Integrated process design,scheduling, and model predictive control of batch processes with closed-loop implementation

Simultaneous evaluation of multiple time scale decisions has been regarded as a promising avenue to increase the process efficiency and profitability through leveraging their synergistic interactions. Feasibility of such an integral approach is essential to establish a guarantee for operability of the derived decisions. In this study, we present a modeling methodology to integrate process design, scheduling, and advanced control decisions with a single mixed-integer dynamic optimization (MIDO) formulation while providing certificates of operability for the closed-loop implementation. We use multi-parametric programming to derive explicit expressions for the model predictive control strategy, which is embedded into the MIDO using the base-2 numeral system that enhances the computational tractability of the integrated problem by exponentially reducing the required number of binary variables. Moreover, we apply the State Equipment Network representation within the MIDO to systematically evaluate the scheduling decisions. The proposed framework is illustrated with two batch processes with different complexities.     

Explicit model predictive control of hybrid systems and multiparametric mixed integer polynomial programming

Hybrid systems are dynamical systems characterized by the simultaneous presence of discrete and continuous variables. Model‐based control of such systems is computationally demanding. To this effect, explicit controllers which provide control inputs as a set of functions of the state variables have been derived, using multiparametric programming mainly for the linear systems. Hybrid polynomial systems are considered resulting in a Mixed Integer Polynomial Programming problem. Treating the initial state of the system as a set of bounded parameters, the problem is reformulated as a multiparametric Mixed Integer Polynomial optimization (mp‐MIPOPT) problem. A novel algorithm for mp‐MIPOPT problems is proposed and the exact explicit control law for polynomial hybrid systems is computed. The key idea is the computation of the analytical solution of the optimality conditions while the binary variables are treated as relaxed parameters. Finally, using symbolic calculations exact nonconvex critical regions are computed. © 2016 The Authors AIChE Journal published by Wiley Periodicals, Inc. on behalf of American Institute of Chemical Engineers AIChE J, 62: 3441–3460, 2016     

Design of multi-parametric NCO tracking controllers for linear dynamic systems

A methodology for combining multi-parametric programming and NCO tracking is presented in the case of linear dynamic systems. The resulting parametric controllers consist of (potentially nonlinear) feedback laws for tracking optimality conditions by exploiting the underlying optimal control switching structure. Compared to the classical multi-parametric MPC controller, this approach leads to a reduction in the number of critical regions. It calls for the solution of more difficult parametric optimization problems with linear differential equations embedded, whose critical regions are potentially nonconvex. Examples of constrained linear quadratic optimal control problems with parametric uncertainty are presented to illustrate the approach.     

Analysis of linear programming in model predictive control

The linear programming formulations of model predictive control are known to exhibit degenerate solution behavior. In this work, a multi-parametric linear programming technique is utilized to analyze the control laws that are generated from various linear programming based MPC routines. These various routines explore a number of factors, including objective function selection and constraint handling on the control laws generated from LP based MPC. A single input single output system is used to demonstrate that the use of input velocity penalties, input blocking, and ∞-norm objective functions can limit or eliminate this undesirable behavior. Finally, a paper machine cross directional control problem is used to demonstrate the control laws generated from LP based MPC for a multivariable example.     

Off-line model reduction for on-line linear MPC of nonlinear large-scale distributed systems

Model predictive control (MPC) is an efficient method for the controller design of a large number of processes. However, linear MPC is often inappropriate for controlling nonlinear large-scale systems, while non-linear MPC can be computationally costly. The resulting optimization-based procedure can lead to local minima due to the, non-convexities that non-linear systems can exhibit. To overcome the excessive computational cost of MPC application for large-scale nonlinear systems, model reduction methodology in conjunction with efficient system linearizations have been exploited to enable the efficient application of linear MPC for nonlinear distributed parameter systems (DPS). An off-line model reduction technique, the proper orthogonal decomposition (POD) method, combined with a finite element Galerkin projection is first used to extract accurate non-linear low-order models from the large-scale ones. Trajectory Piecewise-Linear (TPWL) methodologies are subsequently developed to construct a piecewise linear representation of the reduced nonlinear model, both in a static and in a dynamic fashion. Linear MPC, based on quadratic programming, can then be efficiently performed on the resulting low-order, piece-wise affine system. Our combined methodology is readily applicable in combination with advanced MPC methodologies such as multi-parametric MPC (MP-MPC) (Pistikopoulos, 2009). The stabilisation of the oscillatory behaviour of a tubular reactor with recycle is used as an illustrative example to demonstrate our methodology.     

