Recent advances in optimization-based simultaneous process and control design

Abstract In this work, we first discuss recent advances towards the integration of process design, process control and process operability from the open literature and then we focus on techniques towards this endeavor that were developed within our group at Imperial College. While most of the approaches employ controllability measures to achieve this goal, our developments can be classified as a simultaneous process and control design methodology. Based on novel mixed integer dynamic optimization algorithms, our strategy features high fidelity process dynamic models, conventional PI control schemes, explicit consideration of structural process and control design aspects (such as number of trays, pairing of manipulated and controlled variables) through the introduction of 0–1 variables, and explicit consideration of time-varying disturbances and time-invariant uncertainties. The application of this strategy to a typical distillation system is discussed. In the second part of this chapter we present an extension of the process and control design framework that incorporates advanced model-based predictive controllers. Parametric programming is used for the controller derivation giving rise to a closed-form controller structure and removing the need for solving an optimization problem on-line. The resulting parametric controller is readily incorporated in the design optimization framework bringing about significant economic and operability benefits. The key features and advantages of this approach are highlighted via a simple binary distillation example.

[1]  Vikrant Bansal,et al.  Analysis, design and control optimization of process systems under uncertainty , 2000 .

[2]  Alberto Bemporad,et al.  The explicit linear quadratic regulator for constrained systems , 2003, Autom..

[3]  Lorenz T. Biegler,et al.  A unified approach for the simultaneous synthesis of reaction, energy and separation systems , 1993 .

[4]  Manfred Morari,et al.  Design of resilient processing plants—IV: Some new results on heat exchanger network synthesis , 1984 .

[5]  Antonis C. Kokossis,et al.  On a new measure for the integration of process design and control: the disturbance resiliency index , 2002 .

[6]  R. Reid,et al.  The Properties of Gases and Liquids , 1977 .

[7]  Nilay Shah,et al.  Modelling and optimisation of general hybrid systems in the continuous time domain , 1998 .

[8]  M. Morari,et al.  Explicit solution of LP-based model predictive control , 2000 .

[9]  A. Grancharova,et al.  APPROXIMATE EXPLICIT MODEL PREDICTIVE CONTROL IMPLEMENTED VIA ORTHOGONAL SEARCH TREE PARTITIONING , 2002 .

[10]  A. Bemporad,et al.  Suboptimal explicit MPC via approximate multiparametric quadratic programming , 2001, Proceedings of the 40th IEEE Conference on Decision and Control (Cat. No.01CH37228).

[11]  John D. Perkins,et al.  Optimization as a tool for design/control integration , 1994 .

[12]  John D. Perkins,et al.  Operability and Control in Process Synthesis and Design , 1996 .

[13]  J. D. Perkins,et al.  Assessing controllability of chemical plants , 1985 .

[14]  Efstratios N. Pistikopoulos,et al.  Flexibility analysis and design of linear systems by parametric programming , 2000 .

[15]  Thomas F. Edgar,et al.  Process Dynamics and Control , 1989 .

[16]  J. D. Perkins,et al.  A case study in simultaneous design and control using rigorous, mixed-integer dynamic optimization models , 2002 .

[17]  Christodoulos A. Floudas,et al.  Interaction of Design and Control: Optimization with Dynamic Models , 1998 .

[18]  Imad M. Jaimoukha,et al.  Numerical solution of large scale Lyapunov equations using Krylov subspace methods , 1992, [1992] Proceedings of the 31st IEEE Conference on Decision and Control.

[19]  D. Chmielewski,et al.  On constrained infinite-time linear quadratic optimal control , 1996, Proceedings of 35th IEEE Conference on Decision and Control.

[20]  Efstratios N. Pistikopoulos,et al.  Optimal design of dynamic systems under uncertainty , 1996 .

[21]  V. D. Dimitriadis,et al.  Flexibility Analysis of Dynamic Systems , 1995 .

[22]  M. Morari,et al.  Effect of disturbance directions on closed-loop performance , 1987 .

[23]  Vassilios Vassiliadis,et al.  Computational solution of dynamic optimization problems with general differential-algebraic constraints , 1993 .

[24]  A. Bemporad,et al.  Efficient on-line computation of constrained optimal control , 2001, Proceedings of the 40th IEEE Conference on Decision and Control (Cat. No.01CH37228).

[25]  Lazaros G. Papageorgiou,et al.  Robustness metrics for dynamic optimization models under parameter uncertainty , 1998 .

[26]  Ignacio E. Grossmann,et al.  Optimization strategies for flexible chemical processes , 1983 .

[27]  William L. Luyben,et al.  Analysis of Control Structures for Reaction/Separation/Recycle Processes with Second-Order Reactions , 1996 .

[28]  Efstratios N. Pistikopoulos,et al.  Optimal retrofit design for improving process flexibility in linear systems , 1988 .

[29]  David A. Kendrick,et al.  GAMS : a user's guide, Release 2.25 , 1992 .

[30]  N. Lawrence Ricker,et al.  Decentralized control of the Tennessee Eastman Challenge Process , 1996 .

[31]  Nilay Shah,et al.  On the design of multicomponent batch distillation columns , 1998 .

[32]  Efstratios N. Pistikopoulos,et al.  New algorithms for mixed-integer dynamic optimization , 2003, Comput. Chem. Eng..

[33]  Johan Grievink,et al.  Optimum Controllability of Distributed Systems based on Non-equilibrium Thermodynamics , 2002 .

[34]  Ignacio E. Grossmann,et al.  Systematic Methods of Chemical Process Design , 1997 .

[35]  Tor Arne Johansen,et al.  Explicit sub-optimal linear quadratic regulation with state and input constraints , 2002, Autom..

