Temperature and concentration control of exothermic chemical processes in continuous stirred tank reactors

Exothermic chemical reaction taking place in continuous stirred tank reactor is considered. Heat release from the chemical reaction, non-linear dynamic behavior of the process and uncertainty in parameters are the main factors motivating the use of robust control design. Viewing temperature and molar concentration as variables both accessible in real time, PI and optimal state-feedback controllers driven by temperature and concentration error signals are proposed to regulate the system over reactor’s steady-state working points by counteracting undesired disturbances. Since access to concentration value has proved beneficial for the reactor’s performance, estimation techniques are examined to compensate for the problematic nature of the concentration’s measurement. A linear reduced-order observer is first proposed to estimate the concentration value using temperature measurements. In addition, assuming concentration measurement is available with a relatively short delay via sample analysis, a linear and non-linear discrete-time predictor is constructed to estimate the concentration’s real-time value. A linear combination of the two estimation schemes (observer, predictor) is proposed resulting in a combined estimator, in which the emphasis between the two individual schemes can be controlled via a scalar parameter. The work presented in this paper was supported by the GLOW project – New weather-stable low gloss powder coatings based on bifunctional acrylic solid resins and nanoadditives – as part of the development of novel and efficient processing technologies regarding the production of new families of powder coatings, responding to industrial requirements for quality improvement at lower cost and shorter development cycles

Instrumentation and control of anaerobic digestion processes: a review and some research challenges

The final publication is available at Springer via http://dx.doi.org/10.1007/s11157-015-9382-6[EN] To enhance energy production from methane or resource recovery from digestate, anaerobic digestion processes require advanced instrumentation and control tools. Over the years, research on these topics has evolved and followed the main fields of application of anaerobic digestion processes: from municipal sewage sludge to liquid mainly industrial then municipal organic fraction of solid waste and agricultural residues. Time constants of the processes have also changed with respect to the treated waste from minutes or hours to weeks or months. Since fast closed loop control is needed for short time constant processes, human operator is now included in the loop when taking decisions to optimize anaerobic digestion plants dealing with complex solid waste over a long retention time. Control objectives have also moved from the regulation of key variables measured online to the prediction of overall process perfor- mance based on global off-line measurements to optimize the feeding of the processes. Additionally, the need for more accurate prediction of methane production and organic matter biodegradation has impacted the complexity of instrumentation and should include a more detailed characterization of the waste (e.g., biochemical fractions like proteins, lipids and carbohydrates)andtheirbioaccessibility andbiodegradability characteristics. However, even if in the literature several methodologies have been developed to determine biodegradability based on organic matter characterization, only a few papers deal with bioaccessibility assessment. In this review, we emphasize the high potential of some promising techniques, such as spectral analysis, and we discuss issues that could appear in the near future concerning control of AD processes.The authors acknowledge the financial support of INRA (the French National Institute for Agricultural Research), the French National Research Agency (ANR) for the "Phycover" project (project ANR-14-CE04-0011) and ADEME for Inter-laboratory assay financial support.Jimenez, J.; Latrille, E.; Harmand, J.; Robles Martínez, Á.; Ferrer Polo, J.; Gaida, D.; Wolf, C.... (2015). Instrumentation and control of anaerobic digestion processes: a review and some research challenges. Reviews in Environmental Science and Biotechnology. 14(4):615-648. doi:10.1007/s11157-015-9382-6S615648144Aceves-Lara CA, Latrille E, Steyer JP (2010) Optimal control of hydrogen production in a continuous anaerobic fermentation bioreactor. 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Fermentation: Metabolism, Kinetic Models, and Bioprocessing

Biochemical and metabolic interpretation of microbial growth is an important topic in bioreactor design. We intend to address valuable information about the relation of critical operation variables and the simulation of bioprocesses with unstructured and structured kinetic models. Process parameters such as nutrient supply, pH, dissolved oxygen, and metabolic end-products directly impact the physiology and metabolism of microorganisms. Changes in the membrane as well as cell viability are of interest since protein expression and maturation in prokaryota are directly related to membrane integrity. This chapter intends to deliver an insight of different alternatives in kinetic modeling

