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Article history: Challenges in real-time process optimization mainly arise from the inability to build and adapt accurate
Received 13 October 2008 models for complex physico-chemical processes. This paper surveys different ways of using measure-
Received in revised form 23 February 2009 ments to compensate for model uncertainty in the context of process optimization. Three approaches
Accepted 28 April 2009
can be distinguished according to the quantities that are adapted: model-parameter adaptation updates
Available online 9 May 2009
the parameters of the process model and repeats the optimization, modier adaptation modies the
constraints and gradients of the optimization problem and repeats the optimization, while direct input
Keywords:
adaptation turns the optimization problem into a feedback control problem and implements optimality
Measurement-based optimization
Real-time optimization
via tracking of appropriate controlled variables. This paper argues in favor of modier adaptation, since it
Batch-to-batch optimization uses a model parameterization and an update criterion that are well tailored to meeting the KKT condi-
Plantmodel mismatch tions of optimality. These considerations are illustrated with the real-time optimization of a semi-batch
Model adaptation reactor system.
Model parameterization 2009 Elsevier Ltd. All rights reserved.
0098-1354/$ see front matter 2009 Elsevier Ltd. All rights reserved.
doi:10.1016/j.compchemeng.2009.04.014
1558 B. Chachuat et al. / Computers and Chemical Engineering 33 (2009) 15571567
design (Francois et al., 2005; Skogestad, 2000; Srinivasan, Primus, p and , the KKT conditions also known as the rst-order nec-
Bonvin, & Ricker, 2001). essary conditions of optimality (NCO) must hold at such optimal
These approaches are reviewed in the rst part of the paper. points (Bazaraa, Sherali, & Shetty, 1993). For Problem (3), the KKT
A critical discussion follows, which argues in favor of modier- conditions read:
adaptation methods. It is shown that the modier-adaptation
Gk ( , ) 0, k 0, k = 1, . . . , ng ,
methods do indeed share the advantages of the other methods, i.e.,
in converging to a KKT point for the plant and also in exhibiting fast G ng
k Gk ( , ) = 0, k = 1, . . . , ng .
2. Static optimization problem
where Rng is the vector of KKT multipliers. The KKT conditions
For continuous processes operating at steady-state, optimiza- involve the quantities G1 , . . . , Gng , G1 /, . . . , Gng /, /,
tion typically consists in determining the operating point that which are denoted collectively by the vector C RnC subsequently,
optimizes process performance such as minimization of operating with nC := ng + n (ng + 1).
cost or maximization of production rate, while satisfying a num- The rst step in satisfying the NCO for a given problem consists in
ber of constraints (such as bounds on process variables or product determining the active set. This discrete decision can be taken based
specications). In mathematical terms, this optimization problem on the sign of the KKT multipliers. Once the active set represented
can be stated as follows: by Ga is known, the multipliers can be eliminated from (4), thereby
leading to two sets of conditions:
minimize : p () := (, yp ) +
(1) Ga Ga
subject to : Gp () := g(, yp ) 0 a
G = 0, r := I = 0. (5)
where Rnand yp Rny
stand for the process input (set point)
and output vectors, respectively; : Rn Rny R is the plant The former guarantees that the active constraints are met,
performance index; and g : Rn Rny Rng is the vector of con- whereas the latter forces the reduced gradient to 0. In real-time
straints imposed on the input and output variables. It is assumed, optimization, these two sets of conditions can be treated using quite
throughout this paper, that and g are known and the output different techniques. This important aspect will be discussed in the
variables yp can be either measured or estimated. next section.
In contrast to continuous processes, the optimization of batch
and semi-batch processes consists in determining time-varying 3. Classication of real-time optimization schemes
control proles, u(t). This typically involves solving a dynamic opti-
mization problem, possibly with path and terminal constraints. A RTO improves process performance iteratively by adjusting
practical way of solving such problems is by parameterizing the selected optimization variables using measurement data. The goal
control proles using a nite number of parameters , e.g., a poly- of this closed-loop adaptation is to drive the operating point
nomial approximation of u(t) on nite elements. Although the towards the actual plant optimum in spite of inevitable structural
process is dynamic in nature, a static map can then be used to and parametric model mismatch. RTO methods can be classied in
describe the relationship between the process inputs and the different ways. This paper proposes a classication based on the
outcome of the batch yp . Hence, the problem can be regarded as type and the objective of such adaptation.
