Addressing the control problem of algae growth in water reservoirs with advanced dynamic optimization approaches

In this work, we develop a lake eutrophication model to determine restoration policies for water quality improvement. This hybrid biogeochemical model has been formulated within a simultaneous dynamic optimization framework as an optimal control problem, whose solution provides limiting nutrient inflow profiles to the lake, as well as in-lake biomanipulation profiles. The water quality model comprises a set of partial differential algebraic equations in time and space, which result from dynamic mass balances on main phytoplankton groups, nutrients, dissolved oxygen and biochemical demand of oxygen. Spatial discretization has been performed in two layers. The simultaneous approach proceeds by discretizing control and state variables by collocation over finite elements and solving the large scale nonlinear program with an interior point method with successive quadratic programming techniques.     

A bilevel NLP sensitivity‐based decomposition for dynamic optimization with moving finite elements

Optimal control has guided numerous applications in chemical engineering, and exact determination of optimal profiles is essential for operation of separation and reactive processes, and operating strategies and recipe generation for batch processes. Here, a simultaneous collocation formulation based on moving finite elements is developed for the solution of a class of optimal control problems. Novel features of the algorithm include the direct location of breakpoints for control profiles and a termination criterion based on a constant Hamiltonian profile. The algorithm is stabilized and performance is significantly improved by decomposing the overall nonlinear programming (NLP) formulation into an inner problem, which solves a fixed element simultaneous collocation problem, and an outer problem, which adjusts the finite elements based on several error criteria. This bilevel formulation is aided by a NLP solver (the interior point optimizer) for both problems as well as an NLP sensitivity component, which provides derivative information from the inner problem to the outer problem. This approach is demonstrated on 11 dynamic optimization problems drawn from the optimal control and chemical engineering literature. © 2014 American Institute of Chemical Engineers AIChE J, 60: 966–979, 2014     

一种求解化工动态优化问题的迭代自适应粒子群方法

智能优化方法因其简单、易实现且具有良好的全局搜索能力,在动态优化中的应用越来越广泛,但传统的智能方法收敛速度相对较慢。提出了一种迭代自适应粒子群优化方法（IAPSO）来求解一般的化工动态优化问题。首先通过控制变量参数化将原动态优化问题转化为非线性规划问题,再利用所提出的迭代自适应粒子群优化方法进行求解。相比传统的粒子群优化方法,该种迭代自适应粒子群优化方法具有收敛速度更快的优点,主要原因是：该算法根据粒子种群分布特性自适应调整参数;该算法通过缩减搜索空间并迭代使用粒子群算法搜索最优解。将提出的迭代自适应粒子群方法应用到多个经典动态优化问题中,测试结果表明,该方法简单、有效,精度高,且收敛速度比传统粒子群算法有显著提升。     

Interior point SQP strategies for large-scale,structured process optimization problems

Successive quadratic programming (SQP) has been the method of choice for the solution of many nonlinear programming problems in process engineering. However, for the solution of large problems with SQP based codes, the combinatorial complexity associated with active set quadratic programming (QP) methods can be a bottleneck in exploiting the problem structure. In this paper, we examine the merits of incorporating an interior point QP method within an SQP framework. This provides a novel interpretation of popularly used predictor-corrector interior point (IP) methods. The resulting large-scale SQP algorithm, with an interior point QP, also allows us to demonstrate significant computational savings on problems drawn from optimal control and nonlinear model predictive control.     

基于PSO-控制变量参数化混合策略的间歇化工过程优化控制

控制变量参数化方法作为一种化工过程动态优化的梯度搜索算法，其求解效率过于依赖初始给定轨迹。目前初始轨迹一般都是设定在边界值或中间值，缺乏科学依据，从而大大影响了算法的收敛速度。针对这一问题，提出了一种粒子群优化(PSO)与控制变量参数化方法混合的策略，首先利用粒子群优化对间歇化工过程最优控制量进行求解，结果作为控制变量参数化方法初始给定轨迹，进行二次优化。双层优化的混合策略提高了控制变量参数化方法的收敛速度和粒子群优化算法的求解精度。将混合策略应用于两个间歇化工过程优化控制实例，仿真结果表明了该算法对求解化工过程动态优化问题具有可行性和有效性。     

Optimizing process economics online using model predictive control

Optimizing process economics in model predictive control traditionally has been done using a two-step approach in which the economic objectives are first converted to steady-state operating points, and then the dynamic regulation is designed to track these setpoints. Recent research has shown that process economics can be optimized directly in the dynamic control problem, which can take advantage of potential higher profit transients to give superior economic performance. However, in practice, solution of such nonlinear MPC dynamic control problems can be challenging due to the nonlinearity of the model and/or nonconvexity of the economic cost function. In this work we propose the use of direct methods to formulate the nonlinear control problem as a large-scale NLP, and then solve it using an interior point nonlinear solver in conjunction with automatic differentiation. Two case studies demonstrate the computational performance of this approach along with the economic performance of economic MPC formulation.     

