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

Robust integrated design of processes with terminal penalty model predictive controllers

[EN] In this work, a novel methodology for the Integrated Design (ID) of processes with linear Model Predictive Control (MPC) is addressed, providing simultaneously the plant dimensions, the control system parameters and a steady state working point. The MPC chosen operates over infinite horizon in order to guarantee stability and it is implemented with a terminal penalty. The ID methodology considers norm based indexes for controllability, as well as robust performance conditions by using a multi-model approach. Mathematically, the ID is stated as a multiobjective nonlinear constrained optimization problem, tackled in different ways. Particularly, objective functions include investment, operating costs, and dynamical indexes based on the weighted sum of some norms of different closed loop transfer functions of the system. The paper illustrates the application of the proposed methodology with the ID of the activated sludge process of a wastewater treatment plant (WWTP).[ES] Este trabajo aborda una nueva metodología para el Diseño Integrado (ID) de procesos con Control Predictivo Modelo (MPC) lineal, que proporciona simultáneamente las dimensiones de la planta, los parámetros del sistema de control y un punto de trabajo en estado estacionario. El MPC elegido opera sobre horizonte infinito para garantizar la estabilidad. La metodología de ID considera los índices basados en la norma para la controlabilidad, así como las robustas condiciones de rendimiento mediante el uso de un enfoque multi-modelo. Matemáticamente, la ID se declara como un problema de optimización no lineal multiobjetivo restringido, abordado de diferentes maneras. Particularmente, las funciones objetivas incluyen inversión, costos de operación e índices dinámicos basados en la suma ponderada de algunas normas de diferentes funciones de transferencia en bucle cerrado del sistema. El trabajo ilustra la aplicación de la metodología propuesta con el ID del proceso de lodos activados de una planta de tratamiento de aguas residuales (EDAR)

Dynamic operability assessment : a mathematical programming approach based on Q-parametrization

Bibliography: pages 197-208.The ability of a process plant to guarantee high product quality, in terms of low variability, is emerging as a defining feature when distinguishing between alternative suppliers. The extent to which this can be achieved is termed a plant's dynamic operability and is a function of both the plant design and the control system design. In the limit, however, the closedloop performance is determined by the properties inherent in the plant. This realization of the interrelationship between a plant design and its achievable closed-loop performance has motivated research toward systematic techniques for screening inherently inferior designs. Pioneering research in the early 1980's identified right-half-plane transmission zeros, time delays, input constraints and model uncertainty as factors that limit the achievable closedloop performance of a process. Quantifying the performance-limiting effect of combinations of these factors has proven to be a challenging problem, as reflected in the literature. It is the aim of this thesis to develop a systematic procedure for dynamic operability assessment in the presence of combinations of performance-limiting factors. The approach adopted in this thesis is based on the Q-parametrization of stabilizing linear feedback controllers and involves posing dynamic operability assessment as a mathematical programming problet? In the proposed formulation, a convex objective function, reflecting a measure of closed-loop performance, is optimized over all stable Q, subject. to a set of constraints on the closed-loop behavior, which for many specifications of interest is convex. A discrete-time formulation is chosen so as to allow for the convenient hand.ling of time delays and time-domain constraints. An important feature of the approach is that, due to the convexity, global optimality is guaranteed. Furthermore, the fact that Q parametrizes all stabilizing linear feedback controllers implies that the performance at the optimum represents the best possible performance for any such controller. The results are thus not biased by controller type or tuning, apart from the requirement that the controller be linear

Robust Loopshaping for Process Control

Strong trends in chemical engineering and plant operation have made the control of processes increasingly difficult and have driven the process industry's demand for improved control techniques. Improved control leads to savings in resources, smaller downtimes, improved safety, and reduced pollution. Though the need for improved process control is clear, advanced control methodologies have had only limited acceptance and application in industrial practice. The reason for this gap between control theory and practice is that existing control methodologies do not adequately address all of the following control system requirements and problems associated with control design: * The controller must be insensitive to plant/model mismatch, and perform well under unmeasured or poorly modeled disturbances. * The controlled system must perform well under state or actuator constraints. * The controlled system must be safe, reliable, and easy to maintain. * Controllers are commonly required to be decentralized. * Actuators and sensors must be selected before the controller can be designed. * Inputs and outputs must be paired before the design of a decentralized controller. A framework is presented to address these control requirements/problems in a general, unified manner. The approach will be demonstrated on adhesive coating processes and distillation columns

Integrated design and control of chemical processes : Part II: an illustrative example

