Batch process modelling and simulation

U ovom radu analiziran je šaržni reaktor u proizvodnji farmaceutskog lijeka. Na temelju analize provedeno je matematičko modeliranje i simulacija rada reaktora u svrhu daljnje optimizacije i proučavanja dinamike rada šaržnih reaktora. U teorijskom dijelu rada opisan je šaržni reaktor s osnovnim značajkama. Definirani su osnovni fenomeni prijenosa topline u šaržnim reaktorima. Nadalje, opisan je pristup modeliranja šaržnih reaktora te je izvedena bilanca topline cjelokupnog reaktora. U konačnici su projektirane i ispitane standardne metode vođenja temperature u šaržnim reaktorima. U eksperimentalnom dijelu rada analizirane su dimenzije reaktora neophodne za njegovo modeliranje. Izrađen je energetski model reaktora u odabranome programskom paketu. U svrhu jednostavnije simulacije procesa, napravljen je SCADA sustav (eng. Supervisory Control And Data Acquisition) te je projektirana i testirana kaskadna regulacija temperature u masi reaktora. U završnom koraku simulacijski je ispitan izrađeni model reaktora, bez i s regulacijom, te su ugođeni kaskadni regulacijski krugovi pomoću kojih se vodi glavna vođena varijabla u reaktoru, a to je temperatura. Cilj rada je optimizirati rad šaržnog reaktora radi stabilnosti rada procesa, produktivnosti proizvodnje i kvalitetu proizvoda, manjeg utroška reaktanata i smanjenja neželjenih proizvoda te sigurnosti radnika i postrojenja.In this paper, a batch reactor was analyzed in the manufacture of a pharmaceutical drug. Based on the analysis, mathematical modelling and simulation of reactor operation was carried out in order to further optimize and study the nonlinear dynamics of batch reactors. In the theoretical part of the paper, a batch reactor with basic features is described. Basic heat transfer phenomena were defined in batch reactors. An approach to modeling batch reactors was also described and a reactor model was introduced. Finally, typical temperature control methods are described in batch reactors. In the experimental part of the work, the dimensions of the reactor adequate for its modelling were analyzed. A reactor model was created in the selected program software. For simpler simulation of the process, SCADA was developed and control loops of the existing process were created. In the final step, the reactor model has been simulated, without and with control loops, and the cascade control have been tuned. The aim of the paper is to optimize the operation of the batch reactor for the stability of the process, productivity of production and product quality, lower consumption of reactants and reduction of unwanted products and safety of workers and plants