PROCESS ENGINEERING PLANT MODULE AND METHOD FOR CONTROLLING A PROCESS ENGINEERING PLANT MODULE

Description

[0001] The invention relates to a process engineering plant module and a method for controlling plant components of a process engineering plant module by means of a computer-aided simulation of the process engineering process, as well as a computer program product.

[0002] Before process plants are put into productive use, they are commissioned to test their functionality and prevent errors. This includes virtual commissioning, in which the plant's automation is validated using a computer-aided simulation of the technical process. Typically, a so-called "water run" is simulated. A water run, in this context, refers to a functional test using water or other chemically inert substances instead of the actual chemicals used in the process. The technical process itself is generally not simulated to maintain the real-time capability of the simulation and to keep the modeling complexity low. Subsequently, a real commissioning takes place. This usually also involves a water run in the actual plant; that is, instead of the real chemicals, the plant is tested with harmless inert substances.This allows the flow controls and other functionalities of the plant to be configured and validated before switching to real operating conditions and substances. However, this means that the commissioning of the process plant does not take place under real-world conditions; in particular, the chemical reactions are not taken into account, and thus the plant cannot be pre-tested with the intended chemical substances. US 2021 / 286347 A1 discloses a method for controlling a chemical process in a large-scale chemical plant.

[0003] It is therefore an object of the invention to enable the commissioning of a process engineering plant, in which the process engineering process is also validated.

[0004] The problem is solved by the measures described in the independent claims. Advantageous embodiments of the invention are presented in the dependent claims. According to a first aspect, the invention relates to a process engineering plant module comprising: a. Plant components configured to carry out a process engineering procedure in which a property of a first chemical substance is changed in the process engineering procedure; b. at least one sensor configured to detect a sensor value of a physical quantity of the first chemical substance in a plant component; c. a simulation unit configured to simulate a chemical reaction, a temperature change, and a mass transfer of the process engineering procedure for a second chemical substance as a function of the sensor value, wherein the first and second chemical substances differ, and to output a simulated temperature value and a simulated mole fraction of the second chemical substance; and d.A control unit configured to control actuators of the plant components depending on the simulated temperature value, the simulated mass fraction, and the detected sensor value.

[0005] According to a second aspect, the invention relates to a method for controlling plant components of a process engineering plant module, comprising the following method steps: a. Acquiring a sensor value of a physical quantity of a first chemical substance in a plant component of the process engineering module, wherein the first chemical substance is changed in a process engineering process taking place in the plant components of the process engineering module, b. Computer-aided simulation of a chemical reaction, a temperature change and a mass transfer of the process engineering process for a second chemical substance as a function of the flow rate, wherein the first chemical substance and the second chemical substance differ, c. Outputting a simulated temperature value and a simulated mole fraction of the second chemical substance, and d. Controlling actuators of the plant components as a function of the simulated temperature value, the simulated mole fraction and the acquired sensor value.

[0006] A process engineering plant module can also be referred to as a process engineering plant module or a plant module of the process industry. A process engineering plant module can be coupled with at least one other process engineering plant module to form a process engineering plant. However, a process engineering plant module can also be considered a process engineering plant itself, comprising a multitude of plant components, also referred to as plant modules. In other words, a process engineering plant can also be viewed as a plant module.

[0007] In the process engineering module, a process engineering process can take place in which a chemical substance—that is, an element, compound, or mixture, which can exist as a liquid, solid, or gas—is altered. A change in a chemical substance within a process engineering process can be understood as a substance transformation, meaning a change in the chemical substance with regard to its composition, type, or properties. In the case of a water-based process, for example, during the commissioning of a process engineering plant, the chemical substance is typically water, or nitrogen in the case of gases.

[0008] A computer-aided simulation of the process is performed using a computer-aided simulation model of the process. This simulation model is designed to represent at least one chemical reaction, a mixing process, a temperature change, and / or a mass transfer within the process. In particular, the simulation considers the at least one chemical substance that is intended to be used after commissioning of the process plant module / plant. The simulation model can also be referred to as a digital twin of the process.

[0009] The invention enables, in particular, a hybrid commissioning of a process plant, in which a computer-aided simulation of the process, or at least one process step or aspect of the process, is carried out in parallel with a water trial. The simulation results can then be used to control the plant. Hybrid commissioning means that some of the process steps in the real plant can be replaced by a simulation during the water trial. In other words, during commissioning, a simulated sensor value can be used instead of a real sensor value to control the plant module. Preferably, only one process step that is important for the commissioning of the plant module is virtualized.For this purpose, the plant module is preferably configured to include an edge device on which steps of the process engineering can be simulated in parallel with the watercraft operation. This allows automation to be supplemented with signals from the simulation in order to validate the control of the plant module under realistic conditions.

