A Capstone and Design Project on Process Automation Technical Details and Student Learning
A Capstone and Design Project on Process Automation Technical Details and Student Learning
I am a retired U.S. Army Sergeant, who recently graduated from the University of Houston-Downtown,
with a degree in CIET. I enjoy spending my free time with my two daughters who are eight and two.
Abstract
This paper refers to a capstone and design project and discusses the design, construction,
instrumentation, modeling, simulation and control of a binary distillation column. In addition to
technical details, student learnings on project management, teamwork, and technical
communication are also presented. Results demonstrate the aptitude and skills of engineering
technology students to use sophisticated technologies to solve important technical problems while
working in a team environment and delivering results within budget and schedule constraints.
1. Introduction
Manufacturing industries operate under various constraints while trying to be competitive in
today’s business environment. For instance, they must operate safely and in an environmentally
friendly manner with minimum carbon footprint. This requires better utilization of raw materials
and less energy consumption. One of the most energy consuming manufacturing processes is the
distillation process. Improved distillation column design and automated operation are very
important in achieving energy reduction for such processes. Thus, graduates from
engineering/engineering technology programs must be taught and master the required
technologies and develop skills to implement design and automation projects in a team-based
environment with schedule and budget constraints.
In general, the senior project entails the design and construction of a process, identification of key
control objectives, specification and installation of required instrumentation for process variable(s)
monitoring and control, real time data acquisition, process modeling using empirical and/or
analytical methods, design and tuning of controllers, and closed loop control performance
evaluation. Since the senior project is a team-based project, equally important to technical
requirements are a number of non-technical requirements focusing on project management,
technical writing and presentation of technical topics, teamwork and communication.
This paper discusses the design, construction, instrumentation, modeling, simulation, and control
of a binary distillation column. In addition to technical details, student learnings on project
management, budget and schedule development, teamwork, and technical communication are also
presented. The remaining of the paper is organized as follows. Section 2 discusses the process and
control objectives. Section 3 provides details on the column design using AspenPlus. Sections 4
refers to the computer platform, for data acquisition and operation of the process. Section 5
presents experimental results. Section 6 summarizes student experiences and lessons learned while
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working on this capstone and design project. Section 7 summarizes main results and is followed
by references.
The column operates in continuous, closed loop mode. Feed is separated into two products which
are eventually pumped into the feed drum for reprocessing in a continuous manner. Reflux drum
and bottoms/reboiler levels are maintained by adjusting the distillate and bottoms product flow
rates. A heating element is used to supply the energy required for the separation. The reboiler
vapor stream temperature is maintained by adjusting the supplied heat. Reflux is manually
adjusted. Overhead vapor is condensed by using cooling water from a lab water supply.
The control objectives are to maintain material inventory by controlling the reflux drum and
bottoms/reboiler levels by manipulating the speed of the pumps on the distillate and bottoms
product lines, respectively. Separation is maintained by controlling the reboiler temperature using
the heat supplied to the column. Thus, three controllers are designed to operate in automatic mode
to achieve these control objectives. Feed flow-rate and reflux flow-rate are adjusted using two
controllers which are currently operated in manual mode. The feedback control loop diagrams are
shown in Figures 2 through 4.
2
Fig. 2: Reflux Drum Level Control Loop
Feed stream specifications are shown in Figure 6. It is assumed that the feed temperature is around
66°C at 1atm (because of the continuous loop back to the feed drum).
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Fig. 6: Feed Specifications Setup
In Figure 7, other design parameters are specified. The reflux ratio is 0.5. The component
recoveries were set to 98% for water and 2% for propylene glycol in the distillate product. The
pressures in the condenser and reboiler are set to 1 atm. A total condenser is used.
Figure 8 below indicates that the number of actual trays, NT, is 5 (4.38 is rounded up). Notice that
in AspenPlus terminology, the condenser and reboiler are counted as trays and numbering of trays
starts with the condenser as tray number 1. So, actually, inside the column there should be 3 trays.
