Center of Chemical Process Design and Control

Annual Report 2001

Chemical Process Design and Control

Center for Chemical Process Design and Control Annual Report 2001

www.control.lth.se/cpdc

Acting program director: Associate Professor Bernt Nilsson Lund Institute of Technology Department of Chemical Engineering 1 Box 124 221 00 LUND Phone +46 46 222 80 88 Fax: + 46 46 222 45 26 email: [email protected]

Table of contents Summary 1. The programme 2. The graduate training of the programme 3. The research of the programme 4. Collaborations 5. Management and organization of the programme 6. Budget and financing of the programme Appendix 1: List of publications 2001 Appendix 2: Center economy

2 3 5 9 13 17 19 20 22

CPDC Annual Report 2001 1

Chemical Process Design and Control

Summary The program Chemical Process Design and Control, CPDC, implies the start of a Swedish effort in the field internationally known as Process System Engineering, integrating major elements of chemical engineering and process control and utilising advanced forms of, i.e. mathematical modelling and information technology. Including a graduate school and a joint research program, the Center makes it possible for the Swedish process industry to recruit doctors and licentiates with a deepened insight in chemical engineering as well as control engineering, all qualified in design and planning of industrial process systems leading to economic, resource-efficient and safe plat operations and enhanced product quality. The center for Chemical Process Design and Control during 2001 in figures •= CPDC has currently 14 PhD students. •= The research is organized in 9 projects. •= The researcher in CPDC produced 26 publications during 2001. •= One CPDC PhD student graduated during 2001. •= During 2001 CPDC had industrial collaborations with both direct cash support to projects, valued to be 1.6 MSEK, and support by in-house activities approximated to be 3 MSEK. •= CPDC used 8.2 MSEK of SSF resources for 2001. •= CPDC has decides to start 3 new projects, all with strong industrial collaborations o A project on modelling of fibre suspensions, Anders Rasmuson, CTH, in collaboration with Metso in Sundsvall. o A paper drying project, Stig Stenström, LTH, financed together with Swedish Gas Technology and Metso in Karlstad. o A new concept on continuous multi-purpose reactors, a industrial multidisciplinary project at CTH, Bengt Andersson, and LTH, Per Hagander, in collaboration with Alfa Laval.

CPDC Annual Report 2001 2

Chemical Process Design and Control

1. Center of Chemical Process Design and Control 1.1 Programme description The objective is to strengthen the development of important research environments with a view to enhance the long-term competitiveness of the Swedish process industry. The aim is to pinpoint the importance of an integrated approach to manufacturing in the process industries. The idea is to incorporate the knowledge and skills of chemical engineers, control engineers, statisticians, and analytical chemists in a common research program, which is recognized and encouraged by the industry over several years. Therefore, a number of academic groups with strong support from industry and government have been involved in the discussion of the research and education program during the running period to find a suitable form to make a concentrated contribution on the focused research and development issues. Motivation The focus area of the centre is internationally normally called “process system engineering” and includes research topics like process modelling, process simulation and optimisation, process control, process synthesis and design besides other process operations. Process system engineering has been recognized as strategic for the Swedish process industry since integration of important elements of chemical engineering and process control in the research, using advanced forms of mathematical modelling and information technology, will enhance the long-term competitiveness of the industry. However, to achieve this a closer cooperation between chemical engineering, control engineering, analytical chemistry and statistics is needed. This requires a cross-disciplinary approach, which also combines the knowledge of applied mathematics, fluid dynamics, control synthesis, process safety and environmental engineering. The key issues are fundamental studies of the dynamics of chemical and physical processes, including chemical kinetics, thermodynamics, the transport of mass, heat and momentum as well as control and computing. Objectives The research activities in the centre for Chemical Process Design and Control focus on integrated aspects of design, control, quality, safety, environmental protection and operation with high industrial relevance. The research aims at developing methods for mathematical, numerical and statistical modelling and control of separate parts as well as several interacting process steps including both process syntheses, where new processes are developed, and process analyses where already existing processes are improved. Including a graduate school and a joint research program make it possible to give future doctors and licentiates a deepened multi-disciplinary insight in chemical engineering as well as control engineering. The program will also generate possibilities for knowledge transfer between the academia and the industry by a close cooperation between the different disciplines. The educational aim is to give the students an opportunity to be good contributors in the development of Swedish process industry during the coming years.

