Optimal selection of control structure using a steady-state inversely controlled process model

The profitability of chemical processes strongly depends on their control systems. The design of a control system involves selection of controlled and manipulated variables, known as control structure selection. Systematic generation and screening alternative control structures requires optimization. However, the size of such an optimization problem is much larger when candidate controllers and their parameters are included and it rapidly becomes intractable. This paper presents a novel optimization framework using the notion of perfect control, which disentangles the complexities of the controllers. This framework reduces the complexity of the problem while ensuring controllability. In addition, the optimization framework has a goal-driven multi-objective function and requires only a steady-state inverse process model. Since dynamic degrees of freedom do not appear in a steady-state analysis, engineering insights are employed for developing the inventory control systems. The proposed optimization framework was demonstrated in a case study of an industrial distillation train

Selección óptima de redundancias para el diseño de control tolerante a fallas activo para plantas químicas

Este trabajo presenta un procedimiento preliminar para la selección óptima de redundancias de hardware en el marco de control tolerante a fallas reconfigurable. Suponiendo que se dispone de un controlador nominal de dimensión reducida, el objetivo es manejar un conjunto preestablecido de fallas parciales en actuadores, preservando la estabilidad y el desempeño dinámico del sistema. La metodología se basa en un procedimiento de optimización multi-objetivo para lograr un balance entre criterios de diseño conflictivos como controlabilidad y desempeño. La selección de hardware adicional (no incluido en la estructura nominal) es penalizada para lograr una baja inversión en redundancias. Las estructuras de control propuestas pueden sintetizarse mediante controladores convencionales tipo PI (proporcional-integral). La eficacia del procedimiento es evaluada utilizando el caso de estudio Tennessee Eastman.Sociedad Argentina de Informática e Investigación Operativa (SADIO

Selección óptima de redundancias para el diseño de control tolerante a fallas activo para plantas químicas

Este trabajo presenta un procedimiento preliminar para la selección óptima de redundancias de hardware en el marco de control tolerante a fallas reconfigurable. Suponiendo que se dispone de un controlador nominal de dimensión reducida, el objetivo es manejar un conjunto preestablecido de fallas parciales en actuadores, preservando la estabilidad y el desempeño dinámico del sistema. La metodología se basa en un procedimiento de optimización multi-objetivo para lograr un balance entre criterios de diseño conflictivos como controlabilidad y desempeño. La selección de hardware adicional (no incluido en la estructura nominal) es penalizada para lograr una baja inversión en redundancias. Las estructuras de control propuestas pueden sintetizarse mediante controladores convencionales tipo PI (proporcional-integral). La eficacia del procedimiento es evaluada utilizando el caso de estudio Tennessee Eastman.Sociedad Argentina de Informática e Investigación Operativa (SADIO

China's roadmap to low-carbon electricity and water: Disentangling greenhouse gas (GHG) emissions from electricity-water nexus via renewable wind and solar power generation, and carbon capture and storage

Electricity and water form an intricate nexus, in that water is crucial for power generation, and electricity (or other primary forms of energy) is the key enabler for water purification and waste-water treatment. Nonetheless, both energy conversion and water purification result in substantial amounts of greenhouse gas (GHG) emissions. These negative interactions with potential “snowball” effect, can be decoupled via the deployment of renewable power generation, and carbon capture from fossil-fuelled technologies. However, such retrofits pose new challenges as wind and solar energy exhibit intermittent generation patterns. In addition, integrating thermal power plants with carbon capture and storage (CCS) imposes energy penalties and increases water requirements. In the present research, an optimization framework is developed which enables systematic decision-making for the retrofit of existing power and water infrastructure as well as investment in renewable and green technologies. A key aspect of the applied framework is the simultaneous optimization of design and operational decisions in the presence of uncertainties in the water demand, electricity demand, as well as wind and solar power availability. The proposed methodology is demonstrated for the case of the water-electricity nexus in China, and provides in-depth insights into regional characteristics of low carbon electricity generation, and their implications for water purification and wastewater treatment, demonstrating a roadmap towards sustainable energy and electricity

Integrated design and control of chemical processes : part I : revision and clasification

