AUTOMATED CONTROL OF THE HIGH-TEMPERATURE PROCESS OF ACETYLENE PRODUCTION FROM METHANE

Abstract

Purpose. A comprehensive study and improvement of automatic control systems for the acetylene production process via oxidative pyrolysis of methane. The work is aimed at solving the problem of stabilizing the yield of the target product under high-temperature synthesis conditions while minimizing energy consumption and ensuring maximum production safety.

Methodology. The research is based on a системatic analysis of the technological process as an automation object. Methods of mathematical modeling of chemical engineering systems (CES) were applied, including the development of static and dynamic characteristics of the reaction unit. Classical controller tuning methods (Ziegler–Nichols, M-circle) were used to optimize control parameters in combination with modern automatic tuning software tools (PID Tuner). The software implementation was carried out using an object-oriented approach to create a visual simulation environment.

Results. The kinetic features of oxidative pyrolysis were described in detail; a multi-criteria mathematical model of the reactor was developed, taking into account the influence of temperature and reactant ratio (oxygen/methane). Accurate models of the system’s static and dynamic operating modes were created. A software product was developed that enables simulation of transient processes in the reactor, while integrated controllers ensure the stability of key parameters (temperature, pressure, and reactant composition), which are critical for achieving the desired product yield.

Scientific novelty. A comprehensive approach to modeling methane oxidative pyrolysis is proposed, combining analytical reactor models with modern methods of control system synthesis. A dedicated visual software interface for modeling systems with chemical reactors of this type was developed and implemented, enabling prompt response to technological process anomalies.

Practical significance. The analysis of the obtained results demonstrated that the modeling methods proposed in this study can be applied in industrial production, increasing raw material (methane) utilization efficiency, reducing costs, and ensuring a high level of safety through automatic prevention of emergency situations. The results contribute to the environmental sustainability and economic stability of chemical enterprises.