Modern approaches to control of a multiple hearth furnace in kaolin production

The aim of this thesis is to improve the overall efficiency of the multiple hearth furnace (MHF) in kaolin calcination by developing control strategies which incorporate machine learning based soft sensors to estimate mineralogy related constraints in the control strategy. The objective of the control strategy is to maximize the capacity of the furnace and minimize energy consumption while maintaining the product quality of the calcined kaolin. First, the description of the process of interest is given, highlighting the control strategy currently implemented at the calciner studied in this work. Next, the state of the art on control of calcination furnaces is presented and discussed. Then, the description of the mechanistic model of the MHF, which plays a key role in the testing environment, is provided and an analysis of the MHF dynamic behavior based on the industrial and simulated data is presented. The design of the mineralogy-driven control strategy for the multiple hearth furnace and its implementation in the simulation environment are also outlined. The analysis of the results is then presented. Furthermore, the extensive sampling campaign for testing the soft sensors and the control strategy logic of the industrial MHF is reported, and the results are analyzed and discussed. Finally, an introduction to Model Predictive Control (MPC) is presented, the design of the Linear MPC framework for the MHF in kaolin calcination is described and discussed, and future research is outlined

Advances in Theoretical and Computational Energy Optimization Processes

The paradigm in the design of all human activity that requires energy for its development must change from the past. We must change the processes of product manufacturing and functional services. This is necessary in order to mitigate the ecological footprint of man on the Earth, which cannot be considered as a resource with infinite capacities. To do this, every single process must be analyzed and modified, with the aim of decarbonising each production sector. This collection of articles has been assembled to provide ideas and new broad-spectrum contributions for these purposes

Model-based approach for the plant-wide economic control of fluid catalytic cracking unit

Fluid catalytic cracking (FCC) is one of the most important processes in the petroleum refining industry for the conversion of heavy gasoil to gasoline and diesel. Furthermore, valuable gases such as ethylene, propylene and isobutylene are produced. The performance of the FCC units plays a major role on the overall economics of refinery plants. Any improvement in operation or control of FCC units will result in dramatic economic benefits. Present studies are concerned with the general behaviour of the industrial FCC plant, and have dealt with the modelling of the FCC units, which are very useful in elucidating the main characteristics of these systems for better design, operation, and control. Traditional control theory is no longer suitable for the increasingly sophisticated operating conditions and product specifications of the FCC unit. Due to the large economic benefits, these trends make the process control more challenging. There is now strong demand for advanced control strategies with higher quality to meet the challenges imposed by the growing technological and market competition. According to these highlights, the thesis objectives were to develop a new mathematical model for the FCC process, which was used to study the dynamic behaviour of the process and to demonstrate the benefits of the advanced control (particularly Model Predictive Control based on the nonlinear process model) for the FCC unit. The model describes the seven main sections of the entire FCC unit: (1) the feed and preheating system, (2) reactor, (3) regenerator, (4) air blower, (5) wet gas compressor, (6) catalyst circulation lines and (7) main fractionators. The novelty of the developed model consists in that besides the complex dynamics of the reactorregenerator system, it includes the dynamic model of the fractionator, as well as a new five lump kinetic model for the riser, which incorporates the temperature effect on the reaction kinetics; hence, it is able to predict the final production rate of the main products (gasoline and diesel), and can be used to analyze the effect of changing process conditions on the product distribution. The FCC unit model has been developed incorporating the temperature effect on reactor kinetics reference construction and operation data from an industrial unit. The resulting global model of the FCC unit is described by a complex system of partial-differential-equations, which was solved by discretising the kinetic models in the riser and regenerator on a fixed grid along the height of the units, using finite differences. The resulting model is a high order DAE, with 942 ODEs (142 from material and energy balances and 800 resulting from the discretisation of the kinetic models). The model offers the possibility of investigating the way that advanced control strategies can be implemented, while also ensuring that the operation of the unit is environmentally safe. All the investigated disturbances showed considerable influence on the products composition. Taking into account the very high volume production of an industrial FCC unit, these disturbances can have a significant economic impact. The fresh feed coke formation factor is one of the most important disturbances analysed. It shows significant effect on the process variables. The objective regarding the control of the unit has to consider not only to improve productivity by increasing the reaction temperature, but also to assure that the operation of the unit is environmentally safe, by keeping the concentration of CO in the stack gas below a certain limit. The model was used to investigate different control input-output pairing using classical controllability analysis based on relative gain array (RGA). Several multi-loop control schemes were first investigated by implementing advanced PID control using anti-windup. A tuning approach for the simultaneous tuning of multiple interacting PID controllers was proposed using a genetic algorithm based nonlinear optimisation approach. Linear model predictive control (LMPC) was investigated as a potential multi-variate control scheme applicable for the FCCU, using classical square as well as novel non-square control structures. The analysis of the LMPC control performance highlighted that although the multivariate nature of the MPC approach using manipulated and controlled outputs which satisfy controllability criteria based on RGA analysis can enhance the control performance, by decreasing the coupling between the individual low level control loops operated by the higher level MPC. However the limitations of using the linear model in the MPC scheme were also highlighted and hence a nonlinear model based predictive control scheme was developed and evaluated.EThOS - Electronic Theses Online ServiceGBUnited Kingdo