混杂系统基于参数规划的状态反馈预测控制

In this article, state feedback predictive controller for hybrid system via parametric programming is proposed. First, mixed logic dynamic （MLD） modeling mechanism for hybrid system is analyzed, which has a distinguished advantage to deal with the logic rules and constraints of a plant. Model predictive control algorithm with moving horizon state estimator （MHE） is presented. The estimator is adopted to estimate the current state of the plant with process disturbance and measurement noise, and the state estimated are utilized in the predictive controller for both regulation and tracking problems of the hybrid system based on MLD model. Off-line parametric programming is adopted and then on-line mixed integer programming problem can be treated as the parameter programming with estimated state as the parameters. A three tank system is used for computer simulation, results show that the proposed MHE based predictive control via parametric programming is effective for hybrid system with model/olant mismatch, and has a potential for the engineering applications.     

Simultaneous design of explicit/multi-parametric constrained moving horizon estimation and robust model predictive control

In this work we present a rigorous methodology for the simultaneous design of moving horizon estimation (MHE) and robust model predictive control based on multi-parametric programming. First, an explicit/multi-parametric solution of the MHE is derived. Then, a novel method is presented that allows for the derivation of the estimation error dynamics, the bounding set of the estimation error, and the state estimate dynamic equations of constrained MHE. A framework is then presented for the design of robust explicit/multi-parametric model predictive control (MPC) controllers, based on tube-based MPC methods, which ensures that no constraints are violated due to the estimation error and the process noise in the system. This framework is first shown for the Kalman filter and unconstrained MHE and is then extended to the constrained MHE.     

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.     

From multi-parametric programming theory to MPC-on-a-chip multi-scale systems applications

An overview of multi-parametric programming and control is presented with emphasis on historical milestones, novel developments in the theory of multi-parametric programming and explicit MPC as well as their application to the design of advanced controller for complex multi-scale systems.     

Multi-objective optimization with convex quadratic cost functions: A multi-parametric programming approach

In this note we present an approximate algorithm for the explicit calculation of the Pareto front for multi-objective optimization problems featuring convex quadratic cost functions and linear constraints based on multi-parametric programming and employing a set of suitable overestimators with tunable suboptimality. A numerical example as well as a small computational study highlight the features of the novel algorithm.     

Explicit model predictive control of gas–liquid separation plant via orthogonal search tree partitioning

Solutions to constrained linear model predictive control (MPC) problems can be pre-computed off-line in an explicit form as a piecewise linear (PWL) state feedback defined on a polyhedral partition of the state space. This admits implementation at high sampling frequencies in real-time systems with high reliability and low software complexity. Recently, algorithms that determine an approximate explicit PWL state feedback solution by imposing an orthogonal search tree structure on the partition, have been developed, and it has been shown that they may offer computational advantages. This paper considers the application of an approximate approach to the design of an explicit model predictive controller for a two-input two-output laboratory gas–liquid separation plant, including experimental evaluation. The approximate explicit MPC controller achieves performance close to that of the conventional MPC, but requires only a fraction of the real-time computational machinery, thus leading to fast and reliable computations.     

Hybrid fuzzy model-based predictive control of temperature in a batch reactor

Processes in industry, such as batch reactors, often demonstrate a hybrid and non-linear nature. Model predictive control (MPC) is one of the approaches that can be successfully employed in such cases. However, due to the complexity of these processes, obtaining a suitable model is often a difficult task. In this paper a hybrid fuzzy modelling approach with a compact formulation is introduced. The hybrid system hierarchy is explained and the Takagi–Sugeno fuzzy formulation for the hybrid fuzzy modelling purposes is presented. An efficient method for identifying the hybrid fuzzy model is also proposed.

A MPC algorithm suitable for systems with discrete inputs is treated. The benefits of the MPC algorithm employing the proposed hybrid fuzzy model are verified on a batch-reactor simulation example: a comparison between MPC employing a hybrid linear model and a hybrid fuzzy model was made. We established that the latter approach clearly outperforms the approach where a linear model is used.     

一种新型线性约束系统预测控制算法

通过对无约束预测控制算式的修正,应用线性规划求解技术,提出了一种基于脉冲响应模型的线性约束系统的预测控制算法。理论特性分析表明,该方法在一般情况下具有与无约束预测控制算法相同的稳定性和鲁棒性。以蒸馏塔质量控制为例进行了控制仿真,结果表明,这种新的预测控制算法不仅能满足系统存在的线性约束条件,而且有着比无约束预测控制和最优状态反馈控制更好的控制响应;与二次规划等优化算法比较,这种新的预测控制算法计算效率更高,能更好地满足生产过程实时控制需要。     

基于模糊预测型线性规划模型的矿山产能配置

将线性规划与模糊数学及灰色理论有机结合,构建了与产能分配实际情况较为接近的模糊预测型线性规划模型.利用灰色预测理论对各灰色系数进行白化,将模糊预测型线性规划模型转化为模糊线性规划模型,利用最优判决条件进一步转化,得到以最大隶属度为目标函数的一般线性规划模型,求解得到了矿山的最优产能分配,以实现矿山产能的科学配置和效益的最大化.     