[EN] This work presents a comprehensive classification of the different methods and procedures for integrated synthesis, design and control of chemical processes, based on a wide revision of recent literature. This classification fundamentally differentiates between “projecting methods”, where controllability is monitored during the process design to predict the trade-offs between design and control, and the “integrated-optimization methods” which solve the process design and the control-systems design at once within an optimization framework. The latter are revised categorizing them according to the methods to evaluate controllability and other related properties, the scope of the design problem, the treatment of uncertainties and perturbations, and finally, the type the optimization problem formulation and the methods for its resolution.[ES] Este trabajo presenta una clasificación integral de los diferentes métodos y procedimientos para la síntesis integrada, diseño y control de procesos químicos. Esta clasificación distingue fundamentalmente entre los "métodos de proyección", donde se controla la controlabilidad durante el diseño del proceso para predecir los compromisos entre diseño y control, y los "métodos de optimización integrada" que resuelven el diseño del proceso y el diseño de los sistemas de control a la vez dentro de un marco de optimización. Estos últimos se revisan clasificándolos según los métodos para evaluar la controlabilidad y otras propiedades relacionadas, el alcance del problema de diseño, el tratamiento de las incertidumbres y las perturbaciones y, finalmente, el tipo de la formulación del problema de optimización y los métodos para su resolución

Energy efficient control and optimisation techniques for distillation processes

PhD ThesisDistillation unit is one of the most energy intensive processes and is among the major CO2 emitter in the chemical and petrochemical industries. In the quest to reduce the energy consumption and hence the environmental implications of unutilised energy, there is a strong motivation for energy saving procedures for conventional columns. Several attempts have been made to redesign and heat integrate distillation column with the aim of reducing the energy consumption of the column. Most of these attempts often involve additional capital costs in implementing. Also a number of works on applying the second law of thermodynamics to distillation column are focused on quantifying the efficiency of the column. This research aims at developing techniques of increasing the energy efficiency of the distillation column with the application of second law using the tools of advanced control and optimisation. Rigorous model from the fundamental equations and data driven models using Artificial neural network (ANN) and numerical methods (PLS, PCR, MLR) of a number of distillation columns are developed. The data for the data driven models are generated from HYSYS simulation. This research presents techniques for selecting energy efficient control structure for distillation processes. Relative gain array (RGA) and relative exergy array (REA ) were used in the selection of appropriate distillation control structures. The viability of the selected control scheme in the steady state is further validated by the dynamic simulation in responses to various process disturbances and operating condition changes. The technique is demonstrated on two binary distillation systems. In addition, presented in this thesis is optimisation procedures based on second law analysis aimed at minimising the inefficiencies of the columns without compromising the qualities of the products. ANN and Bootstrap aggregated neural network (BANN) models of exergy efficiency were developed. BANN enhances model prediction accuracy and also provides model prediction confidence bounds. The objective of the optimisation is to maximise the exergy efficiency of the column. To improve the reliability of the optimisation strategy, a modified objective function incorporating model prediction confidence bounds was presented. Multiobjective optimisation was also explored. Product quality constraints introduce a measure of penalization on the optimisation result to give as close as possible to what obtains in reality. The optimisation strategies developed were applied to binary systems, multicomponents system, and crude distillation system. The crude distillation system was fully explored with emphasis on the preflash unit, atmospheric distillation system (ADU) and vacuum distillation system (VDU). This study shows that BANN models result in greater model accuracy and more robust models. The proposed ii techniques also significantly improve the second law efficiency of the system with an additional economic advantage. The method can aid in the operation and design of energy efficient column.Commonwealth scholarship commissio

Efficient Ranking-Based Methodologies in the Optimal Design of Large-Scale Chemical Processes under Uncertainty

