Heterogeneous Batch Distillation Processes: Real System Optimisation

In this paper, optimisation of batch distillation processes is considered. It deals with real systems with rigorous simulation of the processes through the resolution full MESH differential algebraic equations. Specific software architecture is developed, based on the BatchColumn® simulator and on both SQP and GA numerical algorithms, and is able to optimise sequential batch columns as long as the column transitions are set. The efficiency of the proposed optimisation tool is illustrated by two case studies. The first one concerns heterogeneous batch solvent recovery in a single distillation column and shows that significant economical gains are obtained along with improved process conditions. Case two concerns the optimisation of two sequential homogeneous batch distillation columns and demonstrates the capacity to optimize several sequential dynamic different processes. For such multiobjective complex problems, GA is preferred to SQP that is able to improve specific GA solutions

Application of iterative nonlinear model predictive control to a batch pilot reactor

IFAC WORLD CONGRESS (16) (16.2005.PRAGA, REPÚBLICA CHECA)The aim of this article is to present the Iterative Model Predictive Controller, inmpc, as a good candidate to control chemical batch reactors. The proposed control approach is derived from a model-based predictive control formulation which takes advantage of the repetitive nature of batch processes. The proposed controller combines the good qualities of Model Predictive Control (mpc) with the possibility of learning from past batches, that is the base of Iterative Control. It uses a nonlinear model and a quadratic objective function that is optimized in order to obtain the control law. The controller is tested on a batch pilot reactor, and a comparison with an Iterative Learning Controller (ilc) is made. Under input constraints and for this nonlinear plant, a fast convergence rate is obtained with the proposed controller, showing good operational results. Although the controller is designed for discrete-time systems, it is a necessary condition that the continuous-time model does not present blow-up characteristics. The batch pilot reactor emulates an exothermal chemical reaction by means of electrical heating

Robust PID based indirect-type iterative learning control for batch processes with time-varying uncertainties

ased on the proportional-integral-derivative (PID) control structure widely used in engineering applications, a robust indirect-type iterative learning control (ILC) method is proposed for industrial batch processes subject to time-varying uncertainties. An important merit is that the proposed ILC design is independent of the PID tuning that aims primarily to hold robust stability of the closed-loop system, owing to the fact that the ILC updating law is implemented through adjusting the setpoint of the closed-loop PID control structure plus a feedforward control to the plant input from batch to batch. According to the robust H infinity control objective, a robust discrete-time PID tuning algorithm is given in terms of the plant state-space model description to accommodate for time-varying process uncertainties. For the batchwise direction, a robust ILC updating law is developed based on the two-dimensional (2D) control system theory. Only measured output errors of current and previous cycles are used to implement the proposed ILC scheme for the convenience of practical application. An illustrative example from the literature is adopted to demonstrate the effectiveness and merits of the proposed ILC method