Monitoring and Fault Diagnosis for Chylla-Haase Polymerization Reactor

The main objective of this research is to develop a fault detection and isolation (FDI) methodologies for Cylla-Haase polymerization reactor, and implement the developed methods to the nonlinear simulation model of the proposed reactor to evaluate the effectiveness of FDI methods. The first part of this research focus of this chapter is to understand the nonlinear dynamic behaviour of the Chylla-Haase polymerization reactor. In this part, the mathematical model of the proposed reactor is described. The Simulink model of the proposed reactor is set up using Simulink/MATLAB. The design of Simulink model is developed based on a set of ordinary differential equations that describe the dynamic behaviour of the proposed polymerization reactor. An independent radial basis function neural networks (RBFNN) are developed and employed here for an on-line diagnosis of actuator and sensor faults. In this research, a robust fault detection and isolation (FDI) scheme is developed for open-loop exothermic semi-batch polymerization reactor described by Chylla-Haase. The independent (RBFNN) is employed here when the system is subjected to system uncertainties and disturbances. Two different techniques to employ RBF neural networks are investigated. Firstly, an independent neural network is used to model the reactor dynamics and generate residuals. Secondly, an additional RBF neural network is developed as a classifier to isolate faults from the generated residuals. In the third part of this research, a robust fault detection and isolation (FDI) scheme is developed to monitor the Chylla-Haase polymerization reactor, when it is under the cascade PI control. This part is really challenging task as the controller output cannot be designed when the reactor is under closed-loop control, and the control action will correct small changes of the states caused by faults. The proposed FDI strategy employed a radial basis function neural network (RBFNN) in an independent mode to model the process dynamics, and using the weighted sum-squared prediction error as the residual. The Recursive Orthogonal Least Squares algorithm (ROLS) is employed to train the model to overcome the training difficulty of the independent mode of the network. Then, another RBFNN is used as a fault classifier to isolate faults from different features involved in the residual vector. In this research, an independent MLP neural network is implemented here to generate residuals for detection task. And another RBF is applied for isolation task performing as a classifier. The fault diagnosis scheme is developed for a Chylla-Haase reactor under open-loop and closed-loop control system. The comparison between these two neural network architectures (MPL and RBF) are shown that RBF configuration trained by (RLS) algorithm have several advantages. The first one is greater efficiency in finding optimal weights for field strength prediction in complex dynamic systems. The RBF configuration is less complex network that results in faster convergence. The training algorithms (RLs and ROLS) that used for training RBFNN in chapter (4) and (5) have proven to be efficient, which results in significant faster computer time in comparison to back-propagation one. Another fault diagnosis (FD) scheme is developed in this research for an exothermic semi-batch polymerization reactor. The scheme includes two parts: the first part is to generate residual using an extended Kalman filter (EKF), and the second part is the decision making to report fault using a standardized hypothesis of statistical tests. The FD simulation results are presented to demonstrate the effectiveness of the proposed method. In the lase section of this research, a robust fault diagnosis scheme for abrupt and incipient faults in nonlinear dynamic system. A general framework is developed for model-based fault detection and diagnosis using on-line approximators and adaptation/learning schemes. In this framework, neural network models constitute an important class of on-line approximators. The changes in the system dynamics due to fault are modelled as nonlinear functions of the state, while the time profile of the fault is assumed to be exponentially developing. The changes in the system dynamics are monitored by an on-line approximation model, which is used for detecting the failures. A systematic procedure for constructing nonlinear estimation algorithm is developed, and a stable learning scheme is derived using Lyapunov theory. Simulation studies are used to illustrate the results and to show the effectiveness of the fault diagnosis methodology. Finally, the success of the proposed fault diagnosis methods illustrates the potential of the application of an independent RBFNN, an independent MLP, an Extended kalman filter and an adaptive nonlinear observer based FD, to chemical reactors