CPDC Annual Report 2001 3

Chemical Process Design and Control

1.2 CPDC project portfolio The interdisciplinary research projects are performed in two thematic programs focused on •= Continuous processes A number of projects are focused on pulp and paper industry, particular paper machine applications. The other projects are methodology oriented. •= Batch processes Almost all projects are focused on the AKD-process at Akzo Nobel, Eka Chemicals in Trollhättan. This guarantee's a common platform for interdisciplinary research. Continuous Processes This thematic program contains currently 5 projects with 6 PhD students and 2 new ones. The projects C1, C2 and C3 are directly or indirectly dealing with paper machine applications. The projects C4 and C5 are focused on modelling methodology. CPDC has also appointed two associated projects A1 and A2, which both increase the research effort in this thematic program. Both these associated projects deal with research problems in pulp and paper industry. Table 1.1: Projects in the thematic program Continuous Processes Project

Title

C1

Modelling of the Consolidation Phase of the Forming Section in a Paper Machine C2ab Modelling and Control of the Drying Section of the Paper Machine C2c C3 C4 C5 C7

Design of Energy Distribution Systems for Gas-Heated Through Air Dryiers Loop and Quality Assessment Grey-Box Identification of Models Governed by Partial Differential Equations Reduction and Aggregation of Process Models Fluid Dynamics and Mixing of Fibre Suspensions

Project leader

Department

Budget

Period

Bo Norman

Paper Technology, KTH

1560

01-03

a) Stig Stenström

a) Chemical Engineering I, LTH b) Automatic Control, LTH Chemical Engineering I, LTH Automatic Control, LTH Process Control, KTH

a) 2850

a) 99-03

b) 1040

b) 01-04

550

02-04

2590

99-03

3335

99-03

b) Björn Wittenmark Stig Stenström Tore Hägglund Eling Jacobsen Anders Rantzer

Automatic 3400 Control, LTH Anders Rasmuson Chemical 1760 Engineering Design, CTH Sum: 15325

99-04 02-04

The project C2c and C7 was decided in the autumn 2001 and will be started during 2002. C2c is becoming a subproject in the paper drying project. C7 is a work on fibre suspensions and can also be seen as an project dealing with paper machine problems. CPDC Annual Report 2001 4

Chemical Process Design and Control

Batch processes The thematic program contains 4 projects with 8 PhD students and one new project. One PhD student in project B2a has graduated in March 2001 and the subproject B2b will be finished during 2001. The projects B1, B2 and B3 work with a common process, Eka Chemicals AKDprocess in Trollhättan. Particularly the large B3 project uses this process for problem formulation. Table 1.2: Projects in the thematic program Batch Processes Project

Title

Project leader

Department

Budget

Period

B1

Control and Diagnosis in Batch Processes Kinetic Parameters from Spectroscopic Monitoring

Karl-Erik Årzén a) Lars-Göran Danielsson

Automatic Control, LTH a) Analytical Chemistry, KTH b) Mathematical Statistics, CTH a) Chemical Reaction Engineering b,c) Chemical Engineering Design d) Automatic Control, CTH Automatic Control, LTH Chemical Reaction Engineering, CTH and Automatic Control, LTH Sum:

3400

99-03

a) 2800

a) 99-03

b) 840

b) 99-01

a) 2080

a) 99-03

b) 2080

b) 99-03

c) 2080

c) 99-04

d) 2080

d) 99-04

2000

00-03

200

02

B2ab

b) Sture Holm B3abcd Dynamic mathematical modelling of reaction/separation processes

B4

Fluid Bed Coating

B5

Multi Purpose Reactor

a,b) Bengt Andersson b,c) Anders Rasmuson d) Claes Breitholtz Anders Rasmuson Bengt Andersson Per Hagander

21140

A pre study of project B5 was approved in late autumn 2001 and during spring 2002 a major project plan will be put forward to the Board. This project will probably become a major project with a large industrial engagement together with a number of international collaborations.

CPDC Annual Report 2001 5

Chemical Process Design and Control

2. The graduate training of the programme The graduate training is CPDC is organised through the graduate school based on courses and in the relation to the research projects. 2.1 PhD students There have been 18 PhD students working in the program during the period 1999-2001. Three of them have graduated and one has aborted his graduate training. Four of the PhD students are female. Table 2.1: Former and present PhD students in CPDC Name Adolphsson, Tobias Björk, Anders

Sex M M

Born 1971 1969

Start 99 99

Department Mathematics, CTH Analytical Chemistry, KTH Analytical Chemistry, KTH Automatic Control, LTH

Furusjö, Erik

M

1972

99

Ingimundarsson, Ari

M

1972

99

Karlsson, Magnus

M

1977

00

Karlsson, Stina

F

1977

00

Liu, Yi

F

1974

99

Lobosco, Vinicius Mide, Henrik

M M

1974 1971

01 99

Mortensen, Mikael

M

1974

00

Panagopoulos, Hélène

F

1973

99

Paper Technology, KTH Chemical Reaction Engineering, CTH Chemical Reaction Engineering, CTH Automatic Control, LTH