[0010] For example, a flow controller that is intended to keep the molar concentration of a reactant in a reaction vessel constant can be validated in the real plant during the water trial by simulating the reaction, the temperature change, the mixing of chemical substances and / or the change in the molar concentration in the reactor, even though this reaction does not yet take place in reality during the water trial.

[0011] Furthermore, the invention enables the operation of a process engineering plant module, whereby values ​​from the simulation can be used for control. For example, virtual sensor values ​​can be used to control the process engineering plant module. This can improve the accuracy of the control and / or the operational reliability.

[0012] In one embodiment of the invention, the first chemical substance can be chemically inert.

[0013] In particular, the first chemical substance can be water and / or nitrogen. This allows a water test to be carried out in the actual plant components, for example to test the mechanical functionalities of the plant module.

[0014] In one embodiment of the invention, the sensor can be designed as a virtual sensor and provide a simulated sensor value.

[0015] This allows simulated sensor values ​​to be recorded additionally or alternatively and used for control.

[0016] In one embodiment of the invention, the sensor can be a flow sensor or a level sensor.

[0017] In one embodiment of the invention, control commands from the control unit can be taken into account in the computer-aided simulation of the process engineering process.

[0018] This means that the simulation can be adapted using the current control commands. This allows for a simulation to be carried out in parallel with real-world watercraft operation.

[0019] In one embodiment of the invention, the computer-aided simulation can be carried out in real time and in parallel with the process engineering process.

[0020] According to a further aspect, the invention relates to a process engineering plant comprising at least two process engineering plant modules according to the invention and a higher-level control unit, wherein the respective control units of the process engineering plant modules are coupled to each other by the higher-level control unit and wherein the respective simulation units of the process engineering plant modules are coupled to each other.

[0021] Alternatively, the process plant can simply include a simulation unit, which can be implemented as an edge device or in the cloud.

[0022] In one embodiment of the process plant, the respective simulation units of the process plant modules can be coupled together using a co-simulation environment, and a first simulated temperature value and a first simulated molar fraction output by the first simulation unit can be used as input data for the second simulation unit.

[0023] Furthermore, the invention relates to a computer program product that can be directly loaded into a programmable computer, comprising program code parts which, when the program is executed by a computer, cause it to perform the steps of a method according to the invention.

[0024] A computer program product can be provided or delivered from a server in a network, for example, on a storage medium such as a memory card, USB stick, CD-ROM, DVD, a non-volatile / permanent storage medium, or in the form of a downloadable file.

[0025] Exemplary embodiments of the invention are shown in the drawings and are explained in more detail below. The drawings show: Fig. 1: an embodiment of a process engineering plant module; Fig. 2: an embodiment of a process engineering plant; Fig. 3: a first embodiment of a method for controlling plant components of a process engineering plant module; and Fig. 4: a second embodiment of a method for controlling plant components of a process engineering plant module.

[0026] Corresponding parts are marked with the same reference symbols in all figures.

[0027] In particular, the following embodiments merely show exemplary implementation possibilities of how such implementations of the teaching according to the invention could look, since it is impossible and also not helpful or necessary for understanding the invention to name all these implementation possibilities.

[0028] Furthermore, a person skilled in the art, with knowledge of the method claim(s), is of course aware of all the possibilities for realizing products or implementation methods that are customary in the prior art, so that a separate disclosure in the description is not necessary. In particular, these common implementation variants known to the person skilled in the art can be realized exclusively by hardware (components) or exclusively by software (components). Alternatively and / or additionally, the person skilled in the art can, within the scope of their professional competence, choose virtually any combination of hardware (components) and software (components) according to the invention in order to implement the implementation variants according to the invention.

[0029] Figure 1Figure 1 shows an embodiment of a process engineering plant module AM ​​according to the invention. This process engineering plant module enables, in particular, hybrid virtual commissioning, combining a water voyage with a computer-aided simulation of the chemical reaction, temperature changes, mixing of substances, and / or mass transport. For this purpose, the process engineering plant module AM ​​is preferably equipped with an edge device on which the process engineering process can be simulated in parallel with the actual water voyage. Alternatively, the computer-aided simulation can also be performed in the cloud. Thus, for example, not only flow rates but also mass transport, temperature changes, and chemical reactions can be observed and validated during the water voyage.

