Control Talk Blog

Checklist for Success Tips

This last checklist may help you get the most out of your career and your life.  Our accomplishments and our humanity are tightly related. The checklist is a summary of an understanding gained of an attitude and philosophy that has helped me be a better engineer and person.  The checklist...

Checklist for Bioreactor Control Tips

Contrary to common conceptions, bioreactors have more sophisticated analysis and control and with the advent of at-line analyzers more extensive opportunities than chemical reactors. The specialty chemical industry can get a preview of the future from the biopharmaceutical industry.

Checklist for Liquid Pressure and Flow Control Tips

Nearly every process input is a flow, whether directly via a material input flow or indirectly via an energy input (e.g., utility flow). Good flow control is important for achieving the desired material and energy balance and stoichiometric ratio for reaction rates.

Checklist for Gas Pressure Control Tips

Nearly all of the deadtime in pressure loops comes from the automation system. For gas pressure there is a process time constant or integrating process gain that becomes slower as the volume increases and the throughput decreases.

Checklist for Compressor Surge Control Tips

Compressor surge is the fastest gas dynamic phenomena. A precipitous drop in flow occurs in 0.05 seconds and subsequent flow reversals occur every 1 to 2 seconds. The speed of response requirements for control valves, measurements, and controllers are extraordinary.

Checklist for Level Control Tips

The maximum level controller gain for stability is one or two orders of magnitude higher than expected. The main limit to how high you can go in controller gain is often measurement noise and control objective.

Checklist for pH Control Tips

pH is the most common analytical measurement. pH is important for product purity and environmental compliance. The most stringent pH control requirements occur in bioreactors for biopharmaceuticals where a deviation of 0.05 pH can cause a noticeable degradation in mammalian cell growth rate and product formation rate.

Checklist for Batch Optimization

Batch processing is a critical part of many high value added biological and chemical processes. Batch processes are capable of higher conversions than continuous processes because there is no discharge flow until the batch is deemed complete.

Checklist for Flow Feed-Forward Control

Flow feed-forward control is the most utilized and underutilized advanced regulatory control technique. Proper implementation involves the use of ratio control and cascade control. Processes can be started up and moved quickly to new operating points by achieving a new flow ratio.  Temperature and composition loops have a particular ratio...

Checklist for Batch Reactor Temperature Control

Tight reactor temperature control enables the optimization of capacity and yield. What happens upfront in the reaction sets the stage for downstream processing and what ultimately ends up in the final product. Generally, increasing reactor temperature will increase reaction rate (capacity) but if the temperature is too high, side reactions...