Olesen, Veronica

F

1975

99

Automatic Control, CTH

Olsson, Rasmus

M

1974

99

Automatic Control, LTH

Sandberg, Henrik

M

1976

00

Automatic Control, LTH

Slätteke, Ola

M

1972

01

Automatic Control, LTH

Svensson, Fredrik

M

1975

99

Wallén, Anders

M

1971

99

Chemical Engineering Design, CTH Automatic Control, LTH

Virdung, Torbjörn

M

1974

99

Chemical Engineering, LTH Chemical Engineering Design, CTH Process Control, KTH

Chemical Engineering Design, CTH

Supervisor Sture Holm Lars-Göran Danielsson Lars-Göran Danielsson Tore Hägglund Stig Stenström Anders Rasmuson Elling Jacobsen Bo Norman Bengt Andersson Bengt Andersson Björn Wittenmark Claes Breitholtz Karl-Erik Årzén Anders Rantzer Björn Wittenmark Anders Rasmuson Tore Hägglund Anders Rasmuson

Exam

CPDC 30% 100%

Dr 01

40% 85% 100% 100% 100%

Lic 01 aborted 99

100% 80%

Dr 00

20% 100% 100% 100% 100% 100%

Dr 00

15% 100%

CPDC Annual Report 2001 6

Chemical Process Design and Control

2.2 PhD courses, research seminars and workshops Courses CPDC organize a set of compulsory courses of total 20 credits. The courses are often organized with two or three meetings with concentrated lectures and exercises. Each meeting take 2 or 3 days. Before the course there are preparation material and between the courses meetings the students do project exercises that are discussed at the following meeting. The students work in interdisciplinary groups. One course was planned for 2001 •= Chemical Process Control, 4p, was given first time 1999. •= Mathematical Modelling, 6p, was given first time 2000. •= Chemometrics and System Identification, 5p, planned 2001 but rescheduled A graduate course on Chemometrics and System Identification was initiated and scheduled for spring 2001. This subject is new on the Swedish arena and draws input from at least two disciplines. Unfortunately it had to be rescheduled. However, the organizers feel that this is a relevant subject and that the course should be held in another setting and for a wider group of students. •= Design and Control, 5p, planned to 2002 Development of the graduate course program The CPDC PhD courses will be reorganized in minor parts, concentrated in time and location. This means that the number of courses will increase. The courses will also be more focused and specialized. It is also our opinion that this will attract more students and even industrial participants. Some courses will also be organized as research seminars and workshops. Annual research workshop Each year an annual CPDC workshop is organized. These workshops are aimed to stimulate the creation of network between researchers and PhD students with CPDC and with industrial partners. The second CPDC workshop was held in August 2001 in Tylösand. The workshop contained both project presentations of all CPDC projects and a visit to the pulp and paper factory at Hylte. The third CPDC Workshop will be held in Stockholm in June 2002. 2.3 PhD students that abort their studies No student aborted their studies during 2001. 2.4 PhD Thesis During 2001 one PhD thesis was presented. Erik Furusjö, Analytical Chemistry, KTH, March 2001, "Chemometric methods for analysis of spectroscopic data from batch process monitoring". Erik Furusjö has performed about 40% of his work within the project B2 in CPDC. Erik Furusjö has a position at ABB in Västerås. 2.5 Licentiate Thesis No Licentiate thesis was presented during 2001 of PhD students financed by CPDC.

CPDC Annual Report 2001 7

Chemical Process Design and Control

2.6 Important events during 2001 Mid Term Evaluation During the spring of 2001 large effort was put on the Mid Term Evaluation of the CPDC programme and an oral presentation of the programme with a discussion was performed in Juni 2001. The evaluation committee found the research programme to be industrial relevant and pointed out the need of formalized industrial collaboration. SSF also put forward complaints on the programme administration, which is going to be corrected. CPDC Workshop The annual CPDC Workshop is the most important event within the programme. At this meeting all research is presented and discussed. It is also a meeting where organisation and planning discussed. SAB project evaluation During the autumn 2001 the on going projects in the center was evaluated by the Scientific Advisory Board, SAB. The projects where presented in a written report, presenting project goals, results and future plans. SAB evaluated the reports and the evaluation where discussed by the Board. CPDC PhD student meeting In December 2001 the PhD student with CPDC had a meeting in Stockholm. The meeting where followed by a meeting between the Board and the PhD students. A number of questions where discussed and some suggestions where put forward to the Board. 2.7 Current positions for graduated PhD students Three PhD students have graduated, which have had partial CPDC funding Table 2.2: Former CPDC PhD students Name Exam Anders Wallén Dr Hélène Panagopoulos Dr Erik Furusjö Dr