Full-scale digesters: an online model parameter identification strategy

This work presents a new standard in the model, identification, and control of monitoring purposes over anaerobic reactors. One requirement that guarantees a normal controller operation is for the faculty to measure the data needed periodically. Due to its inability to easily obtain the concentrations of acidogenic bacteria and methanogenic archaea periodically using reliable and commercial sensors, this paper presents an algorithm composed of an asymptotic observer (considering the reaction rates are unknown), aiming to estimate these concentrations. This method represents a significant advantage because it is possible to perform a resource-saving strategy using standard measurements, such as pH or alkalinity, to calculate them analytically in natural environments. Additionally, two yield parameters were included in the original anaerobic model two (AM2) to unlock implementations for a wide range of organic substrates. The static parameter identification was improved using a new method called step-ahead optimization. It demonstrates significant improvements fitting the mathematical model to data until a (Formula presented.) increase in efficiency (compared with the traditional optimization method genetic algorithm). After the period of convergence, the state observer evidences a small error with a maximum (Formula presented.) deviation. Finally, numerical simulations demonstrate the structure’s strengths, which constitutes a significant step in paving the way further to implement feasible, cost-effective controls and monitoring systems in the industr

Neural Network-based Finite-time Control of Nonlinear Systems with Unknown Dead-zones: Application to Quadrotors

Over the years, researchers have addressed several control problems of various classes of nonlinear systems. This article considers a class of uncertain strict feedback nonlinear system with unknown external disturbances and asymmetric input dead-zone. Designing a tracking controller for such system is very complex and challenging. This article aims to design a finite-time adaptive neural network backstepping tracking control for the nonlinear system under consideration. In addition,  all unknown disturbances and nonlinear functions are lumped together and approximated by radial basis function neural network (RBFNN). Moreover, no prior  information about the boundedness of the dead-zone parameters is required in the controller design. With the aid of a Lyapunov candidate function, it has been shown that the tracking errors converge near the origin in finite-time. Simulation results testify that the proposed control approach can force the output to follow the reference trajectory in a short time despite the presence of  asymmetric input dead-zone and external disturbances. At last, in order to highlight the effectiveness of the proposed control method, it is applied to a quadrotor unmanned aerial vehicle (UAV)

Robust fault diagnosis for an exothermic semi-batch polymerization reactor under open-loop

An independent radial basis function neural network (RBFNN) is developed and employed here for an online diagnosis of actuator and sensor faults. In this research, a robust fault detection and isolation scheme is developed for an open-loop exothermic semi-batch polymerization reactor described by Chylla–Haase. The independent RBFNN is employed here for online diagnosis of faults when the system is subjected to system uncertainties and disturbances. Two different techniques to employ RBFNNs are investigated. Firstly, an independent neural network (NN) is used to model the reactor dynamics and generate residuals. Secondly, an additional RBFNN is developed as a classifier to isolate faults from the generated residuals. Three sensor faults and one actuator fault are simulated on the reactor. Moreover, many practical disturbances and system uncertainties, such as monomer feed rate, fouling factor, impurity factor, ambient temperature and measurement noise, are modelled. The simulation results are presented to illustrate the effectiveness and robustness of the proposed method

The predictive functional control and the management of constraints in GUANAY II autonomous underwater vehicle actuators

Autonomous underwater vehicle control has been a topic of research in the last decades. The challenges addressed vary depending on each research group's interests. In this paper, we focus on the predictive functional control (PFC), which is a control strategy that is easy to understand, install, tune, and optimize. PFC is being developed and applied in industrial applications, such as distillation, reactors, and furnaces. This paper presents the rst application of the PFC in autonomous underwater vehicles, as well as the simulation results of PFC, fuzzy, and gain scheduling controllers. Through simulations and navigation tests at sea, which successfully validate the performance of PFC strategy in motion control of autonomous underwater vehicles, PFC performance is compared with other control techniques such as fuzzy and gain scheduling control. The experimental tests presented here offer effective results concerning control objectives in high and intermediate levels of control. In high-level point, stabilization and path following scenarios are proven. In the intermediate levels, the results show that position and speed behaviors are improved using the PFC controller, which offers the smoothest behavior. The simulation depicting predictive functional control was the most effective regarding constraints management and control rate change in the Guanay II underwater vehicle actuator. The industry has not embraced the development of control theories for industrial systems because of the high investment in experts required to implement each technique successfully. However, this paper on the functional predictive control strategy evidences its easy implementation in several applications, making it a viable option for the industry given the short time needed to learn, implement, and operate, decreasing impact on the business and increasing immediacy.Peer ReviewedPostprint (author's final draft