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Shen F, Ye L, Guan H, He Y. Enhanced control structure design for an industrial off-gas system: Simple reconfigurations benefit the economy. Heliyon 2023; 9:e12934. [PMID: 36704278 PMCID: PMC9871233 DOI: 10.1016/j.heliyon.2023.e12934] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 06/30/2022] [Revised: 11/22/2022] [Accepted: 01/09/2023] [Indexed: 01/18/2023] Open
Abstract
For control structure design of the industrial off-gas benchmark system, application of the Skogestad's state-of-art design procedure has suggested the scrubber inlet pressure (P si in the roaster) and one of the fan speeds (N fan1 or N_fan2 in the furnace) as the self-optimizing controlled variables CVs. In this study, we stress and advocate the gSOC-plus-BAB approach as an enhanced design toolkit for the classical and systematical design procedure. The gSOC (global self-optimizing control) is able to efficiently solve measurement combinations as CVs with improved economic performances, while the BAB (branch and bound) algorithm serves to fast screen promising measurement subsets for large-scale problems. Using the enhanced design for the off-gas system, our new findings are to control the combination of roaster's ID fan outlet pressures, 0.494P IDfan1+0.506P IDfan2 (setpoint: -257.04 Pa), and the furnace's fan pressure difference, P IDfan1- P IDfan2 (setpoint: 0). Such simple reconfigurations can dramatically reduce the average economic loss by 53.3% for the roaster and even achieve perfect optimal control for the furnace. Both steady state and dynamic evaluations are carried out to validate the reconfigured control structures. © 2017 Elsevier Inc. All rights reserved.
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Affiliation(s)
- Feifan Shen
- NingboTech University, Ningbo, 315100, China
| | - Lingjian Ye
- Huzhou Key Laboratory of Intelligent Sensing and Optimal Control for Industrial Systems, School of Engineering, Huzhou University, Huzhou, 313000, China,Key Laboratory of Intelligent Manufacturing Quality Big Data Tracing and Analysis of Zhejiang Province, China Jiliang University, Hangzhou, 310018, China,Corresponding author. School of Engineering, Huzhou University, Huzhou, 313000, China.
| | - Hongwei Guan
- Ningbo University of Finance and Economics, Ningbo, 315175, China
| | - Yuchen He
- Key Laboratory of Intelligent Manufacturing Quality Big Data Tracing and Analysis of Zhejiang Province, China Jiliang University, Hangzhou, 310018, China
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Plantwide control of a biodiesel production process with variable feedstock. Chem Eng Res Des 2022. [DOI: 10.1016/j.cherd.2022.07.037] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/21/2022]
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Kumar V, Kaistha N. Inferential Self-Optimizing Control of a Reactor–Separator–Recycle Process. Ind Eng Chem Res 2019. [DOI: 10.1021/acs.iecr.9b00172] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/29/2022]
Affiliation(s)
- Vivek Kumar
- Department of Chemical Engineering, Indian Institute of Technology Kanpur, Kanpur 208016, India
| | - Nitin Kaistha
- Department of Chemical Engineering, Indian Institute of Technology Kanpur, Kanpur 208016, India
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Periyasamy B, Khanolkar MB. Effect of coolant flow rate on the dynamics of delayed recycle continuous stirred tank reactor. J Taiwan Inst Chem Eng 2017. [DOI: 10.1016/j.jtice.2017.03.003] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/19/2022]
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Ojasvi, Kaistha N. Plantwide Control for Maximum Throughput Operation of an Ester Purification Process. Ind Eng Chem Res 2016. [DOI: 10.1021/acs.iecr.6b02997] [Citation(s) in RCA: 10] [Impact Index Per Article: 1.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/29/2022]
Affiliation(s)
- Ojasvi
- Department of Chemical Engineering, Indian Institute of Technology Kanpur, Kanpur 208016, India
| | - Nitin Kaistha
- Department of Chemical Engineering, Indian Institute of Technology Kanpur, Kanpur 208016, India
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Jogwar SS, Rangarajan S, Daoutidis P. Reduction of complex energy-integrated process networks using graph theory. Comput Chem Eng 2015. [DOI: 10.1016/j.compchemeng.2015.04.025] [Citation(s) in RCA: 10] [Impact Index Per Article: 1.1] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/17/2022]
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Ramírez-Corona N, Mascote-Pérez D, Sánchez-Hijar A, Fernández-Pastrana MI, Jiménez-Gutiérrez A. Insights on the dynamic behavior of thermally coupled distillation columns implemented on processes with recycles. Chem Eng Res Des 2015. [DOI: 10.1016/j.cherd.2014.05.015] [Citation(s) in RCA: 3] [Impact Index Per Article: 0.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/25/2022]
