the references at the end of trol concepts, and advanced control strategies. We have each chapter have been updated and new exercises have organized this book so that the instructor can cover been added.
the basic material while having the flexibility to include Exercises in several chapters are based on MATLAB® advanced topics on an individual basis. The textbook simulations of two physical models, a distillation col- provides the basis for 10–30 weeks of instruction for umn and a furnace. Both the book and the MATLAB a single course or a sequence of courses at either the simulations are available on the book’s website (www. undergraduate or first-year graduate levels.
It is also wiley.com/college/seborg). National Instruments has suitable for self-study by engineers in industry. The provided multimedia modules for a number of examples book is divided into reasonably short chapters to make in the book based on their LabVIEW™ software. it more readable and modular.
This organization allows Revisions to the five parts of the book can be sum- some chapters to be omitted without a loss of continuity. marized as follows. Part I provides an introduction to The mathematical level of the book is oriented toward process control and an in-depth discussion of process a junior or senior student in chemical engineering who modeling. It is an important topic because control sys- has taken at least one course in differential equations.
tem design and analysis are greatly enhanced by the Additional mathematical tools required for the analysis availability of a process model. of control systems are introduced as needed. We empha- Steady-state and unsteady-state behavior of pro- size process control techniques that are used in practice cesses are considered in Part II (Chapters 3 through 7). and provide detailed mathematical analysis only when Transfer functions and state-space models are used iv Preface v to characterize the dynamic behavior of linear and Dave Camp, Jarrett Campbell, I-Lung Chien, Will nonlinear systems.
However, we have kept deriva- Cluett, Oscar Crisalle, Patrick Daugherty, Bob Desho- tions using classical analytical methods (e., Laplace tels, Rainer Dittmar, Jim Downs, Ricardo Dunia, David transforms) to a minimum and prefer the use of com- Ender, Stacy Firth, Rudiyanto Gunawan, Juergen puter simulation to determine dynamic responses.