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"
of Chemical Processes
Market Fluctuations,
Demand, Price!
Decision Levels!
Planning & Scheduling!
Production Rates
Raw Material Allocation!
Measurements!
Medium term
day!
Real-Time Optimization!
Optimal Operating
Conditions - Set Points!
Measurements!
Short term
second/minute!
Fluctuations in
Pressure, Flowrates,
Compositions!
Control!
Measurements!
Manipulated
Variables!
Large-scale complex
processes!
Changing conditions!
Real-time adaptation!
2
BATCH PLANT
PRODUCTS
LABORATORY
Sca
le-u
p"
Production Constraints
meet product specifications!
meet safety and environmental constraints!
adhere to equipment constraints!
PRODUCTION
Different conditions Run-to-run adaptation!
3
Outline
What is real-time optimization
o Goal: Optimal plant operation
o Tool: Model-based numerical optimization, experimental optimization
o Key feature: use of real-time measurements
Plant!
( )
( u ) := g ( u, y ) 0
min
p ( u ) := p u, y p
s. t.
Gp
F ( u, y, ) = 0
min
u
(u) := ( u, y )
s. t. G ( u ) := g ( u, y ) 0
NLP"
?
u ?
(set points)!
u?
(set points)!
5
min := x p (t f )
u[0,t f ]
s. t.
Model-based Optimization!
min
u[0,t f ]
S(x p , u) 0
s. t.
T x p (t f ) 0
:= x(t f ),
x = F(x, u, ) x(0) = x 0
S(x, u, ) 0
T x(t f ), 0
?
u(t)
x p (t f )
u(t) ?
Predicted
States x(t)
6
u(t)
:= x(t f ),
min
u[0,t f ]
s. t.
x = F(x, u, ) x(0) = x 0
S(x, u, ) 0
T x(t f ), 0
u(t)!
umax"
Input Parameterization
u 1!
u[0,t f ] = U( )
umin"
0"
Gp
Batch plant!
viewed as a static map!
t1!
t2!
t f"
min ( , )
s. t.
G ( , ) 0
NLP"
Outline
What is real-time optimization
o Goal: Optimal plant operation
o Tool: Model-based numerical optimization, experimental optimization
o Key feature: use of real-time measurements
FB , X B,in = 1
TR
3-reaction system
A+BC
B+CP+E
C+PG
2-reaction model
k1!
A + 2B P + E
k2!
A+B+P G
Model
- 4th-order model
- 2 inputs
- 2 adjustable parameters (k10, k20)
input update: u
u* arg min (u, y)
u
parameter update:
No Measurement:
Robust Optimization
Measurements:
Adaptive Optimization
Adaptation of
Model Parameters
Adaptation of
Cost & Constraints
- two-step approach
(repeated identification
and optimization)
- bias update
- constraint update
- gradient correction
- modifier adaptation
g(u, y) 0
Adaptation of
Inputs.
- tracking active constraints
- NCO tracking
- extremum-seeking control
- self-optimizing control
10
FA , X A,in = 1
FB , X B,in = 1
TR
F = FA + FB
X A , X B , XC , X E , XG , X P
Williams-Otto Reactor
- 4th-order! model
- 2 inputs
- 2 adjustable par.
Does not
converge to plant
optimum
11
Two-step approach
J kid
Optimization Problem!
uk +1 arg min
u
s.t.
u, y(u, k )
g u, y(u, k ) 0
uL u uU
uk +1 uk
Optimization!
y(u , )
*
k
k*
Parameter!
Estimation!
*
k
y p (uk )
Plant!
at!
steady state!
12
u
Optimization!
y(uk* , )
Parameter
Estimation!
converged value!
J id
yp (up ), y(up , ) = 0,
yp (u )
Plant!
at!
optimum!
2J id
y
(u
),
y(u
p
p
p , ) > 0,
2
Gi (up , ) = 0,
i A(up )
Gi (up , ) < 0,
i A(up )
SOSC!
Par.
Est.!
Opt.!
r (up , ) = 0,
r2 (up , ) > 0
J.F. Forbes, T.E. Marlin. Design Cost: A Systematic Approach to Technology Selection for Model-Based
Real-Time Optimization Systems. Comp. Chem. Eng., 20(6/7), 717-734, 1996
13
Affine corrections of
cost and constraint
functions!
m (u) := (u) + kT [u uk ]
s.t.
Gm (u) := G(u) + k + kG [u uk ] 0
constraint value!
uL u uU
Gm (u)
Gp (u)
k
G(u)
kGT[u uk ]
uk
P.D. Roberts and T.W. Williams, On an Algorithm for Combined System Optimization
and Parameter Estimation, Automatica, 17(1), 199209, 1981
14
uk +1 arg min
m (u) := (u) + k [u uk ]
s.t.
Gm (u) := G(u) + k + kG [u uk ] 0
uL u uU
KKT Elements:!
