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Ask Greg McMillan - What role do you see dynamic simulation playing in the future of best distillation column temperature controller tuning? automation test systems greg mcmillan multi-purpose dynamic simulation Mar 19, 2025

We ask Greg:

What role do you see dynamic simulation playing in the future of best distillation column temperature controller tuning?

Greg's Response:

Dynamic simulations running faster than real time are key to ensuring the best column temperature controller tuning. Except for high purity

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Ask Russ Rhinehart - How does one Test Dynamic Models? automation test systems multi-purpose dynamic simulation russ rhinehart Mar 14, 2025

 

We ask Russ:

How does one Test Dynamic Models?

Russ' Response:

Test means to review the model predictions (output values) with both data and logical expectations.  If your model outputs adequately match the process data and expectations over a wide range of operating conditions, then you

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Ask Greg McMillan - What role do you see dynamic simulation playing in the future of best distillation column temperature control strategy? automation test systems greg mcmillan multi-purpose dynamic simulation Mar 12, 2025

We ask Greg:

What role do you see dynamic simulation playing in the future of best distillation column temperature control strategy?

Greg's Response:

Dynamic simulations running faster than real time are key to ensuring the best column temperature control strategy. The manipulation of separ

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Ask Russ Rhinehart - How does one develop First-Principles Dynamic Models numerically? automation test systems multi-purpose dynamic simulation russ rhinehart Mar 07, 2025

We ask Russ:

How does one develop First-Principles Dynamic Models numerically?

Russ' Response:

Here are eight steps in developing a dynamic model. Details and examples can be accessed under the Modeling/Simulation menu on my web site, www.r3eda.com.

  1. Inventory - Decide the inventory that
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Ask Greg McMillan - What role do you see dynamic simulation playing in the future of best distillation column pressure control? automation test systems greg mcmillan multi-purpose dynamic simulation Mar 06, 2025

We ask Greg:

What role do you see dynamic simulation playing in the future of best distillation column pressure control?

Greg's Response:

Dynamic simulations can be help ensure distillation column pressure does not cause instability from operation at the weep point or flood point. The opera

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Ask Russ Rhinehart - What are the pros for first-principles models? automation test systems multi-purpose dynamic simulation russ rhinehart Feb 28, 2025

We ask Russ:

What are the pros for first-principles models?

Russ' Response:

Earlier I shared that I typically classify models as empirical or phenomenological.

In phenomenological models, the mathematical functions are grounded in a mechanistic relation. These models could be termed rigoro

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Ask Greg McMillan - What role do you see dynamic simulation playing in the future of best crystallizer temperature control? automation test systems greg mcmillan multi-purpose dynamic simulation Feb 26, 2025

We ask Greg:

What role do you see dynamic simulation playing in the future of best crystallizer temperature control?

Greg's Response:

Batch-operated stirred cooling crystallizers are the most common type in the industry, but they tend to yield poor quality, primarily due to the high cooling

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Ask Russ Rhinehart - What are the pros for empirical models? automation test systems multi-purpose dynamic simulation russ rhinehart Feb 13, 2025

We ask Russ:

What are the pros for empirical models?

Russ' Response:

I would broadly classify models as empirical or phenomenological.  

Empirical models are developed by matching flexible mathematical functions to data.  The functions might be neural networks, or classic statistical power

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Ask Greg McMillan - What role do you see dynamic simulation playing in the future of best dryer temperature control? automation test systems greg mcmillan multi-purpose dynamic simulation Feb 09, 2025

We ask Greg:

What role do you see dynamic simulation playing in the future of best dryer temperature control?

Greg's Response:

The basic loop arrangement for dryer temperature control would use cascade control of outlet temperature to set inlet temperature. However, a constant outlet temper

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Ask Julie Smith - How has simulation contributed to operator training and control strategy development in your organization? automation test systems julie smith multi-purpose dynamic simulation Feb 09, 2025

We ask Julie:

How has simulation contributed to operator training and control strategy development in your organization?

Julie's Response:

Many years ago, one site had an incident where an interruption in the flow of an organic fuel led to a deflagration. As a result, the operators always r

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Ask Russ Rhinehart - Why use phenomenological models based on first principles over data-based modeling options? automation test systems multi-purpose dynamic simulation russ rhinehart Jan 29, 2025

We ask Russ:

Why use phenomenological models based on first principles over data-based modeling options?

Russ' Response:

I would broadly classify models as empirical or phenomenological.

Empirical models are developed by matching flexible mathematical functions to data.  The functions migh

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Ask Greg McMillan - What role do you see dynamic simulation playing in the future of best kiln and calciner temperature control? automation test systems greg mcmillan multi-purpose dynamic simulation Jan 12, 2025

We ask Greg:

What role do you see dynamic simulation playing in the future of best kiln and calciner temperature control?

Greg's Response:

In kilns and calciners, there are typically four zones. First is a drying zone of constant temperature, followed by a heating zone of rising temperature

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Ask Julie Smith - What strategies have you found effective for starting small, low-risk simulation projects to build credibility and trust? automation test systems julie smith multi-purpose dynamic simulation Jan 02, 2025

We ask Julie:

What strategies have you found effective for starting small, low-risk simulation projects to build credibility and trust?