Year 2000 2000 2001

Current employer Ericsson, Lund MoDo, Husum ABB, Västerås

CPDC Annual Report 2001 8

Chemical Process Design and Control

3. The research of the programme The interdisciplinary research projects are performed in two thematic programs focused on •= Continuous processes •= Batch processes In each thematic area different research projects associated with both present and future industrial applications are formulated. The idea is to focus on process areas with a specific development potential where new or improved methods can be valuable tools. The projects cover modelling and design of equipment and control systems and open a possibility of developing measuring techniques, including statistical methods. The organization of the individual projects is seen in Figure 2.1. Here is indicated that a third of the projects are focused upon methodology that are common for both programs. A1. Heat and Mass in Drying

Continuous C1. Forming in Paper Machine

Methodology C2. Drying in Paper Machine C3. Loop and Quality Assessment C7. Fibre suspensions

C4. Grey-box modelling and PDE

C5. Model Reduction and Aggregation A2. Control of disc refiner

B5. Multi Purpose Reactor B1. Control and Diagnosis B2. Spectroscopic Monitoring B3. Dynamic Modelling of Reaction/Separation Processes

Batch

B4. Fluidized Bed Coating

Figure 2.1: The principle organisation of the projects within Center for Chemical Process Design and Control. 3.1 Participating researchers and PhD students within the Center Continuous Processes This thematic program contains currently 5 projects with 6 PhD students. Two new projects was initialised in the end of 2001, project C7 and C2c. A number of projects are focused on pulp and CPDC Annual Report 2001 9

Chemical Process Design and Control

paper industry, particular paper machine applications. The other projects are methodology oriented. A brief description of each project is give below. Contact persons for each project are mark with *. C1: Modelling of the Consolidation Phase of the Forming Section in a Paper Machine Vinicius Lobosco and Bo Norman* at Paper Technology at KTH and STFI The objective of this project is to develop a physically based and validated model of the dewatering in the consolidation phase of the forming section. C2: Modelling and Control of the Drying Section of the Paper Machine Stig Stenström*, Magnus Karlsson at Chemical Engineering I, LTH and Björn Wittenmark*, Ola Slätteke at Automatic Control, LTH, and Krister Forsman at ABB. The project is collaboration between Dept. of Chemical Engineering 1 and Dept. of Automatic Control at LTH. The project has one industrial PhD student from ABB, Ola Slätteke. The project has organised an Industrial Reference Group with participants from: ABB, Assi Domän, MoDo, Stora Enso and Valmet, for advice, relevance discussion and for technology transfer. A new project focused on air through heated paper drying is accepted and will start in 2002 and it will be organised as a subproject of C2, called C2c. C3: Loop and Quality Assessment Tore Hägglund*, Ari Ingimundarson at Automatic Control, LTH The main objective is to investigate and develop new supervision, detection and design procedure for local control loops mainly in pulp and paper industry. Stora Hylte Enso AB, ABB Automation Products and MoDo Husum are collaboration partners in the project. C4: Grey-Box Identification of Models Governed by Partial Differential Equations Elling Jacobsen*, Torsten Bohlin and Yu Liu at Process Control, KTH, and Alf Isaksson at ABB. The objective is to develop a method for grey-box identification of processes that are naturally modelled with spatial descriptions. These models become partial differential equations. Grey-box identification estimates models that are partly known in structure, white-box, and models that are unknown in structure, black box. C5: Reduction and Aggregation of Process Models Anders Rantzer*, Henrik Sandberg at Automatic Control, LTH Physical based modelling generates often models with high complexity. Here is the objective to develop methods and tools for reduction of model complexity and to analyse robustness and sensitivity of simulated trajectories. C7: Fluid Dynamics and Mixing of Fibre Suspensions Anders Rasmuson* at Chemical Engineering Design, CTH, A new project that starts 2002. Physical based modelling of fibre suspensions. An important application is paper fibre behaviour in high concentrations. This work is performed together with Metso in Sundsvall. Batch Processes The thematic program, Batch processes, contains 4 projects with 8 PhD students. Almost all projects are focused on the AKD-process at Akzo Nobel, Eka Chemicals in Trollhättan. CPDC Annual Report 2001 10