Gng
G1
n
C = G1,,Gng ,
,,
,
K
u
u u
KKT Modifiers:!
T
T
G
= 1,, ng , G1 ,, ng , nK
nK = ng + nu (ng + 1)
Requires evaluation of
KKT elements of plant!
k = (I K) k 1 + K Cp (uk ) C(uk )
W. Gao and S. Engell, Iterative Set-point Optimization of Batch Chromatography, Comput. Chem. Eng., 29, 14011409, 2005
A. Marchetti, B. Chachuat and D. Bonvin, Modifier-Adaptation Methodology for Real-Time Optimization, I&EC Research,
48(13), 6022-6033 (2009)
15
Example Revisited
Modifier adaptation
FA , X A,in = 1
FB , X B,in = 1
TR
F = FA + FB
X A , X B , XC , X E , XG , X P
Williams-Otto Reactor
- 4th-order
! model
- 2 inputs
- 2 adjustable par.
Converges to plant
optimum
A. Marchetti, PhD thesis, EPFL, Modifier-Adaptation Methodology for Real-Time Optimization, 2009
16
17
Run-to-Run Optimization
of Semi-Batch Reactor
Simulated
Reality
Manipulated Variables:
Objective:
Constraints:
Model
18
A solution model
- 3 arcs: Fmax, Fs and Fmin
- 3 adjustable parameters tm, ts and Fs
- Measurements to adjust tm, ts and Fs
Optimal Solution
Approximate Solution
u"
19
3. Adaptation of Inputs
NCO"
cB(tf)=0.025!
cD(tf)=0.15!
CV ?"
MV ?"
Optimizing"
Controller"
Inputs ?!
Measurements!
Real Plant"
Disturbances!
Feasibility OK!
Optimal performance OK!
Control problem!
Set points ?!
Solution model!
NCO tracking
20
Simulated
Reality
Manipulated Variables:
Objective:
Constraints:
Model
21
Measurement Noise:
Identification Objective:
Large
optimality
loss!
22
Measurement Noise:
No Gradient Correction
Recovers most
of the optimality loss
23
Measurement Noise:
No Gradient Correction
Controller Design:
tk
s
k
Fs
t k1
s
= k1
Fs
= k1
Recovers most
of the optimality loss
24
Outline
What is real-time optimization
o Goal: Optimal plant operation
o Tool: Model-based numerical optimization, experimental optimization
o Key feature: use of real-time measurements
26
Experimental features
Inputs: flowrates (H2, O2), current (or load)!
Outputs: power density, cell potential, electrical efficiency!
Time-scale separation!
slow temperature dynamics, treated as process drift ! !
static model (for the rest)!
Power demand changes without prior knowledge!
!
Inaccurate model in the operating region (power, cell)!
27
pelAc
Ucell I! (W)
Ncells
I (A)
u2,k = I k
max ( u k , )
uk
s.t.
pel
pel ( u k , ) + k1
= pelS
U cell
Ucell ( u k , ) + k1
0.75V
( u k ) 0.75
42
u2,k
= air ( u k ) 7
u1,k
kpel
(1-K )
pel
pel
k-1
kUcell
(1-K )
U cell
U cell
k-1
!
30
!
31
Industrial process!
1-ton reactor, risk of runaway!
Initiator efficiency can vary considerably!
T (t)
M w (t)
X(t)
F j, T j,in
Tj
Several recipes!
different initial conditions!
different initiator feeding policies!
use of chain transfer agent!
Modeling difficulties!
Uncertainty!
Industrial Practice
33
TTr,max
max!
5!
Current practice: isothermal!
Piecewise constant
Numerical optimization!
1.5
TTr [[ ]!]
1
1!
2!
Piecewise-constant input!
3! 4!
Isothermal
Active constraints!
Interval 1: heat removal !
0.5
Interval 5: Tmax!
0
0
0.2
0.4
time/t [ ]
0.6
0.8
Timef tf
34
T(tf) = Tmax!
Tmax!
Compromise*
adiabatic
Heat removal limitation
isothermal operation
*Compromise between
conversion and quality
2!
1!
Tiso!
t!
ts!
tf!
run-to-run adjustment of ts
35
1-ton reactor
Final time!
Isothermal: 1.00 !
Batch 0"
Batch 1:
0.78!
Batch 2:
0.72!
Batch 3:
0.65!
1.0"
36
Conclusions
Process optimization is difficult in practice
o Models are often inaccurate use real-time measurements
o Repeated estimation and optimization lacks model adequacy
o Which measurements? How to best exploit them?
NCO (active constraints and reduced gradients)
37
NCO tracking
New Paradigm for RTO
Operator-friendly approach
o Start with best current operation (nominal model-based solution) and
push the process until constraints are reached
o Know what to manipulate solution model
o Determine how much to change from measurements
Important features
o
o
o
o
o
o