Low-Cost and Efficient Solution for the Automation of Laboratory Scale Experiments: The Case of Distillation Column

Abstract

Chemical laboratories badly need efficient support for human works when experiments are carried out. Process control and data acquisition at the laboratory scale are still practical challenges among others, due to equipment prices and the relative complexity of the different scientific disciplines. There is, however, a large demand recently for the so-called Internet of Things (IoT), intelligent/smart labeled solutions that also include laboratory equipment items. Such solutions have enormous potential in making research activity and routine laboratory work efficient and easy by implementing proper data acquisition and control for laboratory-scale equipment items. To solve these practical challenges, an efficient and simple solution was designed and completed for the control and data acquisition of a laboratory-scale rectification process by a well-known microcontroller connected to MATLAB/Simulink. The straightforward application of this solution is demonstrated in case study measurements. The data acquired were used also for process identification. The data were then further processed for various simple and more advanced tunings that were applied, evaluated, and compared. By implementing gain scheduling, significant improvements can be achieved compared to model-based PID tunings while the application of self-tuning by adaptive interaction demands too much consideration for better evaluation with low benefit. Furthermore, the developed device introduces the advantages of digitalization and the 4.0 industrial revolution in the laboratory as well as supports human laboratory work. It also narrows the gap between the laboratory and industrial environment items since the final design can provide a complete process control experience already at the laboratory scale.