Chemical process design is still an active area of research since it largely determines the optimal and safe operation of a new process under various conditions. The design process involves a series of steps that aims to identify the most economically attractive design typically using steady-state optimization. However, optimal steady-state designs may fail to comply with the process constraints when the system under analysis is subject to uncertainties in the inputs (e.g. the composition of a reactant in a feedstream) or in the system’s parameters (e.g. the activation energy in a chemical reaction). This has motivated the development of systematic methods that explicitly account for uncertainty in optimal process design. In this work, a new efficient approach for the optimal design under uncertainty is presented. The key idea is to approximate the process constraint functions and outputs using Power Series Expansions (PSE)-based functions. A ranking-based approach is adopted where the user can assign priorities or probabilities of satisfaction for the different process constraints and process outputs considered in the analysis. The methodology was tested on a reactor-heat exchanger system, the Tennessee Eastman plant, which is an industrial benchmark process, and a post-combustion CO2 capture plant, which is a large-scale chemical plant that has recently gained attention and significance due to its potential to mitigate CO2 emissions from fossil-fired power plants. The results show that the present method is computationally attractive since the optimal process design is accomplished in shorter computational times when compared to the stochastic programming approach, which is the standard method used to address this type of problems. Furthermore, it has been shown that process dynamics play an important role while searching for the optimal process design of a system under uncertainty. Therefore, a stochastic-based simultaneous design and control methodology for the optimal design of chemical processes under uncertainty that incorporates an advanced model-based scheme such as Model Predictive Control (MPC) is also presented in this work. The key idea is to determine the time-dependent variability of the system that will be accounted for in the process design using a stochastic-based worst-case variability index. A case study of an actual wastewater treatment industrial plant has been used to test the proposed methodology. The MPC-based simultaneous design and control approach provided more economical designs when compared to a decentralized multi-loop PI control strategy, thus showing that this method is a practical approach to address the integration of design and control while using advanced model-based control strategies

Integration of design and control for large-scale applications: a back-off approach

Design and control are two distinct aspects of a process that are inherently related though these aspects are often treated independently. Performing a sequential design and control strategy may lead to poor control performance or overly conservative and thus expensive designs. Unsatisfactory designs stem from neglecting the connection of choices made at the process design stage that affects the process dynamics. Integration of design and control introduces the opportunity to establish a transparent link between steady-state economics and dynamic performance at the early stages of the process design that enables the identification of reliable and optimal designs while ensuring feasible operation of the process under internal and external disruptions. The dynamic nature of the current global market drives industries to push their manufacturing strategies to the limits to achieve a sustainable and optimal operation. Hence, the integration of design and control plays a crucial role in constructing a sustainable process since it increases the short and long-term profits of industrial processes. Simultaneous process design and control often results in challenging computationally intensive and complex problems, which can be formulated conceptually as dynamic optimization problems. The size and complexity of the conceptual integrated problem impose a limitation on the potential solution strategies that could be implemented on large-scale industrial systems. Thus far, the implementation of integration of design and methodologies on large-scale applications is still challenging and remains as an open question. The back-off approach is one of the proposed methodologies that relies on steady-state economics to initiate the search for optimal and dynamically feasible process design. The idea of the surrogate model is combined with the back-off approach in the current research as the key technique to propose a practical and systematic method for the integration of design and control for large-scale applications. The back-off approach featured with power series expansions (PSEs) is developed and extended to achieve multiple goals. The proposed back-off method focuses on searching for the optimal design and control parameters by solving a set of optimization problems using PSE functions. The idea is to search for the optimal direction in the optimization variables by solving a series of bounded PSE-based optimization problems. The approach is a sequential approximate optimization method in which the system is evaluated around the worst-case variability expected in process outputs. Hence, using PSE functions instead of the actual nonlinear dynamic process model at each iteration step reduces the computational effort. The method mostly traces the closest feasible and near-optimal solution to the initial steady-state condition considering the worst-case scenario. The term near-optimal refers to the potential deviations from the original locally optimum due to the approximation techniques considered in this work. A trust-region method has been developed in this research to tackle simultaneous design and control of large-scale processes under uncertainty. In the initial version of the back-off approach proposed in this research, the search space region in the PSE-based optimization problem was specified a priori. Selecting a constant search space for the PSE functions may undermine the convergence of the methodology since the predictions of the PSEs highly depend on the nominal conditions used to develop the corresponding PSE functions. Thus, an adaptive search space for individual PSE-optimization problems at every iteration step is proposed. The concept has been designed in a way that certifies the competence of the PSE functions at each iteration and adapts the search space of the optimization as the iteration proceeds in the algorithm. Metrics for estimating the residuals such as the mean of squared errors (MSE) are employed to quantify the accuracy of the PSE approximations. Search space regions identified by this method specify the boundaries of the decision variables for the PSE-based optimization problems. Finding a proper search region is a challenging task since the nonlinearity of the system at different nominal conditions may vary significantly. The procedure moves towards a descent direction and at the convergence point, it can be shown that it satisfies first-order KKT conditions. The proposed methodology has been tested on different case studies involving different features. Initially, an existent wastewater treatment plant is considered as a primary medium-scale case study in the early stages of the development of the methodology. The wastewater treatment plant is also used to investigate the potential benefits and capabilities of a stochastic version of the back-off methodology. Furthermore, the results of the proposed methodology are compared to the formal integration approach in a dynamic programming framework for the medium-scale case study. The Tennessee Eastman (TE) process is selected as a large-scale case study to explore the potentials of the proposed method. The results of the proposed trust-region methodology have been compared to previously reported results in the literature for this plant. The results indicate that the proposed methodology leads to more economically attractive and reliable designs while maintaining the dynamic operability of the system in the presence of disturbances and uncertainty. Therefore, the proposed methodology shows a significant accomplishment in locating dynamically feasible and near-optimal design and operating conditions thus making it attractive for the simultaneous design and control of large-scale and highly nonlinear plants under uncertainty