过程动态优化问题的自热式求解策略

分析了基于微分代数方程（DAE）的动态优化问题的联立求解原理,提出了基于Lobatto配置的全离散模型的简洁描述形式。根据离散化模型的最优解具有结构相似性的特点,利用低密度离散的解来近似高密度离散的解,并且配合内点法求解的暖启动技术与障碍参数初值设定方法,提出了能实现动态优化问题快速求解的自热式策略。最后通过求解一个结晶过程的动态优化算例,证实了所提出的自热式策略能够将求解速度提高6倍左右。     

Control of pH neutralization process using simulation based dynamic programming

The pH neutralization process has long been taken as a representative benchmark problem of nonlinear chemical process control due to its nonlinearity and time-varying nature. For general nonlinear processes, it is difficult to control with a linear model-based control method so nonlinear controls must be considered. Among the numerous approaches suggested, the most rigorous approach is the dynamic optimization. However, as the size of the problem grows, the dynamic programming approach suffers from the curse of dimensionality. In order to avoid this problem, the Neuro-Dynamic Programming (NDP) approach was proposed by Bertsekas and Tsitsiklis [1996]. The NDP approach is to utilize all the data collected to generate an approximation of optimal cost-to-go function which was used to find the optimal input movement in real time control. The approximation could be any type of function such as polynomials, neural networks, etc. In this study, an algorithm using NDP approach was applied to a pH neutralization process to investigate the feasibility of the NDP algorithm and to deepen the understanding of the basic characteristics of this algorithm. As the approximator, the neural network which requires training and the k-nearest neighbor method which requires querying instead of training are investigated. The approximator has to use data from the optimal control strategy. If the optimal control strategy is not readily available, a suboptimal control strategy can be used instead. However, the laborious Bellman iterations are necessary in this case. For pH neutralization process it is rather easy to devise an optimal control strategy. Thus, we used an optimal control strategy and did not perform the Bellman iteration. Also, the effects of constraints on control moves are studied. From the simulations, the NDP method outperforms the conventional PID control.     

基于知识改进的文化算法及其在化工动态优化中的应用

针对化工以及生化过程的动态优化问题,提出了一种基于改进知识引导的文化算法。该算法首先对控制搜索域与时间域分别进行了等分和离散化,利用"软约束"思想编码控制序列,采用"种群产生"-"控制域进化"-"种群寻优"迭代过程实现对控制序列的逐步寻优;其次在种群空间采用遗传算法,在信度空间采用差分算法,并将进化过程中的已有种群信息设计为3种知识,通过分析知识、提取知识、管理知识来指导进化过程。由于引入了文化进化理念和机制,大大提高了动态优化问题的搜索效率。通过3种典型化工动态优化问题的仿真实例,表明该算法具有较好的寻优效率以及更好的优化结果,验证了该算法在解决具有非线性动态约束问题的有效性。     

Inferential Control of Reactive Destillation Columns – An Algorithmic Approach

Decentralized control system design comprises the selection of a suitable control structure and controller parameters. Here, mixed integer optimization is used to determine the optimal control structure and the optimal controller parameters simultaneously. The process dynamics is included explicitly into the constraints using a rigorous nonlinear dynamic process model. Depending on the objective function, which is used for the evaluation of competing control systems, two different formulations are proposed which lead to mixed‐integer dynamic optimization (MIDO) problems. A MIDO solution strategy based on the sequential approach is adopted in the present paper. Here, the MIDO problem is decomposed into a series of nonlinear programming (NLP) subproblems (dynamic optimization) where the binary variables are fixed, and mixed‐integer linear programming (MILP) master problems which determine a new binary configuration for the next NLP subproblem. The proposed methodology is applied to inferential control of reactive distillation columns as a challenging benchmark problem for chemical process control.     