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Jones D, Bhattacharyya D, Turton R, Zitney SE. Plant-wide control system design: Primary controlled variable selection. Comput Chem Eng 2014. [DOI: 10.1016/j.compchemeng.2014.08.004] [Citation(s) in RCA: 15] [Impact Index Per Article: 1.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/16/2022]
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Steady state analysis of snowball effects for reaction–separation–recycle systems with thermally coupled distillation sequences. Chem Eng Res Des 2011. [DOI: 10.1016/j.cherd.2011.02.035] [Citation(s) in RCA: 12] [Impact Index Per Article: 0.9] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/21/2022]
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Jacobsen MG, Skogestad S. Active Constraint Regions for Optimal Operation of Chemical Processes. Ind Eng Chem Res 2011. [DOI: 10.1021/ie2012196] [Citation(s) in RCA: 16] [Impact Index Per Article: 1.2] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/28/2022]
Affiliation(s)
- Magnus G. Jacobsen
- Department of Chemical Engineering, Norwegian University of Science and Technology, NTNU, N-7491, Trondheim, Norway
| | - Sigurd Skogestad
- Department of Chemical Engineering, Norwegian University of Science and Technology, NTNU, N-7491, Trondheim, Norway
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Jagtap R, Kaistha N, Skogestad S. Plantwide Control for Economic Optimum Operation of a Recycle Process with Side Reaction. Ind Eng Chem Res 2011. [DOI: 10.1021/ie1024358] [Citation(s) in RCA: 21] [Impact Index Per Article: 1.6] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/28/2022]
Affiliation(s)
- Rahul Jagtap
- Chemical Engineering, Indian Institute of Technology Kanpur, Kanpur 208016, India
| | - Nitin Kaistha
- Chemical Engineering, Indian Institute of Technology Kanpur, Kanpur 208016, India
| | - Sigurd Skogestad
- Chemical Engineering, Norwegian University of Science and Technology, Trondheim N7491, Norway
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12
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Jogwar SS, Baldea M, Daoutidis P. Tight energy integration: Dynamic impact and control advantages. Comput Chem Eng 2010. [DOI: 10.1016/j.compchemeng.2010.02.005] [Citation(s) in RCA: 22] [Impact Index Per Article: 1.6] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/29/2022]
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Seki H, Ogawa M, Itoh T, Ootakara S, Murata H, Hashimoto Y, Kano M. Plantwide control system design of the benchmark vinyl acetate monomer production plant. Comput Chem Eng 2010. [DOI: 10.1016/j.compchemeng.2009.11.022] [Citation(s) in RCA: 13] [Impact Index Per Article: 0.9] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/20/2022]
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Affiliation(s)
- Elvira Marie B. Aske
- Department of Chemical Engineering, Norwegian University of Science and Technology, Trondheim, Norway
| | - Sigurd Skogestad
- Department of Chemical Engineering, Norwegian University of Science and Technology, Trondheim, Norway
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Vasudevan S, Rangaiah GP, Konda NVSNM, Tay WH. Application and Evaluation of Three Methodologies for Plantwide Control of the Styrene Monomer Plant. Ind Eng Chem Res 2009. [DOI: 10.1021/ie900022h] [Citation(s) in RCA: 33] [Impact Index Per Article: 2.2] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 01/14/2023]
Affiliation(s)
- Suraj Vasudevan
- Department of Chemical and Biomolecular Engineering, National University of Singapore, Engineering Drive 4, Singapore 117576
| | - G. P. Rangaiah
- Department of Chemical and Biomolecular Engineering, National University of Singapore, Engineering Drive 4, Singapore 117576
| | - N. V. S. N. Murthy Konda
- Department of Chemical and Biomolecular Engineering, National University of Singapore, Engineering Drive 4, Singapore 117576
| | - Wee Hwa Tay
- Department of Chemical and Biomolecular Engineering, National University of Singapore, Engineering Drive 4, Singapore 117576
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Griffin DW, Mellichamp DA, Doherty MF. Effect of Competing Reversible Reactions on Optimal Operating Policies for Plants with Recycle. Ind Eng Chem Res 2009. [DOI: 10.1021/ie801482z] [Citation(s) in RCA: 11] [Impact Index Per Article: 0.7] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/30/2022]
Affiliation(s)
- Derek W. Griffin
- Department of Chemical Engineering, University of California, Santa Barbara, California 93106-5080
| | - Duncan A. Mellichamp
- Department of Chemical Engineering, University of California, Santa Barbara, California 93106-5080
