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Outline
Introduction
Economic Plantwide Control
Case study - RSR process
Conclusions and future work
Introduction
Most industrial process control strategies are not
designed to optimally handle frequent market
conditions changes.
Introduction
Most industrial process control strategies are not
designed to optimally handle frequent market
conditions changes.
Integration between process optimization and control
is needed to reduce the production cost
Introduction
Industry adapts simple control strategies that are
easily understood by the operators and engineers.
Introduction
Industry adapts simple control strategies that are
easily understood by the operators and engineers.
Essential characteristics:
1. It has to be fairly simple
2. It has to be able to keep the process operation close-to-optimal
while satisfying the operational constraints
3. It has to be easily designed
Introduction
Industry adapts simple control strategies that are
easily understood by the operators and engineers.
Essential characteristics:
1. It has to be fairly simple
2. It has to be able to keep the process operation close-to-optimal
while satisfying the operational constraints
3. It has to be easily designed.
Economic plantwide control can be used to design
control structures that satisfy the first two
characteristics
Top-down part:
Aims to find an optimal control structure
based on plant steady state economics
Bottom-up part:
Aims to find a simple and robust
regulatory control
PC
Process description
PI
LC
CSTR MD
P
XD
1st order kinetics L
R D
A B
A 2C (undesired)
F0
XF
S
MR
F
FC V
TI FI
TR
MB
LC XB
B
PC
Process description
PI
LC
CSTR MD
P
XD
1st order kinetics L
R D
A B
A 2C (undesired)
F0
XF
Column
S
30 stages MR
F
LV - configuration FC V
TI FI
TR
Assumptions: MB
Constant relative volatilities
Constant molar overflows
Constant pressure LC
B
XB
Step 1:
Define the operational objectives (economics) and
constraints.
PC
Step 1:
PI
LC
F0
XF
S
MR
F
FC V
TI FI
TR
MB
LC XB
B
PC
Step 1:
PI
LC
F0
[ pF , pV , pP , pB ] [1, 0.01, 0.5, 2] XF
prices in $/kmol
S
MR
F
FC V
TI FI
TR
MB
LC XB
B
PC
Step 1:
PI
LC
F0
[ pF , pV , pP , pB ] [1, 0.01, 0.5, 2] XF
prices in $/kmol
S
MR
F
FC V
TI FI
TR
Operational constraints*: MB
xB , B 0.9 TR 390 K
M R 11000 mol V 30 mol/s LC XB
B
R 0 mol/s
Step 2:
Determine the steady state optimal operation:
a) Identify the steady-state DOFs
b) Identify the important disturbances and their expected
range
c) Identify the expected active constrains regions
PC
Step 2a:
PI
LC
Degrees of freedom: P
MD
XD
S
MR
F
FC V
TI FI
TR
MB
LC XB
B
PC
Step 2b:
PI
LC
Degrees of freedom: P
MD
XD
Disturbances
S
MR
Main disturbances: F
FC V
Feed flow TR
TI FI
Energy price
MB
d [ F0 , pV ]
Expected disturbance range 30% LC XB
B
Step 2c:
Always active:
xB , B , TR , M R
Remaining
active constraints regions:
(I ) R
(II )
(III ) V
(IV ) V , R
(V ) Infeasible Operational constraints:
Step 2c:
Always active:
xB , B , TR , M R
Remaining
active constraints regions:
(I ) R
(II )
(III ) V
(IV ) V , R
(V ) Infeasible Operational constraints:
xB , B 0.9 TR 390 K
Operating point M R 11000 mol V 30 mol/s
R 0 mol/s
Step 3:
Select primary (economic) controlled variables:
a) Control the active constraints
b) Select the self-optimizing variables
PC
Step 3a:
PI
LC
TR
uSS [ L, V , F , R, S ] MB
(V , xB , B ) ( S , TR ) ( F , M R ) ( R, Closedvalve)
Step 3:
Select primary (economic) controlled variables:
a) Control the active constraints
b) Select the self-optimizing variables
Self-optimizing CVs
Linearized model
y G y u Gdy d
c HG y u HGdy d
Setpoint control
c cS H y 0
Feedback implementation of optimal
operation with separate layers for
optimization (RTO) and control
PC
Available measurements
PI
LC
MD
P
Candidate measurements (y): XD
D L
R
Compositions (noise 0.01):
xB , D , xB , B , xB , F
F0 LC
XF
Input flows (noise 10%):
S
L,V , D, B, F , F0 , R, P MR
F
Reactor level (noise 100 mol): TI
FC
FI
V
CC
MR TC
TR
MB
Column and reactor temperatures (noise 1 K):
T1 , T5 , T9 , T13 , T17 , T21 , T25 , T30 , TR LC XB
B
y opt
Need to estimate : F
d
Performance comparisson
Relative loss
J (u, d ) J opt (d )
LRel
J opt (d )
Conclusions
Automated economic CVs selection could be
considered a successful first step for automating the
entire procedure
Integration of Economic Plantwide Control design
procedure in to popular process simulators could
potentially improve the production costs on a global
scale
Future Work
Handling active constraint changes
Finding a single control structure over multiple active
constraints regions with an acceptable loss
Using the information from the active constraint maps
to estimate G y , Gdy , J uu
Future Work
Handling active constraint changes
Finding a single control structure over multiple active
constraints regions with an acceptable loss
Using the information from the active constraint maps
to estimate G y , Gdy , J uu
Thank you !