[36]  I. David L. Bogle,et al.  Controllability evaluation for nonminimum phase‐processes with multiplicity , 2001 .

[37]  A. M. Geoffrion.  Generalized Benders decomposition , 1972 .

[38]  Manfred Morari,et al.  Design of resilient processing plants—III: A general framework for the assessment of dynamic resilience , 1983 .

[39]  J. A. Bandoni,et al.  Integrated flexibility and controllability analysis in design of chemical processes , 1997 .

[40]  Huibert Kwakernaak,et al.  Linear Optimal Control Systems , 1972 .

[41]  K. P. Madhavan,et al.  Design of controllable batch processes , 2001 .

[42]  C. V. Rao,et al.  Constrained process monitoring: Moving‐horizon approach , 2002 .

[43]  M. A. Henson,et al.  Model Predictive Control of Interconnected Linear and Nonlinear Processes , 2002 .

[44]  Ioannis P. Androulakis,et al.  Kinetic mechanism reduction based on an integer programming approach , 2000 .

[45]  J.A. De Dona,et al.  Finitely parameterised implementation of receding horizon control for constrained linear systems , 2002, Proceedings of the 2002 American Control Conference (IEEE Cat. No.CH37301).

[46]  Efstratios N. Pistikopoulos,et al.  A multiperiod MINLP model for the synthesis of flexible heat and mass exchange networks , 1994 .

[47]  Yan Liu,et al.  Studies in Chemical Process Design and Synthesis. 9. A Unifying Method for the Synthesis of Multicomponent Separation Sequences with Sloppy Product Streams , 1990 .

[48]  William L. Luyben,et al.  Design and control of coupled reactor/column systems—Part 1. A binary coupled reactor/rectifier system , 1997 .

[49]  A. Ichikawa,et al.  Studies in chemical process design and synthesis II. Optimal synthesis of dynamic process systems with uncertainty , 1976 .

[50]  Ioannis K. Kookos,et al.  An Algorithm for Simultaneous Process Design and Control , 2001 .

[51]  Manfred Morari,et al.  Design of resilient processing plants—I Process design under consideration of dynamic aspects , 1982 .

[52]  J. D. Perkins,et al.  Selection of process control structure based on linear dynamic economics , 1993 .

[53]  Stephen Walsh,et al.  Application of integrated process and control system design to waste water neutralisation , 1994 .

[54]  Tor Arne Johansen,et al.  Approximate explicit model predictive control incorporating heuristics , 2002, Proceedings. IEEE International Symposium on Computer Aided Control System Design.

[55]  Paul I. Barton,et al.  Mixed-integer dynamic optimization I: problem formulation , 1999 .

[56]  E. Pistikopoulos,et al.  A multiparametric programming approach for mixed-integer quadratic engineering problems , 2002 .

[57]  S. Skogestad,et al.  Optimal Number of Stages in Distillation with respect to Controllability , 2002 .

[58]  Efstratios N. Pistikopoulos,et al.  Optimal synthesis and design of dynamic systems under uncertainty , 1996 .

[59]  J. Rawlings,et al.  The stability of constrained receding horizon control , 1993, IEEE Trans. Autom. Control..

[60]  Christodoulos A. Floudas,et al.  For the Special Issue Honoring Professor Roy Jackson Optimization Framework for the Synthesis of Chemical Reactor Networks , 1998 .

[61]  David Q. Mayne,et al.  Constrained model predictive control: Stability and optimality , 2000, Autom..

[62]  Johan Grievink,et al.  Process design and control structure screening based on economic and static controllability criteria , 2001 .

[63]  Dale E. Seborg,et al.  Nonlinear Process Control , 1996 .

[64]  John D. Perkins,et al.  Structural design for on‐line process optimization: I. Dynamic economics of MPC , 1999 .

[65]  David D. Brengel,et al.  Coordinated design and control optimization of nonlinear processes , 1992 .

[66]  R. Sargent,et al.  Solution of a Class of Multistage Dynamic Optimization Problems. 2. Problems with Path Constraints , 1994 .

[67]  Efstratios N. Pistikopoulos,et al.  Parametric controllers in simultaneous process and control design optimization , 2003 .

[68]  Efstratios N. Pistikopoulos,et al.  Towards an efficient numerical procedure for mixed integer optimal control , 1997 .

[69]  Christodoulos A. Floudas,et al.  Analyzing the interaction of design and control—1. A multiobjective framework and application to binary distillation synthesis , 1994 .

[70]  Efstratios N. Pistikopoulos,et al.  An adjoint-based algorithm for mixed-integer dynamic optimization , 2001 .

[71]  Ahmet Palazoglu,et al.  A multiobjective approach to design chemical plants with robust dynamic operability characteristics , 1986 .

[72]  James B. Rawlings,et al.  Constrained linear quadratic regulation , 1998, IEEE Trans. Autom. Control..

[73]  Nilay Shah,et al.  A decomposition algorithm for the optimisation of hybrid dynamic processes , 1999 .

[74]  M. Morari,et al.  On-line optimization via off-line parametric optimization tools , 2000 .

[75]  Eric S. Fraga,et al.  Incorporation of dynamic behaviour in an automated process synthesis system , 2000 .

[76]  F. Michiel Meeuse,et al.  Closed loop controllability analysis of process designs:Application to distillation column design , 2001 .

[77]  B. Moore.  Principal component analysis in linear systems: Controllability, observability, and model reduction , 1981 .

[78]  I. Grossmann,et al.  A combined penalty function and outer-approximation method for MINLP optimization : applications to distillation column design , 1989 .