a nite-dimensional static optimization problem similar to (1), The three columns in Fig. 1 differ in the way the adaptation
and the optimization approaches discussed in the following sec- is conducted. In model-parameter adaptation methods, a rst-
tions can also be used in the framework of run-to-run optimization principles model is used, the parameters of which are updated
of batch and semi-batch processes (Francois et al., 2005). The based on measurement data; in turn, the updated model is used to
approach will be illustrated in Section 5. compute the optimal inputs. The middle column corresponds to the
In practice, the mapping relating the process inputs and outputs update of so-called modiers, which capture the difference between
is typically unknown, and only an approximate model is available, the NCO predicted by the model and those of the plant; that is, a
e.g., in the form: rst-principles model is used for prediction, but its parameters are
not adapted. In the third column, nally, the inputs are adapted
y = f (, ), (2) directly via tracking of an appropriate set of controlled variables.
The rows of the classication in Fig. 1, on the other hand, cor-
with y Rny
representing the model outputs, Rn
the model
respond to the two NCO parts discussed in Section 2, namely the
parameters, and f : Rn Rn Rny the input-output mapping.
active constraints and the reduced gradient. The former relates to
Accordingly, an approximate solution of Problem (1) is obtained
the problem of feasibility, while the latter relates to the issue of opti-
by solving the following model-based optimization problem:
mality. In practical applications, guaranteeing feasible operation is
minimize: (, ) := (, f (, )) typically of higher importance than achieving the best possible per-
(3) formance. Interestingly, the results of a variational analysis in the
subject to : G(, ) := g(, f (, )) 0.
presence of small parametric error support the priority given to
This formulation assumes that the functions and g are known constraint satisfaction over the gradient part of the NCO (Chachuat
and independent of the model parameters ; the dependency in et al., 2008).
of these functions is implicit via the model outputs y.
If the objective and constraint functions in (1) and (3) are contin- 3.1. Model-parameter adaptation
uous and the feasible domains of these problems are nonempty and
bounded, (globally) optimal solution points p and are guaran- The standard way of implementing RTO is via the so-called two-
teed to exist for (1) and (3), respectively. Note that there may also step approach (Chen & Joseph, 1987; Marlin & Hrymak, 1997), also
be multiple local optima to these problems due to nonconvexity. referred to as repeated identication and optimization in the litera-
Provided that the active constraints satisfy a regularity condition at ture. In the rst step, the values of (a subset of) the adjustable model
B. Chachuat et al. / Computers and Chemical Engineering 33 (2009) 15571567 1559
Fig. 1. Classication of real-time optimization approaches based on adaptation strategy, feasibility and optimality.
parameters are estimated using the process output measurements eter estimates, and the lower the required excitation. But too few
yp . This is typically done by minimizing the lack of closure in the adjustable parameters can lead to completely erroneous models,
steady-state model Eq. (2). In the second step, the updated model is and therefore to a false optimum. The question of how plant exper-
used to determine a new operating point by solving an optimization iments should be designed to contain sufcient information has
problem such as (3). been addressed, e.g., by Yip and Marlin (2003).
Model-parameter adaptation schemes can be written generi- It is well known that the interaction between the model-
cally using the following two equations (see Fig. 2): parameter adaptation and reoptimization steps must be considered
carefully for the two-step approach to achieve optimality. If the
k = ad (yp (k ), k ), (6)
model is structurally correct and the parameters practically iden-
k+1 = opt ( k ) (7) tiable, convergence to the plant optimum can be achieved in
one iteration. However, in the presence of plant/model mis-
where ad : Rny Rn
Rn
is the map describing model- match, whether the scheme converges, or to which point it
parameter adaptation; and opt : Rn Rn , the map describing converges, becomes anybodys guess. This is due to the fact that
the optimization step. Note that the handles for correction, i.e., the the adaptation objective might be unrelated to the cost and
adjustable model parameters , are a subset of the model parame- constraints in the optimization problem; hence, minimizing the
ters. A possible adaptation strategy is to minimize the weighted sum mean-square error in y may not help in our quest for feasibility and
of squared errors between the measured and predicted outputs, optimality.