Iterative learning control of crystallisation systems

Under the increasing pressure of issues like reducing the time to market, managing lower production costs, and improving the flexibility of operation, batch process industries thrive towards the production of high value added commodity, i.e. specialty chemicals, pharmaceuticals, agricultural, and biotechnology enabled products. For better design, consistent operation and improved control of batch chemical processes one cannot ignore the sensing and computational blessings provided by modern sensors, computers, algorithms, and software. In addition, there is a growing demand for modelling and control tools based on process operating data. This study is focused on developing process operation data-based iterative learning control (ILC) strategies for batch processes, more specifically for batch crystallisation systems. In order to proceed, the research took a step backward to explore the existing control strategies, fundamentals, mechanisms, and various process analytical technology (PAT) tools used in batch crystallisation control. From the basics of the background study, an operating data-driven ILC approach was developed to improve the product quality from batch-to-batch. The concept of ILC is to exploit the repetitive nature of batch processes to automate recipe updating using process knowledge obtained from previous runs. The methodology stated here was based on the linear time varying (LTV) perturbation model in an ILC framework to provide a convergent batch-to-batch improvement of the process performance indicator. In an attempt to create uniqueness in the research, a novel hierarchical ILC (HILC) scheme was proposed for the systematic design of the supersaturation control (SSC) of a seeded batch cooling crystalliser. This model free control approach is implemented in a hierarchical structure by assigning data-driven supersaturation controller on the upper level and a simple temperature controller in the lower level. In order to familiarise with other data based control of crystallisation processes, the study rehearsed the existing direct nucleation control (DNC) approach. However, this part was more committed to perform a detailed strategic investigation of different possible structures of DNC and to compare the results with that of a first principle model based optimisation for the very first time. The DNC results in fact outperformed the model based optimisation approach and established an ultimate guideline to select the preferable DNC structure. Batch chemical processes are distributed as well as nonlinear in nature which need to be operated over a wide range of operating conditions and often near the boundary of the admissible region. As the linear lumped model predictive controllers (MPCs) often subject to severe performance limitations, there is a growing demand of simple data driven nonlinear control strategy to control batch crystallisers that will consider the spatio-temporal aspects. In this study, an operating data-driven polynomial chaos expansion (PCE) based nonlinear surrogate modelling and optimisation strategy was presented for batch crystallisation processes. Model validation and optimisation results confirmed this approach as a promise to nonlinear control. The evaluations of the proposed data based methodologies were carried out by simulation case studies, laboratory experiments and industrial pilot plant experiments. For all the simulation case studies a detailed mathematical models covering reaction kinetics and heat mass balances were developed for a batch cooling crystallisation system of Paracetamol in water. Based on these models, rigorous simulation programs were developed in MATLAB®, which was then treated as the real batch cooling crystallisation system. The laboratory experimental works were carried out using a lab scale system of Paracetamol and iso-Propyl alcohol (IPA). All the experimental works including the qualitative and quantitative monitoring of the crystallisation experiments and products demonstrated an inclusive application of various in situ process analytical technology (PAT) tools, such as focused beam reflectance measurement (FBRM), UV/Vis spectroscopy and particle vision measurement (PVM) as well. The industrial pilot scale study was carried out in GlaxoSmithKline Bangladesh Limited, Bangladesh, and the system of experiments was Paracetamol and other powdered excipients used to make paracetamol tablets. The methodologies presented in this thesis provide a comprehensive framework for data-based dynamic optimisation and control of crystallisation processes. All the simulation and experimental evaluations of the proposed approaches emphasised the potential of the data-driven techniques to provide considerable advances in the current state-of-the-art in crystallisation control

Batch-to-batch iterative learning control of a fed-batch fermentation process

PhD ThesisRecently, iterative learning control (ILC) has been used in the run-to-run control of batch processes to directly update the control trajectory. The basic idea of ILC is to update the control trajectory for a new batch run using the information from previous batch runs so that the output trajectory converges asymptotically to the desired reference trajectory. The control policy updating is calculated using linearised models around the nominal reference process input and output trajectories. The linearised models are typically identified using multiple linear regression (MLR), partial least squares (PLS) regression, or principal component regression (PCR). ILC has been shown to be a promising method to address model-plant mismatches and unknown disturbances. This work presents several improvements of batch to batch ILC strategy with applications to a simulated fed-batch fermentation process. In order to enhance the reliability of ILC, model prediction confidence is incorporated in the ILC optimization objective function. As a result of the incorporation, wide model prediction confidence bounds are penalized in order to avoid unreliable control policy updating. This method has been proven to be very effective for selected model prediction confidence bounds penalty factors. In the attempt to further improve the performance of ILC, averaged reference trajectories and sliding window techniques were introduced. To reduce the influence of measurement noise, control policy is updated on the average input and output trajectories of the past a few batches instead of just the immediate previous batch. The linearised models are re-identified using a sliding window of past batches in that the earliest batch is removed with the newest batch added to the model identification data set. The effects of various parameters were investigated for MLR, PCR and PLS method. The technique significantly improves the control performance. In model based ILC the weighting matrices, Q and R, in the objective function have a significant impact on the control performance. Therefore, in the quest to exploit the potential of objective function, adaptive weighting parameters were attempted to study the performance of batch to batch ILC with updated models. Significant improvements in the stability of the performance for all the three methods were noticed. All the three techniques suggested have established improvements either in stability, reliability and/or convergence speed. To further investigate the versatility of ILC, the above mentioned techniques were combined and the results are discussed in this thesis

Optimisation Methods for Improving Fed-batch Cultivation of E. Coli Producing Recombinant Proteins

Two optimisation techniques for the fed-batch cultivation of high cell density Escherichia coli producing recombinant proteins were compared. An unstructured model for the growth, based on the General State Space Dynamical Model [1] was used to represent the four major metabolic pathways: oxidative growth on glucose, fermentative growth on glucose, oxidative growth on acetate, and maintenance. The dilution rate (dependent on the substrate feed rate) was chosen as the input variable. Recombinant protein production is known to be proportional, in our system, to the biomass concentration. Thus, biomass productivity was chosen as the criterion to be maximized. The two methods compared were a first order gradient method based on Pontryagin’s minimum principle and a stochastic method based on the biological principle of natural evolution, using a genetic algorithm. The former method revealed less efficient concerning to the computed maximum, and dependence on good initial values