[0030] The process engineering module AM ​​comprises, in particular, software and hardware components. The process engineering module AM ​​includes a multitude of (hardware) plant components K, such as chemical reactors, which are interconnected via lines or pipes (not shown) to enable mass transfer between the plant components K. The process engineering module AM ​​is thus configured to carry out a process engineering operation and / or a water flow, whereby a property of a first chemical substance CS1 is modified. The process engineering operation can, for example, change a property of the first chemical substance CS1, such as a temperature change, resulting in the output of a modified chemical substance CS1*.

[0031] The process engineering plant module AM ​​further comprises at least one sensor FM, such as a flow meter or a level sensor, a simulation unit SIM, and a control unit PLC. The sensor FM can also be located outside the process engineering plant module AM, for example, in a coupled plant module, or the sensor can simply be coupled to the process engineering plant module AM, with sensor data being provided via an input unit of the process engineering plant module.

[0032] The PLC control unit is, in particular, the physical control unit of the plant module AM; that is, the control unit controls the actuators of the plant components K. The control unit is preferably a programmable logic controller (PLC). In the architecture, the actuator and sensor parameters that control the mass transfer process are preferably directly connected to the actual sensors. The signals, such as concentrations, temperature, etc., preferably originate from the simulation.

[0033] The at least one sensor FM is configured to measure a sensor value of a physical quantity of the first chemical substance CS1, such as flow rate, temperature, density, pressure, etc. The sensor FM can be located, for example, in a plant component, at the inlet and / or outlet of the process plant module AM ​​or a plant component K, or between two plant components K. For example, the sensor is a flow meter FM that detects a flow rate Q of the first chemical substance CS1 in a plant component. Alternatively, the sensor can also be a level sensor that measures the fill level of the first chemical substance CS1 in a plant component K.

[0034] The simulation unit (SIM) includes, in particular, a physical computer / processor. For example, the simulation unit (SIM) can comprise an edge device on which a computer-aided simulation of a chemical reaction, a temperature change, and / or mass transport of the process engineering procedure is performed. Alternatively, the computer-aided simulation can also be carried out in the cloud, with the simulation data being provided to the simulation unit.

[0035] The simulation unit SIM preferably comprises at least one computer-aided simulation model of the process. The simulation unit SIM is configured to simulate parts of the process for at least one second chemical substance CS2 as a function of the flow rate Q detected by the flow sensor FM, using the simulation model, and to output a simulated temperature value T and a simulated mole fraction x of the second chemical substance CS2 as the simulation result. The first chemical substance C1 can differ from or be the same as the second chemical substance CS2. In particular, the simulation can be performed for more than one second chemical substance.

[0036] In one scenario, the commissioning of the process engineering module might involve a different chemical substance, CS1, compared to CS2. CS1 could be a chemically inert substance, such as water or nitrogen. For example, a water test is performed in the plant components K, controlled by the PLC. During this test, CS1 is processed by the plant components instead of CS2, and no chemical reaction occurs. This effectively serves as a functional test of the process engineering module AM. CS2 could be the chemical substance intended for use after commissioning the process engineering module.Using computer-aided simulation of parts of the process, a chemical reaction, a temperature change, and / or the mass transfer of the second chemical substance CS2 (or several second chemical substances) can be simulated in parallel with a real-world water voyage. Control commands from the control unit are taken into account during the simulation. The computer-aided simulation provides a temperature value T and a mass fraction x of the second chemical substance CS2 at a specific time. The simulated temperature value T and mass fraction x are transmitted to the PLC control unit of the AM plant module and considered in the control of the plant module. The PLC control unit controls actuators of the plant components K of the plant module depending on the measured flow rate Q, the simulated temperature value T, and the mass fraction x.In particular, simulated values ​​are used for commissioning instead of the actual values ​​from the water transport process. Thus, the actuator and sensor parameters that control the water transport process are directly linked to the real sensors. Signals such as concentrations, temperature, etc., originate from the simulation model. Data exchange between the simulation unit (SIM) and the PLC control unit can be carried out, for example, via OPC UA. The exchange of the real and simulated sensor values ​​Q, T, x is preferably governed by a predefined sampling rate of the PLC control unit.

