Economic model predictive control of nonlinear singularly perturbed systems

We focus on the development of a Lyapunov-based economic model predictive control (LEMPC) method for nonlinear singularly perturbed systems in standard form arising naturally in the modeling of two-time-scale chemical processes. A composite control structure is proposed in which, a “fast” Lyapunov-based model predictive controller (LMPC) using a quadratic cost function which penalizes the deviation of the fast states from their equilibrium slow manifold and the corresponding manipulated inputs, is used to stabilize the fast dynamics while a two-mode “slow” LEMPC design is used on the slow subsystem that addresses economic considerations as well as desired closed-loop stability properties by utilizing an economic (typically non-quadratic) cost function in its formulation and possibly dictating a time-varying process operation. Through a multirate measurement sampling scheme, fast sampling of the fast state variables is used in the fast LMPC while slow-sampling of the slow state variables is used in the slow LEMPC. Appropriate stabilizability assumptions are made and suitable constraints are imposed on the proposed control scheme to guarantee the closed-loop stability and singular perturbation theory is used to analyze the closed-loop system. The proposed control method is demonstrated through a nonlinear chemical process example.     

On finite-time and infinite-time cost improvement of economic model predictive control for nonlinear systems

A novel two-layer economic model predictive control (EMPC) structure that addresses provable finite-time and infinite-time closed-loop economic performance of nonlinear systems in closed-loop with EMPC is presented. In the upper layer, a Lyapunov-based EMPC (LEMPC) scheme is formulated with performance constraints by taking advantage of an auxiliary Lyapunov-based model predictive control (LMPC) problem solution formulated with a quadratic cost function. The lower layer LEMPC uses a shorter prediction horizon and smaller sampling period than the upper layer LEMPC and involves explicit performance-based constraints computed by the upper layer LEMPC. Thus, the two-layer architecture allows for dividing dynamic optimization and control tasks into two layers for a computationally manageable control scheme at the feedback control (lower) layer. A chemical process example is used to demonstrate the performance and stability properties of the two-layer LEMPC structure.     

Distributed economic MPC: Application to a nonlinear chemical process network

In the present work, we focus on the development and application of Lyapunov-based economic model predictive control (LEMPC) designs to a catalytic alkylation of benzene process network, which consists of four continuously stirred tank reactors and a flash separator. We initially propose a new economic measure for the entire process network which accounts for a broad set of economic considerations on the process operation including reaction conversion, separation quality and energy efficiency. Subsequently, steady-state process optimization is first carried out to locate an economically optimal (with respect to the proposed economic measure) operating steady-state. Then, a sequential distributed economic model predictive control design method, suitable for large-scale process networks, is proposed and its closed-loop stability properties are established. Using the proposed method, economic, distributed as well as centralized, model predictive control systems are designed and are implemented on the process to drive the closed-loop system state close to the economically optimal steady-state. Extensive simulations are carried out to demonstrate the application of the proposed economic MPC (EMPC) designs and compare them with a centralized Lyapunov-based model predictive control design, which uses a conventional, quadratic cost function that includes penalty on the deviation of the states and inputs from their economically optimal steady-state values, from computational time and closed-loop performance points of view.     

Lyapunov-based model predictive control of stochastic nonlinear systems

In this work, we design a Lyapunov-based model predictive controller (LMPC) for nonlinear systems subject to stochastic uncertainty. The LMPC design provides an explicitly characterized region from where stability can be probabilistically obtained. The key idea is to use stochastic Lyapunov-based feedback controllers, with well characterized stabilization in probability, to design constraints in the LMPC that allow the inheritance of the stability properties by the LMPC. The application of the proposed LMPC method is illustrated using a nonlinear chemical process system example.     

Integrating dynamic economic optimization and model predictive control for optimal operation of nonlinear process systems

In this work, we propose a conceptual framework for integrating dynamic economic optimization and model predictive control (MPC) for optimal operation of nonlinear process systems. First, we introduce the proposed two-layer integrated framework. The upper layer, consisting of an economic MPC (EMPC) system that receives state feedback and time-dependent economic information, computes economically optimal time-varying operating trajectories for the process by optimizing a time-dependent economic cost function over a finite prediction horizon subject to a nonlinear dynamic process model. The lower feedback control layer may utilize conventional MPC schemes or even classical control to compute feedback control actions that force the process state to track the time-varying operating trajectories computed by the upper layer EMPC. Such a framework takes advantage of the EMPC ability to compute optimal process time-varying operating policies using a dynamic process model instead of a steady-state model, and the incorporation of suitable constraints on the EMPC allows calculating operating process state trajectories that can be tracked by the control layer. Second, we prove practical closed-loop stability including an explicit characterization of the closed-loop stability region. Finally, we demonstrate through extensive simulations using a chemical process model that the proposed framework can both (1) achieve stability and (2) lead to improved economic closed-loop performance compared to real-time optimization (RTO) systems using steady-state models.     

