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WINATION
Desalination 133 (2001) 271-283
ELSEVIER
www.elsevier.com/locate/desal
Abstract
An experimental application of advanced control and optimization on a hollow-fiber membrane module (B-9
Permasep@permeator by DuPont) is presented. The objective of the study was to compare the performance of standard
proportional-integral (PI) control with the performance of a constrained model predictive control (CMPC). A proper
control strategy, whether PI or CMPC, should allow for the manipulation (servo control) of the product flow rate while
maintaining product quality. In doing so, a plant can adjust the production of water to meet demand. Several PI control
experiments involving set point changes in product flow rate and conductivity (a measure of quality) were conducted.
It was found that PI control was unable to properly control the quality of the product by means of manipulating the pH
ofthe feed. The PI controller over-compensated for offset in product conductivity. In contrast, CMPC displayed superior
performance in the control of the pilot plant by holding the process outputs within specified bounds; especially the feed
pH which prevented the conductivity PI control loop from becoming unstable. Furthermore, CMPC was able to
maximize the product flow rate by 13.6% while improving the conductivity (quality) by 1.1%.
Keywords: Constrained model predictive control; Reverse osmosis; Avanced control
1. Introduction
area of research
desalination
on advanced
control
001 l-9164/01/$- See front matter 0 2001 Elsevier Science B.V. All rights reserved
PII:SOOll-9164(01)00107-2
focused
272
2. Overview
of conventional
integral control [4]
proportional-
(1)
+ j&z,
de(t)
dt
3. Overview of constrained
model predictive
control [5]
CMPC is a model-based control strategy that
Y = KpiU+KLL+D
Process
e
-bi-di-KLi 1
(4)
j=l
yi +
sy-viu=yiu
yi+s;-v,L
(5)
= y;
(6)
u
miLs m,s m,
(7)
Unmeasured
Disturbances, D
+
Manipulated
Variables, M
(2)
Load
Dynamics
Measured
Disturbances, L
273
+.
+
+1
Outputs,Y
274
4. Description
and the
control system
275
algorithm discussed in previous sections; however, the sampling time is referred to as scan
time, which is the scanning (sampling) period of
the database.
The CMPC software used in this study is
called ONY..,?? which was developed by
Simulation and Advanced Controls Incorporated.
ONLLW? is an external program that optimizes
the pilot plant in conjunction with the normal
operating management of FIX DMACS.
276
1O?hincrease in
Acid-Inlet Valve Position
Permeate
Flow Rate
(gP@
Pemreate
Conductivity
Wcm)
TransMembrane
RCSSUre
(psia)
Inlet pH
0
100
200
300
25
50
75
100
125
277
Table2
Processdata for PI controltest
Table 1
PI controllertuning constants
Flow
controller
Conductivity
controller
p, s
K,, Yd%
-25.5
25
- 11.475
-1.7
150
21,s
20.83
Ziegler-Nichols:
Ku, %I%
Adjusted:
Kc, o/d%
- 11.475
20.83
?, s
- 0.765
125
- 0.765
65
= 2
i=l
hi k+ 1 -i
(8)
Controlled variables:
Permeateflow rate, gph
Permeateconductivity,
pS/cm
Associatedvariables:
Transmembranepressure
psia
Feed pH
Manipulated variables:
Rejectvalve position
% open
Acid-inletvalve position
% open
Initial
values
Final Set
values point
6.97
483.52
6.50
488.8
126.08
5.4
135.95 2.99
-
49.84
52.32
40.0
60.49
6.5
483.0
278
Permeate
7.5
Conductivity
7'
I
I
-'-480
f!
Permeate
8
5.5
Flow
-470
Rate
I
=
,
I
I
,
-- 460
I
I
450
0
10
15
20
25
30
Tim0
35
40
45
50
55
60
65
(mInutea)
200
180
150
170
%
160
150
140
I
,,
130
0
10
15
20
25
30
tlmo
35
40
45
50
55
-0
60
65
(mlnutrr)
90
80
70
Acid-Inlet
Valve
POeltlOtI
Reject
Valve
Posltlon
80
B
ur
50
40
30
20
-r
IO
15
20
25
30
36
40
45
50
55
60
65
Tlm 0 (m Inutrr)
Fig. 4. Unsatisfactory
PI control.
279
99.0
;ofkedvitH
spiral-wound
thin
composite
membranes
occurred around a pH of 5. Fig. 5 illustrates the
non-linear pH effect.
The PI controller for the permeate conductivity only acts upon the error associated with the
set point and the controlled variable as described
previously by the PI control law. Therefore, the
PI controller continues to open the acid-inlet
value to reduce permeate conductivity when
actually the opposite occurs as seen past the
vertical dashed line in Fig. 4.
Table 3
Process data for the first CMPC test
Initial value
Final value
Weight
Upper limit
Lower limit
7.04
476.1
114.2
5.0
7.01
476.8
111.4
4.5
15
3
1
10
7.05
480
170
6
6.95
470
100
4.5
39.88
40.65
41.81
40.93
15
20
70
50
30
0
Controlled variables:
280
if!
-3
-I
510
Permeate
Flow
500
Rate
490
4 -
450
470
3
2
Permeate
%0
450
Conductlvlty
450
1 --
440
07:::::::::::
0
4
5
12
15
20
24
Tlmr
25
(m
32
35
40
:45
44
430
Inutra)
155
5
145
135
Tranr-Mem
-I:
0
brane
Pressure
::::::::
4
12
20
tlm
24
25
0 (m
32
35
I1
40
44
45
Inutr8)
Acid-Inlet
:l,
::
15
Valve
Poetlon
~ctvalve,Poet,ion,
10
0
5
12
15
20
Tlmr
24
25
32
35
40
44
45
(mlnutrr)
281
Initial value
Final value
Weight
Upper limit
Lower limit
6.05
487.5
92.4
5.48
6.87
482.1
110.7
4.51
15
3
1
10
7.0
505
170
6
5.0
470
90
4.5
51.72
27.15
35.42
45.26
15
20
70
50
35
0
Controlled variables:
282
Permeate
Flow
Rate
500
430
8
430
Prrmerto
Conductivity
470
4eo
450
12
13
Ttm
24
20
23
(m Inutor)
9
120
100
Trans.Mom
brrnr
.- 5
Prrrruro
--
30
30
40
20
I L-=y7y~~q#j
0
12
20
15
tlm
0 (m
24
23
Inutrr)
60
Acid-Inlet
Valve
Potltlon
60
40
30
20
to
0
12
Tim
16
20
24
2.8
32
0 (m Inulor)
283
References
PI I.M. Alitiqi, A.H. Ghabris and S. Ebrahim, Desalination, 75 (1989) 119.
6. Conclusions
The PI control strategy was unable to properly
control the permeate conductivity by means of
adjusting the feed pH. When large deviations in
permeate conductivity resulted from changes in
permeate flow, the PI control loop became
unstable. This occurrence is due to the fact that
the feed pH has a maximum effect at a value of
4.5 at which the chloride ion rejection is at a
maximum.
The CMPC control strategy was implemented
using ONLLV.., by which proper control of the
pilot plant was achieved. By using proper output
weighting, the feed pH was held within bounds at
the point of maximum chloride ion rejection.
Furthermore, the permeate flow rate and
conductivity as well as the transmembrane
pressure were also held within bounds. Finally,
ONLINE was able to maximize the throughput
of the pilot plant by a 13.6% increase in the
permeate flow rate with a 1.1% decrease in the
permeate conductivity, indicating an improvement in quality.