| | - Michael F. Doherty
- Department of Chemical Engineering, University of California, Santa Barbara, California 93106-5080
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Seki H, Naka Y. Optimizing Control of CSTR/Distillation Column Processes with One Material Recycle. Ind Eng Chem Res 2008. [DOI: 10.1021/ie800183a] [Citation(s) in RCA: 11] [Impact Index Per Article: 0.7] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/28/2022]
Affiliation(s)
- Hiroya Seki
- Chemical Resources Laboratory, Tokyo Institute of Technology, 4259-R1-19, Nagatsuta, Midori-ku, Yokohama 226-8503, Japan
| | - Yuji Naka
- Chemical Resources Laboratory, Tokyo Institute of Technology, 4259-R1-19, Nagatsuta, Midori-ku, Yokohama 226-8503, Japan
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Griffin DW, Mellichamp DA, Doherty MF. Selectivity versus conversion and optimal operating policies for plants with recycle. AIChE J 2008. [DOI: 10.1002/aic.11583] [Citation(s) in RCA: 3] [Impact Index Per Article: 0.2] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/10/2022]
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Baldea M, Araujo A, Skogestad S, Daoutidis P. Dynamic considerations in the synthesis of self-optimizing control structures. AIChE J 2008. [DOI: 10.1002/aic.11470] [Citation(s) in RCA: 24] [Impact Index Per Article: 1.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/07/2022]
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Griffin DW, Ward JD, Doherty MF, Mellichamp DA. Steady-State Operating Policies for Plants with Multiple Reactions of Equal Overall Order. Ind Eng Chem Res 2006. [DOI: 10.1021/ie051412p] [Citation(s) in RCA: 4] [Impact Index Per Article: 0.2] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/28/2022]
Affiliation(s)
- Derek W. Griffin
- Department of Chemical Engineering, University of California, Santa Barbara, California 93106-5080
| | - Jeffrey D. Ward
- Department of Chemical Engineering, University of California, Santa Barbara, California 93106-5080
| | - Michael F. Doherty
- Department of Chemical Engineering, University of California, Santa Barbara, California 93106-5080
| | - Duncan A. Mellichamp
- Department of Chemical Engineering, University of California, Santa Barbara, California 93106-5080
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Seki H, Naka Y. A Hierarchical Controller Design for a Reactor/Separator System with Recycle. Ind Eng Chem Res 2006. [DOI: 10.1021/ie060538z] [Citation(s) in RCA: 10] [Impact Index Per Article: 0.6] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/28/2022]
Affiliation(s)
- Hiroya Seki
- Chemical Resources Laboratory, Tokyo Institute of Technology, 4259-R1-19, Nagatsuta, Midori-ku, Yokohama 226-8503, Japan
| | - Yuji Naka
- Chemical Resources Laboratory, Tokyo Institute of Technology, 4259-R1-19, Nagatsuta, Midori-ku, Yokohama 226-8503, Japan
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Murthy Konda NVSN, Rangaiah GP, Lim DKH. Optimal Process Design and Effective Plantwide Control of Industrial Processes by a Simulation-Based Heuristic Approach. Ind Eng Chem Res 2006. [DOI: 10.1021/ie060534u] [Citation(s) in RCA: 16] [Impact Index Per Article: 0.9] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/29/2022]
Affiliation(s)
- N. V. S. N. Murthy Konda
- Department of Chemical and Biomolecular Engineering, National University of Singapore, Engineering Drive 4, Singapore 117576
| | - G. P. Rangaiah
- Department of Chemical and Biomolecular Engineering, National University of Singapore, Engineering Drive 4, Singapore 117576
| | - Dennis K. H. Lim
- Department of Chemical and Biomolecular Engineering, National University of Singapore, Engineering Drive 4, Singapore 117576
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Ward JD, Mellichamp DA, Doherty MF. Insight from Economically Optimal Steady-State Operating Policies for Dynamic Plantwide Control. Ind Eng Chem Res 2006. [DOI: 10.1021/ie050396t] [Citation(s) in RCA: 15] [Impact Index Per Article: 0.8] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/28/2022]
Affiliation(s)
- Jeffrey D. Ward
- Department of Chemical Engineering, University of California, Santa Barbara, California 93106-5080
| | - Duncan A. Mellichamp
- Department of Chemical Engineering, University of California, Santa Barbara, California 93106-5080
| | - Michael F. Doherty
- Department of Chemical Engineering, University of California, Santa Barbara, California 93106-5080
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Ward JD, Mellichamp DA, Doherty MF. Novel Reactor Temperature and Recycle Flow Rate Policies for Optimal Process Operation in the Plantwide Context. Ind Eng Chem Res 2005. [DOI: 10.1021/ie0491589] [Citation(s) in RCA: 10] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/28/2022]