[EN] In this paper, the integrated design paradigm is illustrated with several examples taken from the wide range of methodologies developed in last decades and presented in the first article of this series [Part 1]. The techniques included here belong to the category of simultaneous design and control in an optimization framework, and they have been developed by the authors’ research group and applied to the simultaneous process and control system design of the activated sludge process in a wastewater treatment plant (WWTP). In the present article, new aspects and results of those methodologies are presented for further understanding. The scope of the problem considers both a fixed plant layout and the plant structure selection by defining a simple superstructure. The control strategy chosen is a linear Model Predictive Controller (MPC) with terminal penalty in order to guarantee stability. As for the evaluation of the controllability, norm based indexes have been considered, and a multi-model approach to represent the uncertainty and assure robustness. The formulation of the optimization problem can be stated either as a multiobjective one considering costs and controllability, or as monoobjective adding some controllability constraints. Several strategies for solving the optimization problem are presented, mixing stochastic and deterministic methods, and genetic algorithms.[ES] En este artículo, el paradigma de diseño integrado se ilustra con varios ejemplos tomados de la amplia gama de metodologías desarrolladas en las últimas décadas y presentadas en el primer artículo de esta serie. Las técnicas utilizadas pertenecen a la categoría de diseño y control simultáneo en un marco de optimización siendo desarrolladas por el grupo de investigación de los autores y aplicadas al diseño simultáneo de procesos y sistemas de control del proceso de lodos activados en una planta de tratamiento de aguas residuales. El alcance del problema considera tanto una disposición fija de la planta como la selección de la estructura de la planta definiendo una superestructura simple. La estrategia de control elegida es un controlador predictivo modelo lineal (MPC). En cuanto a la evaluación de la controlabilidad, se han considerado índices basados en normas, y un enfoque multi-modelo para representar la incertidumbre y asegurar robustez. La formulación del problema de optimización se puede plantear bien como un objetivo multiobjetivo que considera costos y controlabilidad, o como monoobjetivo que añade algunas restricciones de controlabilidad. Se presentan varias estrategias para resolver el problema de optimización, mezclando métodos estocásticos y determinísticos, y algoritmos genéticos

Assessing plant design with regard to MPC performance

Model Predictive Control is ubiquitous in the chemical industry and offers great advantages over traditional controllers. Notwithstanding, new plants are being projected without taking into account how design choices affect the MPC’s ability to deliver better control and optimization. Thus a methodology to determine if a certain design option favours or hinders MPC performance would be desirable. This paper presents the economic MPC optimization index whose intended use is to provide a procedure to compare different designs for a given process, assessing how well they can be controlled and optimised by a zone constrained MPC. The index quantifies the economic benefits available and how well the plant performs under MPC control given the plant’s controllability properties, requirements and restrictions. The index provides a monetization measure of expected control performance. This approach assumes the availability of a linear state-space model valid within the control zone defined by the upper and lower bounds of each controlled and manipulated variable. We have used a model derived from simulation step tests as a practical way to use the method. The impact of model uncertainty on the methodology is discussed. An analysis of the effects of disturbances on the index illustrates how they may reduce profitability by restricting the ability of a MPC to reach dynamic equilibrium near process restrictions, which in turn increases product quality giveaway and costs. 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 applicability of the index

Design of of model-based controllers via parametric programming

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Design and Control Integration of a Reactive Distillation Column for Ethyl Lactate Production

ABSTRACT: Nowadays, the worldwide tendency to obtain environmentally friendly products through the use of safe and stable production processes, minimizing the energy consumption (i.e. using energy integration), and avoiding products out of specification, are an important motivation for applying a process design methodology that incorporates controllability issues since the earliest design stages. Although the topic of design-control integration has been a research topic investigated from different fronts for more than thirty-five years, it was in 2005 where a methodology incorporating local practical controllability issues for nonlinear systems was proposed. Such methodology allows designing processes that fulfill some controllability criteria, which assures that the resulted design will be controllable from the modern control theory. The mentioned design-control integration methodology was applied in this work for designing a reactive distillation column for producing ethyl lactate, an important green solvent. Production of this green solvent has gained great attention worldwide since it is seen as an excellent alternative for replacing petroleum-based solvents. As with any green product that intends to replace oil-based products, ethyl lactate production needs to be improved (in terms of its economic feasibility) to have an actual chance for replacing the petroleum-based solvents at a worldwide scale. One of the proposals for improving the economic feasibility of this green solvent, is to produce it in a reactive distillation column system, which would reduce the energy consumption, increasing the process profit. The design-control methodology applied here involved several steps. First, the development of a first principles-based model is required. Unfortunately, experimental data for a reactive distillation system for ethyl lactate production are scarce. Therefore, the model was identified and validated using data generated by running simulations in Aspen Plus. After model validation, simulated data were used in conjunction with knowledge of the process (obtained from technical literature) to select the state variables to be controlled. Then the manipulated and controlled variables were paired by applying digraphs theory, which avoids linearization of the nonlinear model. After this, local practical controllability metrics were formulated for being used as constraints during the optimization step of the design-control methodology. Besides the controllability metrics, physical constraints as well as product specifications constraints were included in the optimization. To compare the integrated design methodology with a traditional design methodology, the optimization was also run but considering only the physical and product specifications as constraints, but not the controllability metrics. Results of the comparison of the integrated design and the traditional design methodologies have shown that the design obtained by using the design control methodology leads to a higher profit while fulfilling all the constraints. A key factor in the design of the reactive distillation column is the ratio between the number of trays in the rectification zone and the stripping zone. Therefore, the optimization was run for several values of this ratio. Then the best case for this ratio was used for finally designing the column under the design–control methodology. Furthermore, as defining a ratio between the column length and column diameter is a common practice in the traditional design of distillation columns, in this work, such ratio was also included as a constraint in the optimization problem, to investigate how it impacted the optimal design results. It was observed that such type of constraint is not suitable for being included in the design of the reactive distillation column for the analyzed case study