Air separation industry can be considered as the major source provider of oxygen and nitrogen. It is an energy-intensive process that consumes a large amount of electrical energy. So, this study is concerning on doing improvements in both the process design and the process control in order to decrease the specific energy demands of the products. Therefore, a complete steady state simulation model of a heat integrated double distillation column of a cryogenic air separation unit using Aspen Plus software is presented. The simulation model results are compared with typical real process values showing a good agreement with a maximum deviation of 2.6%. Then, an optimization procedure of the main factors of the distillation columns is proposed. This optimization causing the yields of oxygen and nitrogen to increase from 95% to 99.65% and from 90% to 99.9% respectively while the specific energy demand of nitrogen (at 8 bar) is decreased from 0.25 kW/Sm³ to 0.18 kW/Sm³. After that, a sufficient control system is installed on the simulation model by using simple single input single output (SISO) PI controllers. This system links between the controlled and manipulated variables. Also, it includes a novel operation control strategy to give the plant the ability to be operated under different production modes (liquid oxygen, liquid nitrogen, or both) at wide range of partial loads (typically from 100% to 25%). A careful study of tuning of the critical controllers is provided to select the most proper gain (K) and integral time (IT) values which achieve the maximum purities and the desired product quantities in each different case while the specific energy demands of products are within range. Finally, the performance of the plant under 42 different operation cases is presented for 24 h. These cases include different production modes under different partial loads. The results show that the optimized model, with the proposed control system, can be operated under wide range of partial loads during different production modes while the products qualities are in allowable ranges. This availability of working under any part load percentage led to the provision of a large part of the energy consumed.

空气分离工业可被视为氧气和氮气的主要来源。这是一个耗能的过程，消耗大量电能。因此，这项研究涉及在工艺设计和工艺控制方面进行改进，以降低产品的单位能耗。因此，提出了使用Aspen Plus软件的低温空气分离装置热集成双蒸馏塔的完整稳态仿真模型。仿真模型的结果与典型的实际过程值进行比较，显示出良好的一致性，最大偏差为2.6％。然后，提出了蒸馏塔主要因素的优化程序。这种优化导致氧气和氮气的产率从95％增加到99.65％，从90％增加到99。³至0.18 kW / Sm ³。然后，通过使用简单的单输入单输出（SISO）PI控制器在仿真模型上安装足够的控制系统。该系统链接受控变量和受控变量。此外，它还包括一种新颖的操作控制策略，使工厂能够在不同的生产模式（液氧，液氮或两者）下以较宽的部分负荷范围（通常为100％至25％）运行。提供了对关键控制器调优的仔细研究，以选择最合适的增益（K）和积分时间（IT）值，从而在每种产品的特定能量需求均在此范围内的情况下，实现最大纯度和所需产品数量范围。最后，介绍了该工厂在42个不同操作情况下的性能24小时。这些情况包括在不同的部分负荷下的不同生产模式。结果表明，采用所提出的控制系统，在产品质量处于允许范围内的同时，可以在不同的生产模式下，在较大的部分负荷范围内运行优化模型。在任何部分负载百分比下均可工作的这种可用性导致提供了很大一部分能耗。