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Model-Based Fault Diagnosis and Fault Tolerant Control for Safety-Critical Chemical Reactors: A Case Study of an Exothermic Continuous Stirred-Tank Reactor. Ind Eng Chem Res 2023; 62:13554-13571. [PMID: 38356642 PMCID: PMC10862546 DOI: 10.1021/acs.iecr.3c01205] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Grants] [Track Full Text] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 04/12/2023] [Revised: 07/20/2023] [Accepted: 07/20/2023] [Indexed: 02/16/2024]
Abstract
In safety-critical chemical reactors with potential hazards, reaction kinetics and heat transfer parameters are usually known, and a mathematical model is available. It is then meaningful to base fault detection and isolation algorithms on the first-principles model as opposed to statistics, so that physically meaningful residual signals are generated from material and/or energy balances not closing, leading to reliable fault diagnosis. Additionally, to maintain the safety of the entire system, it is necessary to take appropriate control action based on the mathematical model and the identified faults, to minimize their impact and thus ensure safe operation. In the present work, these ideas will be formulated and illustrated through a continuous stirred-tank reactor case study involving the liquid-phase oxidation of alkylpyridine with hydrogen peroxide. The proposed fault tolerant control strategy monitors the DSM (distance of the system state from the boundary of the dynamic safe set) and the estimate of the fault size, and when they cross a certain limit as a result of an abnormal event, the manipulated input is switched. Simulation results show the effectiveness of the proposed fault tolerant control strategy in dealing with cooling system failure.
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Bayesian-optimized Gaussian process-based fault classification in industrial processes. Comput Chem Eng 2023. [DOI: 10.1016/j.compchemeng.2022.108126] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 01/06/2023]
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Multi‐rate observer design and optimal control to maximize productivity of an industry‐scale fermentation process. AIChE J 2022. [DOI: 10.1002/aic.17946] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/12/2022]
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An operating economics-driven perspective on monitoring and maintenance in multiple operating regimes: Application to monitor fouling in heat exchangers. Chem Eng Res Des 2022. [DOI: 10.1016/j.cherd.2022.05.022] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/30/2022]
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Hidden Markov model based fault diagnoser using binary alarm signals with an analysis on distinguishability. Comput Chem Eng 2022. [DOI: 10.1016/j.compchemeng.2022.107689] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/24/2022]
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Optimal heating profiles in tubular reactors with solid‐phase axial wall conduction for isothermal operation. AIChE J 2019. [DOI: 10.1002/aic.16742] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.2] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/05/2022]
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A dead time compensation approach for multirate observer design with large measurement delays. AIChE J 2018. [DOI: 10.1002/aic.16445] [Citation(s) in RCA: 5] [Impact Index Per Article: 0.8] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/07/2022]
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Multi-rate observer design for process monitoring using asynchronous inter-sample output predictions. AIChE J 2017. [DOI: 10.1002/aic.15707] [Citation(s) in RCA: 11] [Impact Index Per Article: 1.6] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/06/2022]
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An approach to mechanistic event recognition applied on monitoring organic matter depletion in SBRs. AIChE J 2014. [DOI: 10.1002/aic.14536] [Citation(s) in RCA: 5] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/06/2022]
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Modellreduktion des erweiterten ASM3-Modells für die zweistufige Nitrifikation. CHEM-ING-TECH 2010. [DOI: 10.1002/cite.201050509] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/10/2022]
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Nonlinear Multirate Model-Algorithmic Control. 2. Experimental Application to a Polymerization Reactor. Ind Eng Chem Res 2002. [DOI: 10.1021/ie010560m] [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]
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A multirate parallel-modular algorithm for dynamic process simulation using distributed memory multicomputers. Comput Chem Eng 1999. [DOI: 10.1016/s0098-1354(99)00002-2] [Citation(s) in RCA: 3] [Impact Index Per Article: 0.1] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/17/2022]
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A Partially Decentralized State Observer and Its Parallel Computer Implementation. Ind Eng Chem Res 1998. [DOI: 10.1021/ie970553r] [Citation(s) in RCA: 14] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/29/2022]
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Multivariable nonlinear control of a continuous polymerization reactor: An experimental study. AIChE J 1993. [DOI: 10.1002/aic.690391204] [Citation(s) in RCA: 50] [Impact Index Per Article: 1.6] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/10/2022]
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