Chemical Process Design and Control

B1: Control and Diagnosis in Batch Processes Karl-Erik Årzén*, Rasmus Olsson at Automatic Control, LTH The aim is to study integrated information and control systems for batch production. Special emphasis will be put on integration of the monitoring and supervision tasks with recipe-based production. B2: Kinetic Parameters from Spectroscopic Monitoring Lars-Göran Danielsson*, Eric Furusjö, Anders Björk at Analytical Chemistry, KTH and Sture Holm and Tobias Adolphsson at Mathematical Statistics, CTH The overall objective of is to develop new tools for measurements on chemical process systems giving access to information relevant for modelling and control. The work involves both new methods for generating data and new chemometric tools for extracting chemical information from these data. Eric Furusjö graduated in March 2001. Eric is now working at ABB in Västerås. The subproject at CTH is finished with the planned PhD thesis by Tobias Adolphsson in spring 2002. B3: Dynamic mathematical modelling of reaction/separation processes Anders Rasmuson*, Fredrik Svensson, Torbjörn Virdung at Chemical Engineering Design, Bengt Andersson*, Mounir Bouaifi, Mikael Mortensen at Chemical Reaction Engineering, and Claes Breitholtz*, Veronica Lassesson at Automatic Control, CTH. The overall objective with this project is to develop general methods for dynamic modelling of separation/reaction steps including multiphase problems and fast kinetics. These models are used for improved design and scale-up. They form the basis for model reduction into simplified models that can be used for control, supervision and optimisation. A further objective is to find variables and positions for measurements that give abundant information about the process. The project is a major research project with 4 PhD students that work jointly on one industrial process, AKD process at Akzo Nobel, Eka Chemicals AB. B4: Fluidized Bed Coating Anders Rasmuson*, Stina Karlsson at Chemical Engineering Design, CTH. This joint project with the SSF programme "Multiphase flow" is defined and started in 2001. The project aims at developing experimental and theoretical techniques for the characterisation of multiphase systems, in particular fluid bed coating. The project is done in cooperation with AstraZeneca R&D, Mölndal. B5: Multi Purpose Reactor Bengt Andersson* and Mounir Bouaifi at Chemical Reaction Engineering, CTH, Björn Wittenmark and Per Hagander* at Automatic Control, LTH and Tommy Norén at Alfa Laval, Lund. This is a multidisciplinary industrial project initialised by industry. The project is based on the study of a new concept for continuous multi purpose chemical reactor. The project has a number of industrial partners and well-organized international collaborations. The B5 project will be a subproject of a international project coordinated by Alfa Laval. CPDC associated projects CPDC would like to increase collaboration with other researchers by pointing out CPDC associated projects. These projects, mainly financed by other sources, are related to the research in CPDC or are based on the same methodology. CPDC Annual Report 2001 11

Chemical Process Design and Control

A1: Heat and Mass Transfer in the Dryer Section of the Paper Machine. Eric Baggerud and Stig Stenström* at Chemical Engineering I, LTH. Financed by FPIRC (SSF). This project is strongly related to the paper drying research within CPDC. There is already ongoing collaborations between A1 and C2. A2: Modelling and control of disc refiners for thermo-mechanical pulping. Fredrik Rosenqvist and Anders Karlström* Signals and Systems, CTH, Financed by Energimyndigheten. This research project has strong industrial engagement mainly with Stora Enso Hylte. The project has close connections to particular B2. The number of CPDC Associated Projects is planned to increase during 2002 to six or eight projects. 3.2 A brief description of the scientific result The members in CPDC has published or submitted 26 scientific articles to journals, conferences or in other publications, which are listed in Appendix 1. •= Six articles have been submitted or published in scientific journals during 2001. •= 17 conference contributions have been presented or are accepted for presentation. •= Two conference contributions are based on international collaboration. •= Two conference contributions are based on cross disciplinary collaboration between researchers in Control Engineering and Chemical Engineering. •= One PhD thesis was finished during 2001. No patent has been explored during 2001. 3.3 Important results and events during 2001 Mid Term Evaluation The Mid Term Evaluation of the CPDC programme in spring 2001 was good. The evaluation committee found the research programme to be industrial relevant and pointed out the need of formalized industrial collaboration. This will be one of the most important evaluation criteria for the Board during the following period. The multidisciplinary research within CPDC must be strengthened and some new initiative to encourage collaboration between disciplines and universities have been suggested. SAB project evaluation During the autumn 2001 the on going projects in the center was evaluated by the Scientific Advisory Board, SAB. The projects where presented in a written report, presenting project goals, results and future plans. SAB evaluated the reports and the evaluation where discussed by the Board.