Model exibility is a critical issue with model-parameter adapta-
k = argminyp (k ) f(k , ).
tion methods. As far as feasibility is concerned, the selected model
parameterization should permit sufcient exibility for the mea-
In practice, the results of both the identication and optimiza-
sured and predicted constraint values to match. Since the constraint
tion steps clearly need to be diagnosed before implementation; for
expressions g are independent of , this latter requirement is auto-
example, Miletic and Marlin (1998) have proposed to implement
matically enforced via output matching, i.e., y = yp . In the case
only signicant changes from current operation in the sense of a
of ny independent outputs, a necessary condition for feasibility
statistical test.
is therefore that the number of adjustable parameters be greater
A key, yet difcult, decision in model-parameter adaptation is
than the number of outputs, n ny . In terms of optimality, the
to select the parameters to be adapted. These parameters should
selected model parameterization should permit sufcient exi-
be identiable, represent actual changes in the process, and con-
bility for component-wise matching of C and Cp . To achieve this,
tribute to approach the process optimum; also, model adequacy
matching of y and yp alone is no longer sufcient, and it must
proves to be a useful criterion to select candidate parameters for
be complemented with matching of the output derivatives, i.e.,
adaptation (Forbes, Marlin, & MacGregor, 1994). Clearly, the smaller
y/ = yp /. Provided that all the outputs and output deriva-
the subset of parameters, the better the condence in the param-
tives are independent, a model parameterization with at least
ny (n + 1) degrees of freedom is then necessary to achieve optimal-
ity. With such a parameterization, it would also become possible to
modify the identication map ad in (6), e.g., as the minimization
of the weighted sum of squared errors between Cp and C, thereby
explicitly enforcing KKT matching.
Convergence under plantmodel mismatch has been addressed
by several authors (Biegler, Grossmann, & Westerberg, 1985; Forbes
et al., 1994). It has been shown that optimal operation is reached if
model adaptation leads to matched KKT conditions for the model
Fig. 2. Optimization via model-parameter adaptation: two-step approach. and the plant.
1560 B. Chachuat et al. / Computers and Chemical Engineering 33 (2009) 15571567
Table 1
Comparison of various adaptation strategies for real-time optimization.
Fig. 5. Optimal operation in Problem A for two different control parameterizations. Dash-dotted line: CVP with 100 constant-length control stages. Solid line: CVP with 3
variable-length control stages.
thus indicating that this latter parameterization yields an adequate , yet an important optimality gap persists. In particular, the
approximation. leftmost plot indicates that the adapted control prole remain
Solving the discretized optimal control problem using the plant signicantly different from the optimal prole, especially the con-
model (i.e., with k3 = k4 = 0) gives the same optimal solution struc- trol value Fs . The difculty in this case is linked to the fact that
ture (3 arcs, 2 active terminal constraints). Open-loop application of the model parameters do not permit sufcient exibility for
this solution, although feasible, yields a much worse performance the model to match the experimental measurements; in particu-
A 0.3874 mol compared to J A 0.5079 mol.
Jol opt lar, we have n = 2 < ny = 3 here. A way to circumvent this lack
The use of various real-time optimization techniques to reduce of exibility would be, e.g., to add a ctitious reaction to the
this large optimality gap is investigated next. Both terminal con- plant model and estimate the additional kinetic coefcient so that
straints being active in the optimal solution, only constraint n = ny = 3. Another way to guarantee feasibility upon conver-
satisfaction schemes are considered, i.e., without cost and con- gence would be to not take the measurement of cC into account
straint gradient correction. It is assumed that measurements for in the estimation problem (25) so as to force the condition Ga = Gap
the reactor volume and the concentrations of species B, C and D (see Table 1).
are available at the end of the batch. Moreover, a 5% zero-mean Modier adaptation The optimization problem (24) is modi-
Gaussian multiplicative noise is added to the concentration mea- ed by introducing the constraint-value modiers B and D , while
surements, in response to which a 10% back-off is dened for the the cost and constraint gradients remain uncorrected. In the k th
terminal constraints in the optimization problem. RTO execution, the updated control variables k are determined by
Model-parameter adaptation The adjustable model parame- solving the optimization problem:
ters correspond to the kinetic coefcients of the rst two reactions,
:= (k1 , k2 ). At the end of the k th RTO execution, their values are max cC (tf )V (tf ) (26)
updated by minimizing a weighted sum of squared errors between tm ,Fs ,ts
1564 B. Chachuat et al. / Computers and Chemical Engineering 33 (2009) 15571567
Fig. 6. Application of real-time optimization to Problem A. Upper plots: model-parameter adaptation. Middle plots: modier adaptation. Lower plots: direct input adaptation.