Reactor modeling and recipe optimization of polyether polyol processes: Polypropylene glycol

The reactor modeling and recipe optimization of conventional semibatch polyether polyol processes, in particular for the polymerization of propylene oxide to make polypropylene glycol, is addressed. A rigorous mathematical reactor model is first developed to describe the dynamic behavior of the polymerization process based on first‐principles including the mass and population balances, reaction kinetics, and vapor‐liquid equilibria. Next, the obtained differential algebraic model is reformulated by applying a nullspace projection method that results in an equivalent dynamic system with better computational performance. The reactor model is validated against plant data by adjusting model parameters. A dynamic optimization problem is then formulated to optimize the process recipe, where the batch processing time is minimized, given a target product molecular weight as well as other requirements on product quality and process safety. The dynamic optimization problem is translated into a nonlinear program using the simultaneous collocation strategy and further solved with the interior point method to obtain the optimal control profiles. The case study result shows a good match between the model prediction and real plant data, and the optimization approach is able to significantly reduce the batch time by 47%, which indicates great potential for industrial applications. © 2013 American Institute of Chemical Engineers AIChE J, 59: 2515–2529, 2013     

基于全局正交配置的非线性预测控制算法

针对非线性预测控制(NMPC)在线优化计算量大这一关键问题,提出一种基于全局正交配置的非线性预测控制算法。该算法以高阶插值正交多项式为基函数同时配置优化时域内的状态变量和控制变量,将连续动态优化问题转化为非线性规划问题(NLP)求解。全局正交配置可以使用较少的配置点而获得较高的逼近精度,这样即使NMPC使用很长的优化时域,离散化后得到的NLP问题的规模也比较小,能够有效地降低在线优化计算量。最后,以连续聚合反应过程为例验证了算法的有效性。     

分批补料反应过程的非固定终端经济优化控制

针对批次生产周期不确定问题,提出一种非固定终端的经济优化控制方法。首先采用经济模型预测控制方法,用收益最大化的经济型目标函数代替终端约束,并将批次生产周期纳入被优化变量,建立动态经济优化问题,并通过对每个控制变量进行有差异的参数化,将动态优化问题转化为非线性规划（NLP）问题;然后使用内点罚函数法求解含非线性约束的优化问题,得到的最优控制序列和最佳批次生产周期,可将不确定扰动带来的损失降低到最小。其次采用非固定预测时域的滚动时域控制方法,不仅提高多变量系统的协同控制能力,而且根据实时预测终端产品产量不断优化更新关键操纵变量的控制分段函数的分割数及控制序列,从而可灵活优化操纵变量和操作时间的轨迹。最后在苯胺加氢过程上进行了批次优化控制性能测试,测试结果表明,非固定终端的经济优化控制从批次的总生产效益角度来优化每个批次生产的操作条件,实现批次反应过程生产时间与经济效益的最优化管理。     

Dynamic optimization of 1,3-propanediol fermentation process: A switched dynamical system approach

This paper considers a dynamic optimization problem (DOP) of 1,3-propanediol fermentation process (1,3-PFP). Our main contributions are as follows. Firstly, the DOP of 1,3-PFP is modeled as an optimal control problem of switched dynamical systems. Unlike the existing switched dynamical system optimal control problem, the state-dependent switching method is applied to design the switching rule. Then, in order to obtain the numerical solution, by introducing a discrete-valued function and using a relaxation technique, this problem is transformed into a nonlinear parameter optimization problem (NPOP). Although the gradient-based algorithm is very efficient for solving NPOPs, the existing algorithm is always trapped in a local minimum for such problems with multiple local minima. Next, in order to overcome this challenge, a gradient-based random search algorithm (GRSA) is proposed based on an improved gradient-based algorithm (IGA) and a novel random search algorithm (NRSA), which cannot usually be trapped in a local minimum. The convergence results are also established, and show that the GRSA is globally convergent. Finally, a DOP of 1,3-PFP is provided to illustrate the effectiveness of the GRSA proposed by this paper.     

一种改进的差分进化算法及其在补料分批式生化反应器动态优化中的应用

动态优化是生物化工过程中的重要课题,求解动态优化问题通常有两种方法:解析法和数值法。基于智能进化算法的数值方法在动态优化中的应用越来越广泛,但是这些方法局部寻优能力不强,容易陷入局部最优,并且求解速度相对较慢。针对这些方法的不足,提出了一种改进的差分进化算法,设计了新的局部寻优算子来增强算法的局部寻优能力,并且采用一种新的控制策略表示方法来求解动态优化问题。通过求解补料分批式生化反应器的动态优化实例,证明了算法的有效性和鲁棒性。通过与其他几种方法进行对比,实验结果表明,所提出的方法在优化结果和计算代价方面都有优势。     

Integration of scheduling and control with online closed-loop implementation: Fast computational strategy and large-scale global optimization algorithm