Julie's Response:

Back in 2019, the new DuPont was formed after the merger and split with Dow. Many sites were struggling to continue their migration proje

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Ask Greg McMillan - What role do you see dynamic simulation playing in the future of best vessel temperature control? automation test systems greg mcmillan multi-purpose dynamic simulation Dec 16, 2024

We ask Greg:

What role do you see dynamic simulation playing in the future of best vessel temperature control?

Greg's Response:

A vessel is defined here as storage, recycle, blend, or surge volume where there is no heat of reaction and no agitator. Fortunately, most vessel volumes are so la

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Ask Greg McMillan - What role do you see dynamic simulation playing in the future of best heat exchanger temperature control? automation test systems greg mcmillan multi-purpose dynamic simulation Dec 04, 2024

We ask Greg:

What role do you see dynamic simulation playing in the future of best heat exchanger temperature control?

Greg's Response:

Flows much lower than design causes a high process gain and high process deadtime that can lead to temperature oscillations and possible instability. Low v

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Ask Russ Rhinehart - What are some of the benefits of dynamic simulation over steady state simulation? automation test systems multi-purpose dynamic simulation russ rhinehart Dec 04, 2024

We ask Russ:

What are some of the benefits of dynamic simulation over steady state simulation?

Russ' Response:

Traditionally, process design uses steady state (SS) simulation, and it serves its purpose well.  Most analysis of processes and textbook instruction on how processes work use SS r

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Ask Greg McMillan - What role do you see dynamic simulation playing in the future of best temperature measurement installation? automation test systems greg mcmillan multi-purpose dynamic simulation Nov 18, 2024

We ask Greg:

What role do you see dynamic simulation playing in the future of best temperature measurement installation?

Greg's Response:

Temperature RTD sensors should use 4 wires and TC sensors should use extension wires of same material as sensor with length as short as possible to minim

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Ask Greg McMillan - What role do you see dynamic simulation playing in the future of best temperature measurement selection? automation test systems greg mcmillan multi-purpose dynamic simulation Nov 07, 2024

We ask Greg:

What role do you see dynamic simulation playing in the future of best temperature measurement selection?

Greg's Response:

Temperature is often the most important of the common measurements because it is an indicator of process stream composition and product quality. Temperature

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Ask Greg McMillan - What role do you see dynamic simulation playing in the future of best lime system design for pH control? automation test systems greg mcmillan multi-purpose dynamic simulation Oct 22, 2024

We ask Greg:

What role do you see dynamic simulation playing in the future of best lime system design for pH control?

Greg's Response:

Lime feeders have a transportation delay that is proportional to the length of the feeder divided by its speed. This transportation delay may be several min

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Ask Greg McMillan - What role do you see dynamic simulation playing in the future of best liquid reagent dilution for pH control? automation test systems greg mcmillan multi-purpose dynamic simulation Oct 02, 2024

We ask Greg:

What role do you see dynamic simulation playing in the future of best liquid reagent dilution for pH control?

Greg's Response:

A common misconception is that the slope of the titration curve and, therefore, the system sensitivity can be decreased by reagent dilution. Reagent di

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Ask Greg McMillan - What role do you see dynamic simulation playing in the future of best liquid reagent delivery for pH control? automation test systems greg mcmillan multi-purpose dynamic simulation Sep 25, 2024

We ask Greg:

What role do you see dynamic simulation playing in the future of best liquid reagent delivery for pH control?

Greg's Response:

If the reagent pipeline is partially filled or empty or a dip tube is backfilled with process fluid, the regent delivery delay becomes the biggest sour

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Ask Greg McMillan - What role do you see dynamic simulation playing in the future of best reagent selection for pH control? automation test systems greg mcmillan multi-purpose dynamic simulation Sep 18, 2024

We ask Greg:

What role do you see dynamic simulation playing in the future of best reagent selection for pH control?

Greg's Response:

For a reagent dose to be precise enough, the reagent’s logarithmic acid dissociation constant (pKa) should be close to the pH set point so that it tends to f

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Ask Greg McMillan - What role do you see dynamic simulation playing in the future of best control valve deign for pH control? automation test systems greg mcmillan multi-purpose dynamic simulation Sep 10, 2024

We ask Greg:

What role do you see dynamic simulation playing in the future of best control valve deign for pH control?

Greg's Response:

Stick and slip generally occur together and have a common cause of friction in the actuator design, stem packing, and seating surfaces. Rotary valves with

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Ask Greg McMillan - What role do you see dynamic simulation playing in the future of best static mixer use for pH control? automation test systems greg mcmillan multi-purpose dynamic simulation Sep 02, 2024

We ask Greg:

What role do you see dynamic simulation playing in the future of best static mixer use for pH control?

Greg's Response:

Static mixer have noisy pH measurements. Signal filtering can help but a downstream volume is needed to provide smoothing of pH oscillations that can be large

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