The feed tray location is on tray 2 (counting from the bottom of the column). These results are in
agreement with the McCabe-Thiele method (see Appendix A).
To account for future projects, it was decided to design the column with 7 bubble cup trays instead
of the required 3 trays (excluding reboiler and condenser). The as built distillation column is shown
in Figure 9.
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Fig. 9: The as built Distillation Column
Major parts used to build the column along with specifications and sources are included in
Appendix B.
Figure 10 below shows the front panel of the LabVIEW program which is used as Human-
Machine-Interface (HMI) to operate and control the column. It is divided into four squares to
provide a user-friendly control of the distillation column. The bottom two squares are used to
control the reboiler level and temperature while the top two squares are used to control the reflux
drum level and manually manipulate the speed of feed and reflux pumps. Figure 11 shows
programming of various control strategies employed for automatic control.
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Figure 10. Front Panel
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The LabVIEW program consists of a single “while” loop that includes the reboiler temperature
control, reflux drum and reboiler level controls, and manual speed operation for the feed and reflux
pumps along with logic for a solenoid valve at the feed line.
The feed loop as seen in the top portion of Figure 11 is a simple pulse-width-modulation (PWM)
block that takes its input from a digital input/output (DIO) on the NI myRIO. The output of the
PWM is the Duty Cycle and LabVIEW limits the output from 0 to 1. A slider is seen on the
LabVIEW front panel as the manipulated variable for a constant flow of feed. Due to the design
of the feed in this distillation column, a solenoid valve had to be added to prevent feed from free
flowing into the column when the pump is not running. When the pump is at 0 duty cycle, the
solenoid is de-energized and thus closed. When the slide on the duty cycle is greater than 0, the
NI myRIO sends a 5V output to a relay which completes a 12VDC circuit and energizes the
solenoid causing it to open. The reflux drum and bottoms level control strategies are extremely
similar. Both levels are controlled by LabVIEW’s Advanced PID control block. The temperature
control is done using a local controller by Platinum Omega3. The temperature set point, process
variable, and PID gains are all local variables that are brought over to this LabVIEW diagram
using a proprietary LabVIEW temperature controller demo by Platinum Omega.
The distillate pump, reflux pump and reboiler pump are 12VDC high temperature water pumps
with 0-5VDC speed manipulation range. They are connected to a power supply and to the myRIO
analog output connections. The feed pump is a 12VDC pump without variable speed. In order to
manipulate the pump, it was connected to an H-Bridge and to the myRIO using a PWM connection.
An H-Bridge allows using the motor in either direction because it allows the current to flow in
both directions. It is used adjust the motor speed by changing the duty cycle using PWM in
LabVIEW. The feed solenoid uses a 12VDC power and a relay to set the open and closed limits
on the valve. The float transmitter inside the boiler requires a current to voltage converter because
the output signal is 4-20mA. The converter converts the 4-20mA signal to 0-5VDC in order to
connect to myRIO. Both the radar transmitter in the reflux drum and the float transmitter in the
boiler required 24VDC power.
Figure 12 below shows the connections for the various instruments used for the distillation column.
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Fig. 12: Instrumentation and Wiring
5. Results
This section summarizes experimental results obtained while the distillation column was
separating a mixture of ethanol and water. The composition of the feed to the column was
approximately 4 wt% ethanol. The control loops were the liquid levels in the reflux drum and
reboiler, and the temperature at the exit of the reboiler (vapor returned to column). As mentioned
earlier, reflux drum level is controlled by manipulating the distillate pump voltage, reboiler level
by manipulating the bottoms pump voltage and bottoms temperature by manipulating the heat
input to the column. Proportional/integral (PI) controllers are used in these loops. The level loops
were tuned manually while the temperature loop was tuned using the auto-tuning method included
in the Platinum Omega temperature controller.
Figures 23 and 24 show level control. Both levels are measured in inches while the time is in
minutes. Figure 25 show temperature control with the temperature measured in degrees Fahrenheit.
All three figures show satisfactory column control.