[0037] In the second, alternative case, which is not according to the invention, the process engineering module AM ​​can be operated, for example, where the second chemical substance CS2 corresponds to the first chemical substance CS1. Preferably, this is the chemical substance intended for the plant module AM. During operation of the process engineering module AM, at least part of the process can thus be simulated in parallel using a computer. The simulated temperature value T and the simulated mole fraction x of the processed chemical substance can be used for the PLC control of the process engineering plant module AM ​​instead of corresponding, actually measured values. In addition, a simulated flow rate can also be determined by means of the computer simulation and used for the PLC control; that is, the flow sensor can be implemented as a virtual sensor.

[0038] Figure 2shows an exemplary embodiment of a process engineering plant SYS.

[0039] The process plant SYS comprises at least two, preferably a plurality of process plant modules AM1-AM3, as exemplified in Figure 1 The process engineering plant modules AM1-AM3 or their plant components K1-K3 are coupled to each other by lines or pipes (not shown) in order to carry out a process engineering process.

[0040] The process plant SYS further comprises a higher-level control unit POL, also referred to as the orchestration unit / orchestration layer (or Process Orchestration Layer (POL)), which couples the respective control units PLC1-PLC3 of the process plant modules AM1-AM3. This enables coupled control.

[0041] The respective simulation units SIM1-SIM3 of the process plant modules AM1-AM3 are coupled to exchange simulation data. Preferably, the simulation units SIM1-SIM3 are coupled using a co-simulation environment CSIM. Alternatively, the process plant SYS can comprise only one simulation unit.

[0042] In plant modules AM1-AM3, a process engineering operation involving a chemical substance CS1 is carried out. The chemical substance CS1 is processed in the respective plant components K1-K3 of plant modules AM1-AM3. For example, during the commissioning of the process engineering plant SYS, a water test is performed. Parallel to the (real) execution of the process engineering operation or the water test, the process engineering operation of each plant module AM1-AM3 is simulated in the corresponding simulation units SIM1-SIM3. The respective simulation results of the respective plant modules AM1-AM3 are used as input data for the subsequent plant module. For example, a simulated temperature value T1 and a simulated amount of substance value x1, output from the first simulation unit SIM1, are used as input for the second simulation unit SIM2.Accordingly, a simulated temperature value T2 and a simulated amount of substance value x2 as output of the second simulation unit SIM2 are used as input for the third simulation unit SIM3, etc.

[0043] In this way, a process plant consisting of several plant modules AM1-AM3 can be commissioned and operated. The physical connections between the plant modules (water, compressed air, etc.) are interconnected, and the controls are coupled via a process control level (POL). The virtual values ​​of the digital twin of the process, such as substances, temperatures, and, if applicable, densities, are coupled across the plant modules AM1-AM3 using a co-simulation approach. This communication between modules in the co-simulation needs to be less performant than the coupling between the simulation and the process variables in each individual module, since the material transport between modules through pipes is slower than the chemical reactions and their coupling with the automation.

[0044] Figure 3Figure 1 shows an exemplary embodiment of a method for controlling plant components of a process engineering plant module during commissioning of the plant module. The method can be at least partially computer-implemented.

[0045] For example, a water test is carried out to commission the plant module. In the first step S1 of the process, a sensor value of a physical quantity, such as a flow rate or a fill level, of a first chemical substance in a component of the process plant module is recorded. Preferably, the first chemical substance is chemically inert and is used solely for commissioning the process plant module. A property of the first chemical substance is changed in a process taking place in the components of the process plant module; for example, only a temperature change occurs, but no chemical reaction takes place.

[0046] In the second process step S2, a portion of the process engineering process to take place in the plant components is simulated using computer simulation in parallel with the watercraft operation. Consequently, the second process step S2 preferably runs in parallel and in real time with the first process step S1. A chemical reaction, a temperature change, and / or a mass transfer of the process engineering process in at least one part of the plant components is simulated for at least one second chemical substance(s) as a function of the sensor value, and a simulated temperature value and a simulated mole fraction of the second chemical substance are determined. The second chemical substance preferably differs from the first chemical substance and preferably corresponds to the chemical substance with which the process engineering plant module is to be operated after commissioning. The second chemical substance can also be a mixture.

[0047] In the next process step S3, the simulated temperature value and the simulated mole fraction of the second chemical substance(s) are output.

[0048] In the next process step, S4, actuators of the plant components are controlled depending on the simulated temperature value, the simulated mass fraction, and the acquired sensor value. Process steps two through four, S2-S4, can be performed iteratively, whereby control commands for controlling the actuators of the plant components are taken into account during the simulation in process step S2.