Design of observer based nonlinear model predictive controller for a continuous stirred tank reactor

Model predictive control (MPC) schemes are now widely used in process industries for the control of key unit operations. Linear model predictive control (LMPC) schemes which make use of linear dynamic model for prediction, limit their applicability to a narrow range of operation (or) to systems which exhibit mildly nonlinear dynamics.

In this paper, a nonlinear observer based model predictive controller (NMPC) for nonlinear system has been proposed. An approach to design NMPC based on fuzzy Kalman filter (FKF) and augmented state fuzzy Kalman filter (ASFKF) has been presented. The efficacy of the proposed NMPC schemes have been demonstrated by conducting simulation studies on the continuous stirred tank reactor (CSTR). The analysis of the extensive dynamic simulation studies revealed that, the NMPC schemes formulated produces satisfactory performance for both servo and regulatory problems. Simulation results also include an inferential control case, where the reactor concentration is not measured but estimated from temperature measurement and used in the NMPC based on FKF and ASFKF formulations.     

Elucidation of the role of constraints in economic model predictive control

Economic model predictive control (EMPC) is a predictive feedback control methodology that unifies economic optimization and control. EMPC uses a stage cost that reflects the process/system economics. In general, the stage cost used is not a quadratic stage cost like that typically used in standard tracking model predictive control. In this paper, a brief overview of EMPC methods is provided. In particular, the role of constraints imposed in the optimization problem of EMPC for feasibility, closed-loop stability, and closed-loop performance is explained. Three main types of constraints are considered including terminal equality constraints, terminal region constraints, and constraints designed via Lyapunov-based techniques. The paper closes with a well-known chemical engineering example (a non-isothermal CSTR with a second-order reaction) to illustrate the effectiveness of time-varying operation to improve closed-loop economic performance compared to steady-state operation and to demonstrate the impact of economically motivated constraints on optimal operation.     

A hybrid model predictive control strategy for nonlinear plant-wide control

A plant-wide control strategy based on integrating linear model predictive control (LMPC) and nonlinear model predictive control (NMPC) is proposed. The hybrid method is applicable to plants that can be decomposed into approximately linear subsystems and highly nonlinear subsystems that interact via mass and energy flows. LMPC is applied to the linear subsystems and NMPC is applied to the nonlinear subsystems. A simple controller coordination strategy that counteracts interaction effects is proposed for the case of one linear subsystem and one nonlinear subsystem. A reactor/separator process with recycle is used to compare the hybrid method to conventional LMPC and NMPC techniques.     

基于扩张状态观测器的车辆横摆稳定模型预测控制器设计

针对车辆横摆稳定性控制问题,本文提出一种基于扩张状态观测器的线性模型预测控制器设计方法.首先,将非线性车辆模型线性化,建立带有模型误差干扰项的线性模型,其中线性化导致的模型误差采用扩张状态观测器估计得到,并证明了观测器的稳定性.然后基于此模型设计线性预测控制器,近似实现了非线性预测控制器的控制效果,同时降低了计算量.最后,通过不同路况下的仿真实验结果,验证了所提方法的计算性能和控制效果.     

The integration of scheduling and control: Top-down vs. bottom-up

The flexible operation of continuous processes often requires the integration of scheduling and control. This can be achieved by top-down or bottom-up approaches. We compare the two paradigms in-silico using an air separation unit as a benchmark process. To demonstrate the top-down paradigm, we identify data-driven models of the closed-loop process dynamics based on a mechanistic model and use them in scheduling calculations that are performed offline. The resulting target trajectories are passed to a linear model predictive control (LMPC) system and implemented in the process. To demonstrate the bottom-up paradigm, we define an economic nonlinear model predictive control (eNMPC) scheme, which performs dynamic optimization using the full model in closed-loop to directly obtain the control variable profiles to be implemented in the process. We provide implementations of the process model equations as both a gPROMS and a Modelica model to encourage future comparison of approaches for flexible operation, process control, and/or handling disturbances. The performance, advantages, and disadvantages of the two strategies are analyzed using demand-response scenarios with varying levels of fluctuations in electricity prices, as well as considering the cases of known, instantaneous, and completely unknown load changes. The similarities and differences of the two approaches as relevant to flexible operation of continuous processes are discussed. Integrated scheduling and control leverages existing infrastructure and can be immediately applied to real operation tasks. Both operation strategies achieve successful process operation with remarkable economic improvements (up to 8%) compared to constant operation. eNMPC requires more computational resources, and is – at the moment – not implementable in real-time due to maximum optimization times exceeding the controller sampling time. However, eNMPC achieves up to 2.5 times higher operating cost savings compared to the top-down approach, owing in part to the more accurate modeling of key process dynamics.     

