Optimization Approaches to Control-Integrated Design of Industrial Batch Reactors

In this paper optimization based approaches to the design of batch reactors are presented. In addition to operational constraints on manipulated and quality related variables, safety requirements are explicitly incorporated into the design even in the case of possible failure scenarios. Furthermore, since many industrial design problems often have to cope with existing plants and low on-line computational resources, controller limitations should be considered already at the design stage. These aspects render the suggested design problem formulation a nonlinear mixed-integer stochastic optimal control problem for a hybrid discrete-continuous system. In order to make this problem computationally tractable several simplifications are discussed. A decomposition is proposed where inherently safe operation profiles for a number of given possible failure scenarios are calculated in an inner problem whereas all control related questions for the nominal mode of operation are dealt with in an outer problem. The ideas and concepts for control-integrated batch reactor design are illustrated by means of an industrial polymerization reactor.

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