Gasification for Practical Applications

Although there were many books and papers that deal with gasification, there has been only a few practical book explaining the technology in actual application and the market situation in reality. Gasification is a key technology in converting coal, biomass, and wastes to useful high-value products. Until renewable energy can provide affordable energy hopefully by the year 2030, gasification can bridge the transition period by providing the clean liquid fuels, gas, and chemicals from the low grade feedstock. Gasification still needs many upgrades and technology breakthroughs. It remains in the niche market, not fully competitive in the major market of electricity generation, chemicals, and liquid fuels that are supplied from relatively cheap fossil fuels. The book provides the practical information for researchers and graduate students who want to review the current situation, to upgrade, and to bring in a new idea to the conventional gasification technologies

Real-Time Substrate Feed Optimization of Anaerobic Co-Digestion Plants

In anaerobic co-digestion plants a mix of organic materials is converted to biogas using the anaerobic digestion process. These organic materials, called substrates, can be crops, sludge, manure, organic wastes and many more. They are fed on a daily basis and significantly affect the biogas production process. In this thesis dynamic real-time optimization of the substrate feed for anaerobic co-digestion plants is developed. In dynamic real-time optimization a dynamic simulation model is used to predict the future performance of the controlled plant. Therefore, a complex simulation model for biogas plants is developed, which uses the famous Anaerobic Digestion Model No. 1 (ADM1). With this model the future economics as well as stability can be calculated resulting in a multi-objective performance criterion. Using multi-objective nonlinear model predictive control (NMPC) the model predictions are used to find the optimal substrate feed for the biogas plant. Therefore, NMPC solves an optimization problem over a moving horizon and applies the optimal substrate feed to the plant for a short while before recalculating the new optimal solution. The multi-objective optimization problem is solved using state-of-the-art methods such as SMS-EMOA and SMS-EGO. The performance of the proposed approach is validated in a detailed simulation studyAlgorithms and the Foundations of Software technolog

Modeling and Simulation of Metallurgical Processes in Ironmaking and Steelmaking

In recent years, improving the sustainability of the steel industry and reducing its CO2 emissions has become a global focus. To achieve this goal, further process optimization in terms of energy and resource efficiency and the development of new processes and process routes are necessary. Modeling and simulation have established themselves as invaluable sources of information for otherwise unknown process parameters and as an alternative to plant trials that involves lower costs, risks, and time. Models also open up new possibilities for model-based control of metallurgical processes. This Special Issue focuses on recent advances in the modeling and simulation of unit processes in iron and steelmaking. It includes reviews on the fundamentals of modeling and simulation of metallurgical processes, as well as contributions from the areas of iron reduction/ironmaking, steelmaking via the primary and secondary route, and continuous casting

Automated Manufacture of Fertilizing Agglomerates from Burnt Wood Ash

In Sweden, extensive research is conducted to find alternative sources of energy that should partly replace the electric power production from nuclear power. With the ambition to create a sustainable system for producing energy, the use of renewable energy is expected to grow further and biofuels are expected to account for a significant part of this increase. However, when biofuels are burned or gasified, ash appears as a by-product. In order to overcome the problems related to deposition in land fills, the idea is to transform the ashes into a product – agglomerates – that easily could be recycled back to the forest grounds; as a fertilizer, or as a tool to reduce the acidification in the forest soil at the spreading area. This work considers the control of a transformation process, which transforms wood ash produced at a district heating plant into fertilizing agglomerates. A robust machine, built to comply with the industrial requirements for continuous operation, has been developed and is controlled by an industrial control system in order to enable an automated manufacture

Implementation and performance assessment of a real-time optimization system on a virtual fluidized-bed catalytic-cracking plant

This thesis develops and evaluates RTO implementation in a FCCU virtual plant, taking into account each RTO stage (noise elimination, steady-state detection, data validation, parameter estimation, and optimization). The dynamic data to carry out this analysis were obtained from an FCCU virtual plant based on a dynamic deterministic model developed in Matlab®. The model output data were contaminated with Gaussian and gross errors to simulate measurements from a real plant. For denoising, steady-state detection, data reconciliation, parameter estimation, and optimization, different strategies and algorithms were studied and assessed, while a decentralized PID was proposed for the control system. Finally, the most appropriate strategies for the case study were implemented and their performance was fully evaluated.Resumen: Esta tesis desarrolla y evalúa la implementación de la RTO en una planta virtual de FCCU, teniendo en cuenta cada etapa de una RTO (eliminación de ruido, detección de estado estable, validación de datos, estimación de parámetros y optimización). Los datos dinámicos para llevar a cabo este análisis se obtuvieron de una planta virtual de FCCU basada en un modelo determinista dinámico desarrollado en Matlab®. Los datos de salida del modelo se contaminaron con error de Gauss y error grueso para simular mediciones de una planta real. Para la eliminación de ruido, la detección de estado estable, la reconciliación de datos, la estimación de parámetros y la optimización, se estudiaron y evaluaron diferentes estrategias y algoritmos, mientras que para el sistema de control se propuso un PID descentralizado. Finalmente, se implementaron las estrategias más apropiadas para el estudio de caso y se evaluó su desempeño en conjunto.Maestrí