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Fig. 24: Reflux Level Control Chart
6. Lessons Learned
This section summarizes student comments and experiences by working on this capstone and
design project.
• Balancing a full time job and the senior project was definitely tough. However, I could not have
asked for a better team to embark on this challenging journey.
• From an organizational standpoint, the course structure ensured we stay on track with our schedule
in order for every team to have a chance to be successful. The weekly status updates were an asset to
the project as they allowed one on one time with the instructor where he provided any and all
available resources he had to offer.
• The proposal, although we worked on a capstone project, enabled the instructor to approve the
success criteria to be worked on for the semester as well as set expectations.
• The final presentation and report, as a combination, were a demonstration of all the hard work the
three of us put in to achieve phenomenal results. All this was made possible with the help of each and
every one of us. The input that each and every one of us had was first and foremost the reason behind
our success.
• The most important part about teamwork, in my opinion, was communication; not just the ability to
speak to one another, but also the ability to truly listen to one another. Our team met physically in
the lab several times during this semester and brainstormed a lot of great ideas but we also
communicated outside of the lab through a group chat which helped bring us close together as a team
even with the challenges of life (work and family responsibilities).
• To the future students who are about to take on this task, I would recommend managing your time
wisely while taking into consideration the time of other tasks in your life. This might sound easy but,
as they say, it’s a lot easier said than done. Make sure you also have the correct equipment from the
beginning of your project. Be diligent in your research to ensure the compatibility of all the
equipment you purchase. Finally, and this is for upcoming students who have just gotten into this
program, make sure you pay attention in every class and take as much of the learnings you receive to
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heart because you will use every single piece of knowledge you have accrued along the years to be
successful in your senior project.
• Working on our senior project was a profound experience for me. Learning to manage time
availability between three students with very different time schedules was a perplexing problem to
solve.
• The manor that the course was organized helped keep us on task by having us not just meet in person
weekly but also making us give status updates to Dr. T.
• Having teams work on project proposal helped our team when it came to writing the final report. Just
having the experience and understanding of what the standard for a technical report is helped
meeting the set standard much easier.
• I think the biggest lesson I learned was how much technical knowledge I have accumulated over the
years: from being able to use Excel to solve linear/nonlinear equations, to programming using
LabVIEW, to using AspenPlus to design a distillation, to designing and tuning controllers.
• For future students embarking in the exciting, yet difficult task of a capstone project be sure to
manage your time wisely. When the semester begins it feels like time is in abundance but soon your
deadline approaches and then your stress levels go through the roof. Secondly, I would advise to take
very specific notes when you come to the lab to work on the project. Trying to remember what issues
the team faced two months ago is very difficult when facing a time crunch. Before the team leaves the
lab use the mandatory lab book to write down everything the team struggled with and how the issues
were eventually resolved.
• The senior project is a representation of what to expect as a professional in industry when working
on a project. In industry, you work with several departments and professionals to get a project
completed in a timely manner and within cost. These departments may include Instrumentation and
Electrical Engineers, Process Engineers, Project Engineers, Mechanical Engineers, Design
Technicians, and many more. In senior project, the small group completes every task crossing over
into every field to complete the project. First, we have the duties of a project engineer. The class was
structured so that we have weekly update meetings with our professor to discuss the group’s progress
similar to projects in industry. We also had a budget to manage and keep track of expenses. We used
Aspen Plus to perform simulations to design the Distillation Column. We also used AutoCAD to draw
the P&ID of our system. We completed the wiring of all the instruments and did some pipe
modifications. Students work hard to complete the project and the knowledge gained throughout the
semester is so rewarding at the end when you do your final presentation and demonstration. Every
mistake or problem encountered is knowledge and problem solving skills gained. It is very important
to have a good team to work with. Everyone brought different ideas to table and we were able to
execute them effectively to complete this project.
• Advice to other senior students: It is hard work and dedication that will get you through the project.