CPDC Annual Report 2001 12

Chemical Process Design and Control

4. Collaborations Collaborations are encouraged by CPDC but the industrial support is concentrated to the project level. This means that industrial cash support is given to a particular project and not to the central budget of CPDC and it means also that these resources are not seen in the traditional economic evaluation of the center. 4.1 Collaboration with Swedish industry The CPDC programme has a strong collaboration with Swedish chemical process industry and pulp and paper industry. Reported collaborations during 2001 is listed in Table 4.1 indicating a cash support from industry to be 1670 kkr. The in-house activities at the different industrial partners have not been valued to given amount but can probably be valued to be at least twice as much. A good approximation of the value of the industrial collaboration and support is about 4 to 4,5 Mkr during 2001. Table 4.1: Collaboration with Swedish industry during 2001 project Industrial partner Cash-support in kkr during 2001 C1 a)STEM b)Metso Paper b)200 C2ab a)Paper drying industrial a) 250 reference group* (ref. group) b)ABB b) 320 (ABB ind PhD) C3 MoDo Husum Assi Frövi Stora Enso Hylte B1 a)Eka Chemicals b)ABB B2 Eka Chemicals B3 B4

a)Eka Chemicals b)CPE Industrial club* AstraZeneca Mölndal

In-house activities a)Equipment Field test at Assi Frövi Experiments at Stora Enso Nymölla Implementations at Assi Frövi

b) Development at ABB Process data from Eka Development of measurement technique at Eka a)Process data from Eka

b)750 kkr 150 kkr Sum: 1670 kkr

* Cash paid by the members of the Paper Drying industrial reference group at Lund and Chemical Process Engineering industrial club at Chalmers.

Collaboration with Pulp and Paper industry CPDC have good collaborations with different partners in pulp and paper. Particular the projects C1, C2 and C3 can report both cash support and large industrial in-house activities. The C1 project performed at STFI and can utilize their industrial network. C2 has an industrial reference group for discussion and exchange. The project also has an industrial PhD student finances by ABB Process. The paper drying activity will increase in 2002 with one associate project, A1 – Heat and Mass Transfer in Paper Drying, and with one new CPDC project, C2c – Design of Energy Distribution in Gas-heated Through Air Dryers. C3 project has a number of industrial collaboration and makes industrial implementations and field tests. The work on disc refiners at CPDC Annual Report 2001 13

Chemical Process Design and Control

CTH is one newly appointed associated project, A2, which also increase research in pulp and paper. A second new CPDC project that will start during 2002 is focused upon modelling fibre suspensions and this project has planned collaboration with Metso Paper in Sundsvall. Paper drying industrial reference group at Lund An industrial reference group has been formed as a platform for discussions and exchange of results in the project, see Fig. 4.1. This referenced group interact mainly with the paper drying research group at Chemical Engineering I in Lund, which means that is serves as a reference group also for projects not supported by CPDC.

CPDC Chemical Engineering

Automatic control

Producing companies

Control companies

AssiDomän MoDo Stora-Enso

ABB Valmet Industrial paper machine

Fig. 4.1. Industrial reference group in the drying project. Presently three producing companies (Stora Enso, MoDo Paper and Assi Domän) and two machine supplying companies (ABB, Metso) are involved in the project. So far three meetings have been held with this group (with roughly 20 participants each time) indicating the large industrial interest in problems related to dynamical behavior and control of the paper dryer. The first two meetings were held in Stockholm and the third meeting at the Stora-Enso mill at Skoghall, Karlstad. During these meetings new results have been presented and discussed. Some of the of important areas mentioned by the industrial reference group are moisture control during quality changes, increased understanding of thermal phenomena in the dryer and improved CD-profile control. Mill visits have been arranged during the meeting in Skoghall as well as during the Tylösand meeting when the Stora-Enso Hylte mill producing newsprint was visited. Collaboration with Chemical Process industry The thematic program Batch Processes is focused upon a common process, Eka Chemicals AKD-production site at Trollhättan. The project B1 and B2 is used as an example for testing new technologies while for the B3 project it is the main source for problem formulation. The overall objective with project B3 is to develop general methods for dynamic modelling of separation/reaction steps including multiphase problems and fast kinetics. These models are used for improved design and scale-up. They form the basis for model reduction into simplified models that can be used for control, supervision and optimisation. A further objective is to find variables and positions for measurements that give abundant information about the process. For this work Eka Chemicals AKD-production site at Trollhättan has been chosen as a case study. This means that there are regular meetings between Eka and researchers mainly from Chalmers. CPDC Annual Report 2001 14