[0049] Figure 4 This shows an exemplary embodiment of a method for controlling plant components of a process engineering plant module during operation of the plant module. For this purpose, the actual process engineering process is simulated at least partially by computer in parallel during the operation of the plant.

[0050] In the first process step S1 of the process, a sensor value, such as a flow rate, of a chemical substance is recorded in a component of the process engineering module. The chemical substance is then modified in a process engineering process taking place within the components of the process engineering module.

[0051] In the second process step S2, the process engineering procedure is simulated using a computer in parallel with operation. A chemical reaction, a temperature change, and / or mass transfer of the chemical substance within the process engineering procedure are simulated as a function of the measured sensor value, and a simulated temperature value and a simulated mole fraction of the chemical substance are determined.

[0052] In the next process step S3, the simulated temperature value and the simulated mole fraction of the second chemical substance are output.

[0053] In the next process step S4, actuators of the plant components are controlled depending on the simulated temperature value, the simulated mass fraction and the recorded flow value.

[0054] All described and / or illustrated features can be advantageously combined within the scope of the invention. The invention is not limited to the described embodiments.

Claims

1. Process-engineering plant module (AM) comprising: a. plant components (K) which are configured to carry out a process-engineering process, wherein a property of a first chemical substance (CS1) is changed in the process-engineering process, b. a sensor (FM) which is configured to detect a sensor value of a physical variable of the first chemical substance in a plant component, c. a simulation unit (SIM) which is configured - to simulate a chemical reaction, a temperature change and / or a mass transfer of the process-engineering process for a second chemical substance (CS2) in a computer-aided manner as a function of the sensor value, wherein the first chemical substance (CS1) and the second chemical substance (CS2) are different, and - to output a simulated temperature value (T) and a simulated mole fraction (x) of the second chemical substance (CS2), and d. a control unit (PLC) which is configured to control actuators of the plant components (K) as a function of the simulated temperature value (T), the simulated mole fraction (x) and the detected sensor value (Q).

2. Process-engineering plant module according to claim 1, wherein the first chemical substance (CS1) is chemically inert.

3. Process-engineering plant module according to claim 1 or 2, wherein the sensor (FM) is a flow sensor or a level sensor.

4. Process-engineering plant module according to one of the preceding claims, wherein the sensor (FM) is designed as a virtual sensor and provides a simulated sensor value.

5. Process-engineering plant module according to one of the preceding claims, wherein control commands (CTL) of the control unit (PLC) are taken into account in the computer-aided simulation of the process-engineering process.

6. Process-engineering plant module according to one of the preceding claims, wherein the computer-aided simulation is carried out in real time and parallel to the process-engineering process.

7. Process-engineering plant (SYS) comprising at least two process-engineering plant modules (AM1, AM2, AM3) according to claims 1 to 6 and a higher-level control unit (POL), wherein the respective control units (PLC1, PLC2, PLC3) of the process-engineering plant modules (AM1, AM2, AM3) are coupled to one another by the higher-level control unit (POL) and wherein the respective simulation units (SIM1, SIM2, SIM3) of the process-engineering plant modules (AM1, AM2, AM3) are coupled to one another.

8. Process-engineering plant according to claim 7, wherein the respective simulation units (SIM1, SIM2, SIM3) of the process-engineering plant modules are coupled to one another by means of a co-simulation environment (CSIM) and wherein a first simulated temperature value (T1) output by the first simulation unit (SIM1) and a first simulated mole fraction (x1) are used as input data for the second simulation unit (SIM2).

9. Method for controlling plant components of a process-engineering plant module, having the method steps: a. detection (S1) of a sensor value of a physical variable of a first chemical substance (CS1) in a plant component (K) of the process-engineering plant module (AM), wherein the first chemical substance (CS1) is changed in a process-engineering process running in the plant components of the process-engineering plant module, b. computer-aided simulation (S2) of a chemical reaction, a temperature change and / or a mass transfer of the process-engineering process for a second chemical substance (CS2) as a function of the sensor value (Q), wherein the first chemical substance (CS1) and the second chemical substance (CS2) are different, c. output (S3) of a simulated temperature value and a simulated mole fraction of the second chemical substance, and d. control (S4) of actuators of the plant components as a function of the simulated temperature value, the simulated mole fraction and the detected sensor value.

10. Computer program product, which can be loaded directly into a programmable computer, comprising program code parts which, when the program is executed on a computer, cause it to carry out the steps of the method according to claim 9.