Repetitive learning control: a Lyapunov-based approach

In this paper, a learning-based feedforward term is developed to solve a general control problem in the presence of unknown nonlinear dynamics with a known period. Since the learning-based feedforward term is generated from a straightforward Lyapunov-like stability analysis, the control designer can utilize other Lyapunov-based design techniques to develop hybrid control schemes that utilize learning-based feedforward terms to compensate for periodic dynamics and other Lyapunov-based approaches (e.g., adaptive-based feedforward terms) to compensate for nonperiodic dynamics. To illustrate this point, a hybrid adaptive/learning control scheme is utilized to achieve global asymptotic link position tracking for a robot manipulator.     

Lyapunov-Based Model Predictive Control of Nonlinear Systems Subject to Data Losses

In this work, we focus on model predictive control of nonlinear systems subject to data losses. The motivation for considering this problem is provided by wireless networked control systems and control of nonlinear systems under asynchronous measurement sampling. In order to regulate the state of the system towards an equilibrium point while minimizing a given performance index, we propose a Lyapunov-based model predictive controller which is designed taking data losses explicitly into account, both in the optimization problem formulation and in the controller implementation. The proposed controller allows for an explicit characterization of the stability region and guarantees that this region is an invariant set for the closed-loop system under data losses, if the maximum time in which the loop is open is shorter than a given constant that depends on the parameters of the system and the Lyapunov-based controller that is used to formulate the optimization problem. The theoretical results are demonstrated through a chemical process example.     

Predictive control of switched nonlinear systems with scheduled mode transitions

In this work, a predictive control framework is proposed for the constrained stabilization of switched nonlinear systems that transit between their constituent modes at prescribed switching times. The main idea is to design a Lyapunov-based predictive controller for each constituent mode in which the switched system operates and incorporate constraints in the predictive controller design which upon satisfaction ensure that the prescribed transitions between the modes occur in a way that guarantees stability of the switched closed-loop system. This is achieved as follows: For each constituent mode, a Lyapunov-based model predictive controller (MPC) is designed, and an analytic bounded controller, using the same Lyapunov function, is used to explicitly characterize a set of initial conditions for which the MPC, irrespective of the controller parameters, is guaranteed to be feasible, and hence stabilizing. Then, constraints are incorporated in the MPC design which, upon satisfaction, ensure that: 1) the state of the closed-loop system, at the time of the transition, resides in the stability region of the mode that the system is switched into, and 2) the Lyapunov function for each mode is nonincreasing wherever the mode is reactivated, thereby guaranteeing stability. The proposed control method is demonstrated through application to a chemical process example.     

Predictive optimal control for thermo-mechanical pulping processes with multi-stage low consistency refining

In this paper, we present a nonlinear model based dynamic optimization approach for optimal control for thermo-mechanical pulping (TMP) processes. The method is based on nonlinear model predictive control (NMPC) technique with an economic objective function. In our previous work [1], an economically oriented NMPC (econNMPC) was presented for a two-stage TMP process with high consistency (HC) refiners. The two-stage TMP process was simulated up to the secondary refiner. In this study, we extend the previous study to multiple stages that include low consistency (LC) refining. Here we can exploit the complexity of interactions of multiple stage TMP for both performance and optimal operations. The first process is a conventional refining process with two stages of HC refining with a primary and a secondary refiner, followed by a latency chest and a third-stage LC refiner. The second TMP process has only a HC primary refiner, and the secondary stage HC refiner is replaced by multiple stages of LC refiners after the latency chest. Both TMP schemes are dynamically optimized against disturbances to produce the same target final pulp qualities while minimizing specific energy consumption of the processes. The simulation results show the potential economic benefits of the proposed method, through a reduction in total specific energy, about 24%, for the second TMP process.     

Stabilization of nonlinear systems with state and control constraints using Lyapunov-based predictive control

This work considers the problem of stabilization of nonlinear systems subject to state and control constraints, for cases where the state constraints need to be enforced at all times (hard constraints) and where they can be relaxed for some time (soft constraints). We propose a Lyapunov-based predictive control design that guarantees stabilization and state and input constraint satisfaction for all times from an explicitly characterized set of initial conditions. An auxiliary Lyapunov-based analytical bounded control design is used to characterize the stability region of the predictive controller and also provide a feasible initial guess to the optimization problem in the predictive controller formulation. For the case when the state constraints are soft, we propose a switched predictive control strategy that reduces the time during which state constraints are violated, driving the states into the state and input constraints feasibility region of the Lyapunov-based predictive controller. We demonstrate the application of the Lyapunov-based predictive controller designs through a chemical process example.     