Chemical Process Design and Control

The collaboration with other chemical process companies will increase during 2002 because the new project B5 will include a number of Swedish companies like Alfa Laval, Perstorp, AstraZeneca and AkzoNobel. Chemical Process Engineering industrial club at Chalmers The organization of the Chemical Process Engineering School at Chalmers is aimed to enhance the research and education in Chemical Process Engineering, including support from other disciplines as Mathematics, Fluid Dynamics, Biotechnology etc. On the same time an industrial club was formed in order to create a community for discussion and exchange of research. The CPDC projects at Chalmers are supported by the CPE industrial club. Total list of industrial collaboration In the Table 4.2 all reported planned and valued collaborations with Swedish industry is listed. It points out that approximately 9 M SEK is total cash support from industry to the CPDC research. The majority of the in-house activities are not valued but a rough approximation is that it is twice as much as the cash support. This indicates that CPDC has a total industrial collaboration in the range of 20-30 M SEK Table 4.2: List of the total industrial engagement in CPDC based research. project Industrial partner Cash-support In-house activities C1 a)STEM Equipment b)Metso Paper b) 200 C2ab a)Paper drying industrial a) 1250* Experiments reference group* Implementations b)ABB b) 1280 Field test C3 MoDo Husum Experiments Assi Frövi Implementations StoraEnso Hylte B1 a)Eka Chemicals Development b)ABB Implementations B2 Eka Chemicals Development Experiments Implementations and tests B3 a)Eka Chemicals Development b)CPE Industrial club* b) 2250* Experiments Implementations and tests B4 AstraZeneca Mölndal 750 kkr Experiments C7 Metso Paper Experiments and equipment valued to 650 kkr C2c a)Swedish Gas Technology a)1440 b) Experiments and equipment b)Metso Karlstad b)150 valued to 600 kkr B5 Alfa Laval** 1700 kkr** Process data Development and implementations Pilot plant tests 9020 * Cash paid by the members of the Paper Drying industrial reference group at Lund and Chemical Process Engineering industrial club at Chalmers. ** Industrial collaboration that is under discussion. This project is not decides by the Board yet. CPDC Annual Report 2001 15

Chemical Process Design and Control

4.2 Industrial usage of CPDC results Metso Paper is sponsoring a further development of the press section model, originally developed in the C1 project, and experiments with parameter estimation. This work is focused on the different pulps produced in the company. The methods developed in the C3 project is currently implemented on a paper machine at Assi Frövi. The methods are used to give the operator information about the quality of the different control loop performances. 4.3 International collaborations In project C2 close co-operation has been established with a European financed project called QUID, Quality in Drying. In this project models for the moisture gradients in the paper sheet have been developed which have been utilised in the dynamic simulation program, which is developed in C2. The work in project B1 is connected to the EU project CHEM, particularly with Prof. Luis Puigjaners group at UPC (Universitat Politechnica de Catalunya) in Barcelona. They work with reactive scheduling for batch production and the idea is to connect to two efforts together through the usage of their laboratory process (PROCEL). Lars-Göran Danielsson is co-ordinator of Nordic Institute for Chemometric Education (NICE) (www.nice.kth.se) a Nordic network supported by Nordic Council through NORFA. CPDC cosponsored a workshop in June t Mariehamn called Process Analysis and Optimisation 4.4 Collaboration with other SSF-programs The C2 project has strong connection to the SSF financed FPIRC programme. For instance is the CPDC associated project, A1, financed by FPIRC. Karl-Erik Årzén is a member of the board in the SSF financed programme ARTES. This is a valuable connection both on the strategic level and on the interaction between mainly the B1 project and the research in real time programming. The project on fluidised bed coating, the B4 project, is a truly interdisciplinary project with interactions SSF financed center, Multiphase Flow, and industry, AstraZeneca, Mölndal. The B4 project is one of three projects focusing on fluid bed coating at Chalmers and with collaboration with AstraZeneca. The second project is financed by the center for Multiphase Flow and the third project by AstraZeneca. 4.5 Other important collaborations The project B1 has strong connections to the work on Languages for Automation that is being carried out in LUCAS, an interdisciplinary research programme on applied software research that is being carried by the departments of Automatic Control, Computer Science, and Telecommunications at LTH. Within LUCAS a project is being performed with ABB Automation Products with the focus on new graphical control languages. LUCAS is a VINNOVA financed center for applied software.

