pH Process Modeling and Control Simulation in Industry 4.0.

CyboSoft has released a Real-Time pH Process Modeling and Control Simulation Software package. It is the first in CyboSoft's virtual plant software family to help engineers learn how a pH process behaves, and how to effectively control this extremely nonlinear process to comply with EPA wastewater discharge codes and save chemical reagent.

CEO Dr. George Cheng said, "We are entering the era of the 4th Industrial Revolution, where everything is supposed to be 'smart'. Ironically, about 90% industrial wastewater pH processes are still controlled by on-off Bang-Bang control, resulting in chemical reagent wastes, equipment corrosion, and environmental pollution. It is our mission to provide software tools and control solutions to help the industry improve control systems and achieve better safety, higher quality, and lower costs."

The Real-Time pH Process Modeling and Control Simulation Software is built in National Instruments' LabVIEW platform and includes:

(1) pH process diagram,
(2) a strong-acid-strong-base pH model,
(3) a weak-acid-strong-base pH model,
(4) a strong-acid-weak-base pH model,
(5) a weak-acid-weak-base pH model,
(6) MFA control simulation for the 4 pH processes using an MFA pH controller,
(7) PID control simulation for the 4 pH processes,
(8) On-Off control simulation for the 4 pH processes,
(9) graphical interface with control faceplates and real-time trends,
(10) LabVIEW diagrams, and
(11) pH process model description, MFA controllers used, and recommended control strategy.

"Most process models are presented as mathematical equations or formulas, which are important but have limited usage. A real-time process model can be used as a virtual process to simulate a real process with minimal setup time and cost. Using a virtual plant software tool to solve real problems is a powerful and cost-effective way to help build a Smart Industry," Dr. Cheng added.

CyboSoft's pH process models are delivered as VIs (virtual instruments) in LabVIEW. The user can design and test their pH control systems using the pH process models running in real-time. For instance, a pH process model can run in a PC with real-time interface to a popular pH controller on the market or to an existing pH controller in service. The control results can be compared with the MFA pH control results obtained in MFA control simulations. The user can then take the results, estimate the chemical reagent savings, and show the potential return-on-investment (ROI) when applying for budget to buy the proper pH controller or control software to improve pH control performance.

CyboSoft will release a number of real-time process modeling and control simulation software products in its virtual plant software family that can be purchased from CyboSoft's online store. The pH Process Modeling and Control Simulation Software can also be purchased from National Instruments' Tools Network store, where a 30-day trial version is available. Customers can contact CyboSoft for various MFA control products or for consulting and engineering services. The pH control device vendors can contact CyboSoft for embedding MFA pH control software in their devices.

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Flare process control.

CyboSoft has developed a flare process control solution that can effectively control the flare vent gas heating value to meet EPA regulations. An MFA flare control system has been running in a plant for 1.5 years and achieved substantial economic benefits for the customer.

EPA is ramping up its enforcement actions to investigate illegal air emissions by industrial flares. Since EPA will want to see the flare net heating value data from the previous 5 years when they issue a Clean Air Act (CAA) section 114 letter, it is very important for all flare operators to install a real-time heating value sensor and control system to comply with the limits and save records.

CyboSoft CEO Dr. George Cheng said, "We have the technology, products, and experience in flare control and want to help the industry effectively control this complex and difficult process."

Most refinery and chemical plants operate flares to burn off waste gas for operational and safety reasons. The vent gas heating value of a flare must be monitored and controlled based on EPA 40CFR60.18 rules. For steam-assisted or air-assisted flares, the net heating value of the gas being combusted must be 300 Btu/scf or greater. When the waste gas heating value is below this limit, supplemental gas such as natural gas must be added to assure sufficient combustion and minimal emission. The MFA control system diagram illustrates a flare process and its key variables.

There are online calorimeters on the market that can determine the heating value or Wobbe-index of a gas in real-time. However, adding a heating value (HV) control loop can be a challenging task due to the following reasons: (1) There are large and varying time delays in the HV control loop; (2) The HV process is nonlinear in different operating conditions; (3) Multiple waste gas streams in a plant are sent to the flare stack, where stream flows can vary widely causing big disturbances to the heating value; (4) The HV of each waste gas stream may change widely under operating condition changes; and (5) Nitrogen is often used as purge gas to keep positive pressure in the vent pipe, making the process more complex.

"The flare process is difficult to control using conventional PID controllers. On the other hand, model-based control can be costly to develop and maintain. CyboSoft's Model-Free Adaptive (MFA) control methods and products are well suited for this application and we are confident to say that it is the most cost-effective and robust control solution for flare processes," Dr. Cheng added.

• See the case study Model-Free Adaptive Control of Flare Heating Value Process here.

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