Long Range Predictive Control of Nonlinear Processes Based on Recurrent Neuro-Fuzzy Network Models

A recurrent neuro-fuzzy network-based nonlinear long range model predictive control strategy is proposed in this paper. The process operation is partitioned into several fuzzy operating regions. Within each region, a local linear model is used to model the process. The global model output is obtained through the centre of gravity defuzzification. Based upon a neuro-fuzzy network model, a nonlinear model-based predictive controller can be developed by combining several local linear model-based predictive controllers which usually have analytical solutions. This strategy avoids the time consuming numerical optimisation procedure, and the uncertainty in convergence to the global optimum which are typically seen in conventional nonlinear model-based predictive control strategies. Furthermore, control actions obtained based on local incremental models contain integration actions which can nat-urally eliminate static control offsets. The technique is demonstrated by an application to the modelling and control of liquid level in a water tank.     

Economic MPC with a contractive constraint for nonlinear systems

In this paper, we consider the stability issue of economic model predictive control (EMPC) for constrained nonlinear systems and propose a new contractive constraint formulation of nonlinear EMPC schemes. This formulation is one of Lyapunov‐based approaches in which the contractive function chosen a priori can be used as a Lyapunov function. Some conditions are given to guarantee recursive feasibility and asymptotic stability of the EMPC. Moreover, we analyze the transient economic performance of the EMPC closed‐loop system in some finite‐time intervals. The proposed EMPC scheme is applied to a chemical reactor model to illustrate its utility and benefits. Copyright © 2016 John Wiley & Sons, Ltd.     

Handling uncertainty in economic nonlinear model predictive control: A comparative case study

In the last years, the use of an economic cost function for model predictive control (MPC) has been widely discussed in the literature. The main motivation for this choice is that often the real goal of control is to maximize the profit or the efficiency of a certain system, rather than tracking a predefined set-point as done in the typical MPC approaches, which can be even counter-productive. Since the economic optimal operation of a system resulting from the application of an economic model predictive control approach drives the system to the constraints, the explicit consideration of the uncertainties becomes crucial in order to avoid constraint violations. Although robust MPC has been studied during the past years, little attention has yet been devoted to this topic in the context of economic nonlinear model predictive control, especially when analyzing the performance of the different MPC approaches. In this work, we present the use of multi-stage scenario-based nonlinear model predictive control as a promising strategy to deal with uncertainties in the context of economic NMPC. We make a comparison based on simulations of the advantages of the proposed approach with an open-loop NMPC controller in which no feedback is introduced in the prediction and with an NMPC controller which optimizes over affine control policies. The approach is efficiently implemented using CasADi, which makes it possible to achieve real-time computations for an industrial batch polymerization reactor model provided by BASF SE. Finally, a novel algorithm inspired by tube-based MPC is proposed in order to achieve a trade-off between the variability of the controlled system and the economic performance under uncertainty. Simulations results show that a closed-loop approach for robust NMPC increases the performance and that enforcing low variability under uncertainty of the controlled system might result in a big performance loss.     

Contractive model predictive control for constrained nonlinearsystems

This paper addresses the development of stabilizing state and output feedback model predictive control (MPC) algorithms for constrained continuous-time nonlinear systems with discrete observations. Moreover, we propose a nonlinear observer structure for this class of systems and derive sufficient conditions under which this observer provides asymptotically convergent estimates. The MPC scheme proposed consists of a basic finite horizon nonlinear MPC technique with the introduction of an additional state constraint, which has been called a contractive constraint. The resulting MPC scheme has been denoted contractive MPC. This is a Lyapunov-based approach in which a Lyapunov function chosen a priori is decreased, not continuously, but discretely; it is allowed to increase at other times. We show in this work that the implementation of this additional constraint into the online optimization makes it possible to prove strong nominal stability properties of the closed-loop system     

Unscented Kalman filter based nonlinear model predictive control of a LDPE autoclave reactor

This paper presents a multivariable nonlinear model predictive control (NMPC) scheme for the regulation of a low-density polyethylene (LDPE) autoclave reactor. A detailed mechanistic process model developed previously was used to describe the dynamics of the LDPE reactor and the properties of the polymer product. Closed-loop simulations are used to demonstrate the disturbance rejection and tracking performance of the NMPC algorithm for control of reactor temperature and weight-averaged molecular weight (WAMW). In addition, the effect of parametric uncertainty in the kinetic rate constants of the LDPE reactor model on closed-loop performance is discussed. The unscented Kalman filtering (UKF) algorithm is employed to estimate plant states and disturbances. All control simulations were performed under conditions of noisy process measurements and structural plant–model mismatch. Where appropriate, the performance of the NMPC algorithm is contrasted with that of linear model predictive control (LMPC). It is shown that for this application the closed-loop performance of the UKF based NMPC scheme is very good and is superior to that of the linear predictive controller.