and (ii) the fact that the cost and constraint gradients have not been using the relative gain array (RGA) technique (Ogunnaike & Ray,
B. Chachuat et al. / Computers and Chemical Engineering 33 (2009) 15571567 1565
Fig. 7. Optimal operation in Problem B for two different control parameterizations. Dash-dotted line: CVP with 100 constant-length control stages. Solid line: CVP with 2
variable-length control stages.
1994), that two independent control loops can be devised by pair- B 0.2135 mol, i.e., not too far from the
the open-loop solution is Jol
ing cp,B (tf ) cBmax with ts , and cp,D (tf ) cD
max with F . Simple discrete
s B
plant optimum Jopt 0.2179 mol.
integral controllers are then used for each loop, Various real-time optimization techniques are investigated next
to reduce this small optimality gap. Because the solution is uncon-
ts,k ts,k1 ts cp,B (tf ) cBmax
= max , strained, the emphasis is on gradient-correction schemes. The
Fs,k Fs,k1 Fs cp,D (tf ) cD
=k1 same measurements as in Problem A are considered. In addi-
tion, estimates of the cost derivatives with respect to the control
with the controller parameters ts [L min mol1 ] and Fs parameters Fs and ts are calculated numerically for each batch and
[L2 min1 mol1 ]. adding a 10% zero-mean Gaussian multiplicative noise to these
The results of direct input adaptation are given in the lower values.
row of Fig. 6, for two different controller settings, starting from the Model-parameter adaptation The values of the adjustable
nominal values of the control variables. Observe that the perfor- model parameters k1 and k2 are updated in a similar way as pre-
mance and adaptation speed of direct input adaptation are similar viously in Problem A. The results for this adaptation scheme, with
to those of modier adaptation. Moreover, on-line complexity is = 1.0 and 0.5, are shown in the upper row of Fig. 8. Quite unex-
greatly reduced in this approach compared to the other schemes. pectedly, model-parameter adaptation in this case results in a loss
of performance (JparB 0.198 mol) compared to the open-loop nom-
Fig. 8. Application of real-time optimization to Problem B. Upper plots: model-parameter adaptation. Middle plots: modier adaptation. Lower plots: direct input adaptation.
The actual plant optimum is represented by the symbol
on the right plots.
The results for modier adaptation, with the initial modier val- are used,
ues 0 = (0 0)T , are shown in the middle row of Fig. 8 for the
lter parameters = 0.5 and 0.2. This scheme converges quickly
to the actual plant optimum. Since no terminal constraint is active, ts,k ts,k1 ts p /ts
the residual optimality gap results from the effect of measurement = ,
Fs,k Fs,k1 Fs p /Fs
noise only. The experimental gradient estimates being corrupted =k1
with large amounts of noise, the use of a small value of the lter
parameter produces better results in this case.
Direct input adaptation The optimal solution of Problem (27) with the controller parameters ts [min2 mol1 ] and Fs
being unconstrained, the available degrees of freedom can be used [L2 min2 mol1 ].
to force the cost gradient to zero. The resulting 2 2 control prob- The results of direct input adaptation are given in the lower row
lem has the manipulated variables (Fs , ts ), the controlled variables of Fig. 8, for two different controller settings. To limit the amount of
(p /Fs , p /ts ) and the set-points (0,0). The control map is interaction between the control loops, the controller Fs p /Fs
found to be scale-independent and diagonally dominant via RGA is tuned to proceed at a faster rate than the controller ts p /ts .
analysis, which leads to the natural pairing of p /Fs with Fs and The convergence of this direct input-adaptation scheme appears to
of p /ts with ts ; yet, some amount of interaction is also detected be rather slow, even though the iterates eventually reach a neigh-
between the two control loops. Simple discrete integral controllers borhood of the actual plant optimum.
B. Chachuat et al. / Computers and Chemical Engineering 33 (2009) 15571567 1567
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