It was possible for me as a mother of two and working a full-time job. Start off strong and finish
strong. You should divide the work so that everyone is a leader in one area, however everyone should
help finish the task by the projected date.
7. Conclusions
This paper presented results and student experiences from a capstone and design project on process
automation. Students used sophisticated tools (the same ones used by industry) to design, construct
and automate the operation of a distillation column. Results demonstrated the aptitude and skills
of engineering technology students using sophisticated technologies to solve important technical
problems while working in a team environment, communicating technical topics, and delivering
results within budget and schedule constraints. In simple terms, the students’ degree may be in
engineering technology but their profession is engineering.
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References
1. AspenTech, “AspenPlus”, www.aspentech.com
2. National Instruments, “myRIO”, www.ni.com
3. Platinum Omega, Temperature Controller, www.omega.com
4. Luyben, W.L., “Distillation Design and Control Using Aspen Simulation”, Wiley 2006.
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Fig.-3: Distillation Process Diagram4
Table A.1 shows the parameters and values used to design the column.
𝑧𝑧−𝑥𝑥𝐵𝐵
𝐷𝐷 = 𝐹𝐹 ⋅ (1)
𝑥𝑥𝐷𝐷 −𝑥𝑥𝐵𝐵
𝑅𝑅 = 𝑅𝑅𝑅𝑅 ⋅ 𝐷𝐷 (2)
𝑉𝑉𝑅𝑅 = 𝑅𝑅 + 𝐷𝐷 (3)
𝐿𝐿𝑅𝑅 𝑅𝑅 𝑅𝑅𝑅𝑅
𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆 𝑜𝑜𝑜𝑜 𝑅𝑅𝑅𝑅𝑅𝑅 = = = (4)
𝑉𝑉𝑅𝑅 𝑅𝑅+𝐷𝐷 1+𝑅𝑅𝑅𝑅
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The relative volatility, α, of water with respect to propylene glycol is 32.52 at 66 C.
An excel spreadsheet is used to analyze the separation of water and propylene glycol by calculating
the parameters in the McCabe-Thiele method and then plotting the data. Table A.2 shows results
for the column design using the McCabe-Thiele method.
Table A.2: McCabe-Thiele Results
Distillate flow, D= 510.6383 moles/h
Using a xy vapor-liquid-equilibrium (VLE) diagram, the stripping and rectifying operating lines
can be drawn as shown in Figure A.2. By following the McCabe-Thiele method, the number of
required trays, NT, is shown to be 3 and the location of feed tray is 2 (from the column bottom).
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Appendix B. Materials for Column Construction
This appendix presents materials that were required to build the distillation column.
Source:
https://www.omega.com/manuals/manualpdf/M
5451.pdf
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Reflux Drum ● Capacity: 2 gallon
Manufacturer: MILLIPORE ● Height: 12”
● Diameter: 7”
Source: http://www.emdmillipore.com/US/en
● Noise: 35 dB
Source: http://www.lightobject.com/Heavy-duty-
30Lm-475GPH-DC12V-High-Temperature-100-
39C-Brushless-Water-Oil-Gasoline-pump-w-speed-
control-P544.aspx
Source: http://www.ni.com/pdf/manuals/376047c.pdf
15
Temperature sensor ● Temperature Sensing Range -70 °C to 260 °C [-
Manufacturer: Honeywell 94 °F to 500 °F]
Item no. HEL-705-U-0-12-00 ● Linearity (% of Full Scale) ±0.1% typ. -40 °C to
125 °C [-40 °F to 257 °F]; ±2.0% max. -75 °C to
540 °C [-167 °F to 1004 °F]
● Stability: >0,25 °C per year; 0,05 °C per five
years in occupied environment
● Supply Current 1 mA typ., 2 mA max.
Source:
http://sensing.honeywell.com/product-
page?pr_id=23053
Source:
http://flowline.com/_data_sheet_and_manuals/curren
t/DL24_m.pdf
16
Fast Blown Fuse and Fuse Box Source: Omega
http://www.omega.com/pptst/CNPT_SERIES.html
17