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Integration of Model
Predictive Control and
Optimization of Processes
T. Backx1, O. Bosgra2, W. Marquardt3
June 2000
Contribution to:
IFAC Symposium Advanced Control of Chemical
Processes,
ADCHEM
2000,
Pisa,
Italy,
1416.6.2000.
Published in:
Conference proceedings, 249260.
1
Lehrstuhl fr Prozetechnik
RWTH Aachen, D52056 Aachen
Abstract: This paper discusses changes in the market of chemical processing industries
and its consequences for process operation. The problem of continuously declining
capital productivity is tackled, which has been faced by the chemical processing
industries during the past decades. In the paper a motivation is given on how new
technologies in the area of model predictive control and dynamic process optimization
can contribute to improve business performance of the chemical processing industries in
the changed markets. These new technologies have to support dynamic operation of
plants at intended dynamics. Extensions and changes required to technologies that are
currently applied in the oil refining industries and in some petrochemical industry
applications are discussed. These extensions and changes are necessary to meet the
specific requirements of the chemical processing industries.
Keywords: Process Control, Model Based Control, Industry Automation, Plantwide
Optimization, Chemical Processing Industry, Process Operations, Capital
Productivity, Manufacturing Execution Systems
1.
INTRODUCTION
C pr :=
with:
M
K * Tcycle
Cpr
M
K
Tcycle
(2.1)
C pr =
n Th [(Vh C in ) P F Feq ]
n (Th + Tw ) ( P C in + F + Feq ) Tcycle
n To [(Vw C in ) P F Feq
n (Th + Tw ) ( P C in + F + Feq ) Tcycle
(2.2)
with:
P
F
Feq
Vh
Vw
Cin
Th
Tw
Variable
P
F
Feq
Vh
Vw
Cin
Th
Tw
n
Tcycle
Value
11416
2750
5900
1.41
0.90
0.56
40
8
1-30
n (Th + Tw )
dimension
[kg/hr]
[DM/hr]
[DM/hr]
[DM/kg]
[DM/kg]
[DM/kg]
[hr]
[hr]
[-]
[hr]
1.2
1
l
at
i
p
a
C
n
o
nr
ut
e
R
0.8
0.6
0.4
0.2
10
15
Number of grades
20
25
30
J = z (k + j | k ) ( j ) z (k + j | k ) (3.1)
T
disturbances
manipulated
variables
Objectives/
Operating
constraints
Measured
disturbances
Unit
Process
controlled
variables
Disturbance
Model
j =0
u min u (k ) u max
k
k
u min u (k ) u max
y min y (k ) y max
k
xmin x(k ) xmax
k
(3.2)
Ranges/
setpoints
Controller
Process
Model
Optimization
and
constraint handling
Model Predictive Controller
Process outputs
0.3
+:Statistical
Statisticalcontrolled
controlled
+:
lowbandwidth
bandwidth
*:*:low
largebandwidth
bandwidth
o:o:large
0.2
0.1
+: Statistical controlled
*: low bandwidth
o: large bandwidth
40
amplitude
30
20
10
0
-10
-20
-30
-40
-50
0
0.2
0.4
0.6
0.8
1.2
1.4
1.6
1.8
2
x 10
time (min)
0.05
0.15
0.25
50
0.35
Plant at
steady state?
No
Wait
Yes
Validate measurements
Feed/Product/Utility
values and limits
Storage of
calculated
parameters
and
off-sets
Perform calculation of
slack parameters
Plant constraints
Optimization calculations
Plant at
steady state?
probability
No
Yes
realize the calculated
optimum operating conditions
using the MPC systems
Time-out
DCS
Plant Processes
Operating point
time
M opt ( y, x, u , , f | 0 f f opt )
M MPC ( y, x, u , , f | 0 f f opt )
Market and
Environment
first principles
empirical model components
Model reduction for D-RTO
and for HP/NL-MPC
Updated Model 2
yopt(t)
Data pre-processing
dynamic data
reconciliation and
time scale separation
Model Update
HP/NL- MPC
short time scale
Dynamic RTO
Optimal Trajectory
generation
uopt(t)
Updated Model 1
+
+
Non-linear MPC
d(t)
y(t)
Process including
primary control u(t)
xk +1
y = M MPC (x k , u k , , t | t = t i )
k
(4.2)
A(t i ) B(t i ) xk
C (t ) D(t ) u
i
k
i
An economically successful production can only be
established, if the process can follow changing
market conditions at each point in the supply chain.
Besides adjustments to changes in the market by
adaptation of the operation including closed loop
(feedforward and feedback) model based control and
optimization, the adaptation to changing conditions
must also span the engineering design processes to
modify the plant, its control system, or its operation
strategy.
The EC funded research project INCOOP is
focussing on
fundamental development of
technologies that enable consistent integration of
model based control and model based optimization
for intentionally dynamic operation of plants as part
of a supply chain.
(4.1)
5.
PC
gascap
Catalyst
feed
TC
LC
Reactor
Product
withdrawal
Heat
Exchanger
Cooling
water
Ethylene
Butene
Nitrogen
Hydrogen
CONCLUDING REMARKS