In this paper, we propose a novel integration method to solve the scheduling problem and the control problem simultaneously. The integrated problem is formulated as a mixed-integer dynamic optimization (MIDO) problem which contains discrete variables in the scheduling problem and constraints of differential equations from the control problem. Because online implementation is crucial to deal with uncertainties and disturbances in operation and control of the production system, we develop a fast computational strategy to solve the integration problem efficiently and allow its online applications. In the proposed integration framework, we first generate a set of controller candidates offline for each possible transition, and then reformulate the integration problem as a simultaneous scheduling and controller selection problem. This is a mixed-integer nonlinear fractional programming problem with a non-convex nonlinear objective function and linear constraints. To solve the resulting large-scale problem within sufficiently short computational time for online implementation, we propose a global optimization method based on the model properties and the Dinkelbach's algorithm. The advantage of the proposed method is demonstrated through four case studies on an MMA polymer manufacturing process. The results show that the proposed integration framework achieves a lower cost rate than the conventional sequential method, because the proposed framework provides a better tradeoff between the conflicting factors in scheduling and control problems. Compared with the simultaneous approach based on the full discretization and reformulation of the MIDO problem, the proposed integration framework is computationally much more efficient, especially for large-scale cases. The proposed method addresses the challenges in the online implementation of the integrated scheduling and control decisions by globally optimizing the integrated problem in an efficient way. The results also show that the online solution is crucial to deal with the various uncertainties and disturbances in the production system.     

Optimization‐Based Nonlinear Centralized Controller Tuning of Liquid‐Liquid Extraction Processes

Abstract

The control problem of an agitated contactor is considered in this work. A Scheibel extraction column is modeled using the non‐equilibrium backflow mixing cell model. Model dynamic analysis shows that this process is highly nonlinear, thus the control problem solution of such a system needs to tackle the process nonlinearity efficiently. The control problem of this process is solved by developing a multivariable nonlinear control system implemented in MATLAB?. In this control methodology, a new controller tuning method is adopted, in which the time‐domain control parameter‐tuning problem is solved as a constrained optimization problem. A MIMO (multi‐input multi‐output) PI controller structure is used in this strategy. The centralized controller uses a 2×2 transfer function and accounts for loops interaction. The controller parameters are tuned using an optimization‐based algorithm with constraints imposed on the process variables reference trajectories. Incremental tuning procedure is performed until the extractor output variables transient response satisfies a preset uncertainty which bounds around the reference trajectory. A decentralized model‐based IMC (internal model control) control strategy is compared with the newly developed centralized MIMO PI control one. Stability and robustness tests are applied to the two algorithms. The performance of the MIMO PI controller is found to be superior to that of the conventional IMC controller in terms of stability, robustness, loops interaction handling, and step‐change tracking characteristics.     

全流程卷式反渗透海水淡化系统操作优化

在对反渗透海水淡化系统流程和实际应用分析的基础上,提出了一种旨在降低总体操作费用的全流程反渗透海水淡化系统优化方法。首先根据系统变参数特点并充分利用蓄水池的缓冲能力,建立了反渗透过程机理模型、蓄水池动态过程模型以及变参数方程模型,实现了整个流程的方程描述。然后根据工艺流程和操作过程费用组成情况建立了总的操作费用模型,得到了全流程单位产水费用指标。在此基础上建立了以总体操作费用最低为目标、以开放方程描述的各模型方程为约束、以设备和产品质量限制为边界的优化命题,采用联立求解技术将该微分代数方程组成的优化（DAOP）问题转化为NLP问题后进行求解。最后对某海水淡化系统进行了实例研究。优化求解结果不仅表明本优化方法可以大幅降低实际操作费用,而且通过求解还可得到各种变参数条件下最优操作费用组成,以及实现费用最低的最优操作压力和流量变化曲线。本研究对优化海水淡化系统操作、降低总体操作费用具有重要意义。     

Optimization and nonlinear control of a batch crystallization process

Crystallization process has been widely used for separation in many chemical industries due to its capability to provide high purity product. To obtain the desired quality of crystal product, an optimal cooling control strategy is studied in the present work. Within the proposed control strategy, a dynamic optimization is first preformed with the objective to obtain the optimal cooling temperature policy of a batch crystallizer, maximizing the total volume of seeded crystals. Two different optimization problems are formulated and solved by using a sequential optimization approach. Owing to the complex and nonlinear behavior of the batch crystallizer, the nonlinear control strategy which is based on a generic model control (GMC) algorithm is implemented to track the resulting optimal temperature profile. The optimization integrated with nonlinear control strategy is demonstrated on a seeded batch crystallizer for the production of potassium sulfate.