Multi‐parametric linear programming under global uncertainty

Multi‐parametric programming has proven to be an invaluable tool for optimisation under uncertainty. Despite the theoretical developments in this area, the ability to handle uncertain parameters on the left‐hand side remains limited and as a result, hybrid, or approximate solution strategies have been proposed in the literature. In this work, a new algorithm is introduced for the exact solution of multi‐parametric linear programming problems with simultaneous variations in the objective function's coefficients, the right‐hand side and the left‐hand side of the constraints. The proposed methodology is based on the analytical solution of the system of equations derived from the first order Karush–Kuhn–Tucker conditions for general linear programming problems using symbolic manipulation. Emphasis is given on the ability of the proposed methodology to handle efficiently the LHS uncertainty by computing exactly the corresponding nonconvex critical regions while numerical studies underline further the advantages of the proposed methodology, when compared to existing algorithms. © 2017 The Authors AIChE Journal published by Wiley Periodicals, Inc. on behalf of American Institute of Chemical Engineers AIChE J, 63: 3871–3895, 2017     

需求不确定下炼油企业生产计划优化混合规划模型

Abstract Production planning under uncertainty is considered as one of the most important problems in plant-wide optimization. In this article, first, a stochastic programming model with uniform distribution assumption is developed for refinery production planning under demand uncertainty, and then a hybrid programming model incorporating the linear programming model with the stochastic programming one by a weight factor is proposed. Subsequently, piecewise linear approximation functions are derived and applied to solve the hybrid programming model-under uniform distribution assumption. Case studies show that the linear approximation algorithm is effective to solve.the hybrid programming model, along with an error≤0.5% when the deviatiorgmean≤20%. The simulation results indicate that the hybrid programming model with an appropriate weight factor （0.1-0.2） can effectively improve the optimal operational strategies under demand uncertainty, achieving higher profit than the linear programming model and the stochastic programming one with about 1.3% and 0.4% enhancement, respectavely.     

Explicit model predictive control through robust optimization

A strategy that calculates an explicit state feedback policy to regulate constrained uncertain discrete-time uncertain linear systems is presented. We consider uncertain processes, affected by box-bounded multiplicative uncertainty as well as bounded additive uncertainty with linear state and inputs constraints. The proposed method includes (i) the calculation of a terminal set constraint and (ii) the robust reformulation of state constraints in the prediction horizon. These features allow the derivation of the desired policy by solving a single multiparametric quadratic programming problem that guarantees feasible operation in the presence of uncertainty. Additionally, we employ variable and constraint elimination approaches to enhance the computational performance of the strategy. We demonstrate the steps and benefits of these developments with a numerical example and a chemical engineering case study.     

Koopman Lyapunov-based model predictive control of nonlinear chemical process systems

In this work, we propose the integration of Koopman operator methodology with Lyapunov-based model predictive control (LMPC) for stabilization of nonlinear systems. The Koopman operator enables global linear representations of nonlinear dynamical systems. The basic idea is to transform the nonlinear dynamics into a higher dimensional space using a set of observable functions whose evolution is governed by the linear but infinite dimensional Koopman operator. In practice, it is numerically approximated and therefore the tightness of these linear representations cannot be guaranteed which may lead to unstable closed-loop designs. To address this issue, we integrate the Koopman linear predictors in an LMPC framework which guarantees controller feasibility and closed-loop stability. Moreover, the proposed design results in a standard convex optimization problem which is computationally attractive compared to a nonconvex problem encountered when the original nonlinear model is used. We illustrate the application of this methodology on a chemical process example.     

改进的模糊预测控制算法及其在CSTR过程中的应用

A finite horizon predictive control algorithm,which applies a saturated feedback control law as its local control law,is presented for nonlinear systems with time-delay subject to input constraints.In the algorithm,N free control moves,a saturated local control law and the terminal weighting matrices are solved by a minimization problem based on linear matrix inequality(LMI) constraints online.Compared with the algorithm with a nonsaturated local law,the presented algorithm improves the performances of the closed-loop systems such as feasibility and optimality.This model predictive control(MPC) algorithm is applied to an industrial continuous stirred tank reactor(CSTR) with explicit input constraint.The simulation results demonstrate that the presented algorithm is effective.     

Integrating data‐based modeling and nonlinear control tools for batch process control

A data‐based multimodel approach is developed in this work for modeling batch systems in which multiple local linear models are identified using latent variable regression and combined using an appropriate weighting function that arises from fuzzy c‐means clustering. The resulting model is used to generate empirical reverse‐time reachability regions (RTRRs) (defined as the set of states from where the data‐based model can be driven inside a desired end‐point neighborhood of the system), which are subsequently incorporated in a predictive control design. Simulation results of a fed‐batch reactor system under proportional‐integral (PI) control and the proposed RTRR‐based design demonstrate the superior performance of the RTRR‐based design in both a fault‐free and faulty environment. The data‐based modeling methodology is then applied on a nylon‐6,6 batch polymerization process to design a trajectory tracking predictive controller. Closed‐loop simulation results illustrate the superior tracking performance of the proposed predictive controller over PI control. © 2011 American Institute of Chemical Engineers AIChE J, 2012