Affiliation(s)
- Jeffrey D. Ward
- Department of Chemical Engineering, University of California, Santa Barbara, California 93106-5080
| | - Duncan A. Mellichamp
- Department of Chemical Engineering, University of California, Santa Barbara, California 93106-5080
| | - Michael F. Doherty
- Department of Chemical Engineering, University of California, Santa Barbara, California 93106-5080
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Govatsmark MS, Skogestad S. Selection of Controlled Variables and Robust Setpoints. Ind Eng Chem Res 2005. [DOI: 10.1021/ie049750y] [Citation(s) in RCA: 33] [Impact Index Per Article: 1.7] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/28/2022]
Affiliation(s)
- Marius S. Govatsmark
- Department of Chemical Engineering, Norwegian University of Science and Technology (NTNU), N-7491 Trondheim, Norway
| | - Sigurd Skogestad
- Department of Chemical Engineering, Norwegian University of Science and Technology (NTNU), N-7491 Trondheim, Norway
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28
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Near-optimal operation by self-optimizing control: from process control to marathon running and business systems. Comput Chem Eng 2004. [DOI: 10.1016/j.compchemeng.2004.07.011] [Citation(s) in RCA: 35] [Impact Index Per Article: 1.8] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/20/2022]
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Ward JD, Mellichamp DA, Doherty MF. Importance of Process Chemistry in Selecting the Operating Policy for Plants with Recycle. Ind Eng Chem Res 2004. [DOI: 10.1021/ie034125z] [Citation(s) in RCA: 19] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/30/2022]
Affiliation(s)
- Jeffrey D. Ward
- Department of Chemical Engineering, University of California, Santa Barbara, Santa Barbara, California 93106-5080
| | - Duncan A. Mellichamp
- Department of Chemical Engineering, University of California, Santa Barbara, Santa Barbara, California 93106-5080
| | - Michael F. Doherty
- Department of Chemical Engineering, University of California, Santa Barbara, Santa Barbara, California 93106-5080
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30
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Contou-Carrere MN, Baldea M, Daoutidis P. Dynamic Precompensation and Output Feedback Control of Integrated Process Networks. Ind Eng Chem Res 2004. [DOI: 10.1021/ie0341909] [Citation(s) in RCA: 7] [Impact Index Per Article: 0.4] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/29/2022]
Affiliation(s)
- Marie-Nathalie Contou-Carrere
- Department of Chemical Engineering and Materials Science, University of Minnesota, 421 Washington Avenue SE, Minneapolis, Minnesota 55455
| | - Michael Baldea
- Department of Chemical Engineering and Materials Science, University of Minnesota, 421 Washington Avenue SE, Minneapolis, Minnesota 55455
| | - Prodromos Daoutidis
- Department of Chemical Engineering and Materials Science, University of Minnesota, 421 Washington Avenue SE, Minneapolis, Minnesota 55455
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Monroy-Loperena R, Solar R, Alvarez-Ramirez J. Balanced Control Scheme for Reactor/Separator Processes with Material Recycle. Ind Eng Chem Res 2004. [DOI: 10.1021/ie0305770] [Citation(s) in RCA: 10] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/29/2022]
Affiliation(s)
- Rosendo Monroy-Loperena
- Departamento de Ingenieria de Procesos e Hidraulica, Universidad Autonoma Metropolitana-Iztapalapa, Apartado Postal 55-534, Mexico D.F., 09340 Mexico, and Programa de Investigación en Ingeniería Molecular, Instituto Mexicano del Petroleo
| | - Rocio Solar
- Departamento de Ingenieria de Procesos e Hidraulica, Universidad Autonoma Metropolitana-Iztapalapa, Apartado Postal 55-534, Mexico D.F., 09340 Mexico, and Programa de Investigación en Ingeniería Molecular, Instituto Mexicano del Petroleo
| | - Jose Alvarez-Ramirez
- Departamento de Ingenieria de Procesos e Hidraulica, Universidad Autonoma Metropolitana-Iztapalapa, Apartado Postal 55-534, Mexico D.F., 09340 Mexico, and Programa de Investigación en Ingeniería Molecular, Instituto Mexicano del Petroleo
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Bildea CS, Dimian AC. Fixing Flow Rates in Recycle Systems: Luyben's Rule Revisited. Ind Eng Chem Res 2003. [DOI: 10.1021/ie020982b] [Citation(s) in RCA: 42] [Impact Index Per Article: 2.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/29/2022]
Affiliation(s)
- Costin S. Bildea
- Delft University of Technology, Julianalaan 136, 2628 BL Delft, The Netherlands
| | - Alexandre C. Dimian
- University of Amsterdam, Nieuwe Achtergracht 166, 1018 WV Amsterdam, The Netherlands
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