Assessing plant design with regards to MPC performance using a novel multi-model prediction method

Model Predictive Control (MPC) is nowadays ubiquitous in the chemical industry and offers significant advantages over standard feedback controllers. Notwithstanding, projects of new plants are still being carried out without assessing how key design decisions, e.g., selection of production route, plant layout and equipment, will affect future MPC performance. The problem addressed in this Thesis is comparing the economic benefits available for different flowsheets through the use of MPC, and thus determining if certain design choices favour or hinder expected profitability. The Economic MPC Optimisation (EMOP) index is presented to measure how disturbances and restrictions affect the MPC’s ability to deliver better control and optimisation. To the author’s knowledge, the EMOP index is the first integrated design and control methodology to address the problem of zone constrained MPC with economic optimisation capabilities (today's standard in the chemical industry). This approach assumes the availability of a set of linear state-space models valid within the desired control zone, which is defined by the upper and lower bounds of each controlled and manipulated variable. Process economics provides the basis for the analysis. The index needs to be minimised in order to find the most profitable steady state within the zone constraints towards which the MPC is expected to direct the process. An analysis of the effects of disturbances on the index illustrates how they may reduce profitability by restricting the ability of an MPC to reach dynamic equilibrium near process constraints, which in turn increases product quality giveaway and costs. Hence the index monetises the required control effort. Since linear models were used to predict the dynamic behaviour of chemical processes, which often exhibit significant nonlinearity, this Thesis also includes a new multi-model prediction method. This new method, called Simultaneous Multi-Linear Prediction (SMLP), presents a more accurate output prediction than the use of single linear models, keeping at the same time much of their numerical advantages and their relative ease of obtainment. Comparing the SMLP to existing multi-model approaches, the main novelty is that it is built by defining and updating multiple states simultaneously, thus eliminating the need for partitioning the state-input space into regions and associating with each region a different state update equation. Each state’s contribution to the overall output is obtained according to the relative distance between their identification point, i.e., the set of operating conditions at which an approximation of the nonlinear model is obtained, and the current operating point, in addition to a set of parameters obtained through regression analysis. Additionally, the SMLP is built upon data obtained from step response models that can be obtained by commercial, black-box dynamic simulators. These state-of-the-art simulators are the industry’s standard for designing large-scale plants, the focus of this Thesis. Building an SMLP system yields an approximation of the nonlinear model, whose full set of equations is not of the user’s knowledge. The resulting system can be used for predictive control schemes or integrated process design and control. Applying the SMLP to optimisation problems with linear restrictions results in convex problems that are easy to solve. The issue of model uncertainty was also addressed for the EMOP index and SMLP systems. Due to the impact of uncertainty, the index may be defined as a numeric interval instead of a single number, within which the true value lies. A case of study consisting of four alternative designs for a realistically sized crude oil atmospheric distillation plant is provided in order to demonstrate the joint use and applicability of both the EMOP index and the SMLP. In addition, a comparison between the EMOP index and a competing methodology is presented that is based on a case study consisting of the activated sludge process of a wastewater treatment plant