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Chemical Process Design and Control

4.6 Web-based information CPDC has an active web site. Here is it possible to find following material: •= addresses to Board members, program administration, scientific advisory board and to all researchers and departments within the center. •= short presentations of all CPDC projects •= presentation of the CPDC graduate school •= CPDC archieve with reports, board meeting protocols and common CPDC material The link to the web site is as follows www.control.lth.se/cpdc The web site is mainly maintained by the program director Bernt Nilsson phone: 046 222 80 88 email: [email protected] 4.7 Information activities The main information activity in CPDC is the regular web based Newsletter. This is a simple information publication for internal information within CPDC and to external partners that already have collaboration with CPDC. Two times the program director has been invited to present the program at different national workshops, namely to the annual meeting of the LiFT programme, a SSF financed graduate school, and to the CBioSep, a VINNOVA center for Bioseparation. 5. Management and organization of the programme The center of Chemical Process Design and Control is a consortium between LTH, CTH and KTH even though the legal agreement has been signed between the Swedish Foundation for Strategic Research and Lund University, where LTH is a faculty. The organizational structure of the program is shown in the figure below. 5.1 The Board and Program Administration The Board The Board consists of five representatives from university and industries. The chairman of the board has been chosen from the industry. The Board has been appointed by Lund University after consultations with CTH and SSF. The Board is the decision-making body and is responsible for how the long-term goals of the program are followed and how the program will develop. It also has the responsibility for the scientific, educational, and economical aspects of the program. Further the board should be responsible for how the research results are transferred to industry, academia, and society. The board is appointed for a period of three years and the chairman belong to a non-academic organization in order to emphasize research topics with industrial relevance for the program.

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Chemical Process Design and Control

Lund Institute of Technology

Organization

Board of Directors

Scientific

Director

Administration

Advisory Board

Activities Program 1 - Batch Processes

Graduate School

Program 2 - Continuous Processes

Project 4 Company 3 Company 2 Company 1

Project 3 Project 2

Company 6

Project 8 Project 7

Course

Project 1

Company 5

Project 6 Project 5

Company 4

Figure 5.1: The organization and activities in Centre for Chemical Process Design and Control. Members of the board at the beginning of 2001 where Anders Broström, Chairman, Akzo Nobel Chemicals BV (resigned July 2001) Lennart Ahlgren, vice Chairman, former CEO AssiDomän Inger Andersson, Arla Lennart Ljung, Linköping University Hans Theliander, Chalmers University of Technology Anders Broström resigned from the board in July 2001. Lennart Ahlgren has taken the position as vice chairmen until a new chairman of the board has been appointed. LTH and CTH have pointed out Mats Nyström, Eka Chemicals, Bohus, as a candidate to replace Anders Broström in the board. A new board will officially be pointed out during spring 2002. The Program Director The former program director Anders Karlström resigned in January 2001. Bernt Nilsson, Chemical Engineering I, LTH, has been acting program director during 2001. A new Program Director will officially be pointed out in spring 2002. One of the major tasks, besides the continuous follow up of the activities within the program, will be to ensure that the activities are in phase with the project plans. The program director will also together with the project leaders specify milestones within each research project in order to give the board a possibility to get measurable goals. The program director will also administrate the annual activity report, which CPDC Annual Report 2001 18

Chemical Process Design and Control

includes project descriptions, economy, records of human resources, training activities and collaboration with other program as well as between the projects in the program. Acting program director during 2001: Bernt Nilsson, associated professor, Chemical Engineering 1, Lund Institute of Technology Administration The program is administratively a part of LTH and CPDC uses some administrative resources, mainly at the Department of Automatic Control, LTH. Scientific Advisory Board The program has a Scientific Advisory Board with representatives from the international research community. This advisory board is necessary for ensuring the relevance and quality of the research activities within the program. The Scientific Advisory Board is elected by the Board. The Scientific Advisory Board, SAB consists of: Guy Dumont, University of British Columbia, Canada John Perkins, Imperial Collage, London, UK John MacGregor, McMaster University, Canada Raficul Gani, Denmark Technical University, Lyngby, Denmark During autumn 2001 the Scientific Advisory Board has evaluated on going projects in CPDC. This is an important work that gives independent and valuable criticism on the research projects and on the programme. The feedback from Scientific Advisory Board was used in the decision of giving the research projects financing the remaining time. Graduate school The Board has appointed Bernt Nilsson on a part-time basis as a Director of studies and head of the graduate school. The Director of studies initialises, plans and organises the graduate courses within CPDC. The director also performs quality assessment on the courses. 6. Budget and financing of the programme The revenue from SSF is 47 MSEK for the period 1999-2003. Total amount consumed resources are 11 MSEK during 1999-2000 and 8,6 MSEK for year 2001. The Board has approved totally 42,5 MSEK for the period 1999 to 2004. There are plans to approve 1,5 MSEK leaving 3 MSEK unallocated for the period 2002-2004. CPDC plan to use resources also for 2004. The economic overview of the center is shown in Appendix 2.

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