Abstract
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.
Access this chapter
Tax calculation will be finalised at checkout
Purchases are for personal use only
Preview
Unable to display preview. Download preview PDF.
References
F. Allgöwer. Definition and computation of a nonlinearity measure. In A.J. Krener and D.Q. Mayne, editors, Proc. of Nonlinear Control System Design Symposium NOLCOS95, pages 257–262, Oxford, UK, 1996. Pergamon.
F. Allgöwer. Näherungsweise Ein-Ausgangs-Linearisierung nichtlinearer Systeme. Reihe 8: Meß-, Steuerungs-und Regelungstechnik Nr. 582. VDI-Verlag, 1996.
M.A. Alós, F. Strozzi, and J.M. Zaldivar. A new method for assessing the thermal stability of semibatch processes based on Lyapunov exponents. Chem. Eng. Sci., 51(11):3089–3094, 1996.
J.-P. Aubin. Viability Theory. Systems & Control: Foundations & Applications. Birkhäuser, Boston, 1991.
P.I. Barton and T. Park. Analysis and control of combined discrete/continuous systems: progress and challenges in the chemical processing industries. In J.C. Kantor, C.E. Garcia, and B. Carnahan, editors, Proc. of Fifth International Conference on Chemical Process Control, volume 93 of AIChE Symposium Series No. 316, pages 102–114. AIChE and CACHE, 1997.
A. Benuzzi and J.M. Zaldivar. Safety of Chemical Batch Reactors and Storage Tanks. Kluwer Academic Publishers, Dordrecht, The Netherlands, 1991.
B.W. Bequette. Operability analysis of an exothermic semi-batch reactor. Comput. Chem. Eng., 20(Suppl.):S.1583–1588, 1996.
B.W. Bequette. Operability of batch reactors: Temperature profile feasibility. In J.C. Kantor, C.E. Garcia, and B. Carnahan, editors, Proc. of Fifth International Conference on Chemical Process Control, volume 93 of AIChE Symposium Series No. 316, pages 315–318, Tahoe City, USA, 1997. AIChE and CACHE.
R. Berber. Control of batch reactors: A review. In R. Berber, editor, Methods of Model-Based Control, NATO-ASI Series, pages 459–494. Kluwer Press, Dordrecht, The Netherlands, 1995.
T. Bhatia and L.T. Biegler. Dynamic optimization in the design and scheduling of multiproduct batch plants. Ind. Eng. Chem. Res., 35(7):2234–2246, 1996.
T. Binder, L. Blank, W. Dahmen, and W. Marquardt. Towards multiscale dynamic data reconciliation. NATO ASI on Nonlinear Model Based Process Control. This volume.
D.B. Birewar and I.E. Grossmann. Incorporating scheduling in the optimal design of muli-product batch plants. Comput. Chem. Eng., 13:141, 1989.
R. Bogusch, B. Lohmann, and W. Marquardt. Computer-aided process modeling with MODKIT. In Proceedings of Chemputers Europe III, Frankfurt, Germany, 29–30 October 1996.
D. Bonvin. Optimal operation of discontinuous reactors — A personal view. In Preprints of the IFAC Symposium ADCHEM’97, pages 155–169, Banff, Canada, 9–11 June 1997.
Y. Cao, D. Biss, and J.D. Perkins. Assessment of input-output controllability in the presence of control constraints. Comput. Chem. Eng., 20(4):337–346, 1996.
M. Caracotsios and W.E. Stewart. Sensitivity analysis of initial value problems with mixed ODEs and algebraic equations. Comput. Chem. Eng., 9(4):359–365, 1985.
J.E. Cuthrell and L.T. Biegler. On the optimization of differential-algebraic process systems. AIChE J., 33(8):1257–1270, 1987.
V.D. Dimitriadis and E.N. Pistikopoulos. Flexibility analysis of dynamic systems. Ind. Eng. Chem. Res., 34:4451–4462, 1995.
V.D. Dimitriadis, N. Shah, and C.C. Pantelides. Modelling, safety verification and design of discrete/continuous processing systems. Paper accepted for publication in AIChE J., 1996.
P. Djavdan. Temperature control of a batch esterification reactor overcoming nonlin-earities using adaptive gain. In J.B. Rawlings, editor, Proc. of the IFAC Symposium DYCORD +’ 95, pages 421–426, Helsingør, Denmark, 7–9 June 1995.
G. Eigenberger and H. Schuler. Reaktorstabilität und sichere Reaktionsführung. Chem. Ing. Tech., 58(8):655–665, 1986.
S. Engell, S. Kowalewski, and B.H. Krogh. Discrete events and hybrid systems in process control. In J.C. Kantor, C.E. Garcia, and B. Carnahan, editors, Proc. of Fifth International Conference on Chemical Process Control, volume 93 of AIChE Symposium Series No. 316, pages 165–176. AIChE and CACHE, 1997.
B.A. Foss, B. Lohmann, and W. Marquardt. A field study of the industrial modeling process. In Preprints of the IFAC Symposium AD CHEM’97, pages 570–585, Banff, Canada, 9–11 June 1997. To be published in J. Proc. Cont., 1998.
M. Friedrich and R. Perne. Design and control of batch reactors — an industrial viewpoint. Comput. Chem. Eng., 19(Suppl.):S357–S368, 1995.
P.E. Gill, W. Murray, M.A. Saunders, and M.H. Wright. User’s Guide for NPSOL, Version 4.0. Systems Optimization Laboratory, Stanford University, Stanford, USA, 1996.
I.E. Grossmann and D.A. Straub. Recent developments in the evaluation and optimization of flexible chemical processes. In L. Puigjaner and A. Espuna, editors, Proceedings Computer-Oriented Process Engineering, page 49. Elsevier, Amsterdam, 1991.
R. Gygax. Chemical reaction engineering for safety; Chem. Eng. Sci., 43(8):1759–1771, 1988.
A. Helbig, O. Abel, A. M’hamdi, and W. Marquardt. Analysis and nonlinear model predictive control of the Chylla-Haase benchmark problem. In Proc. of CONTROLS, pages 1172–1177, Exeter, UK, 2–5 September 1996.
A. Helbig, W. Marquardt, and F. Allgöwer. Nonlinearity measures for batch reactors. Paper submitted to IFAC Symposium DYCOPS-5, 1997.
P. Hugo and J. Steinbach. A comparison of the limits of safe operation of a SBR and a CSTR. Chem. Eng. Sci., 41(4):1081–1087, 1986.
P. Jarupintusophon, M.V. LeLann, M. Cabassud, and G. Casamatta. Realistic model-based predictive and adaptive control of batch reactor. Comput. Chem. Eng., 18(Suppl.):S445–S449, 1995.
M.R. Juba and J.W. Hamer. Progress and challenges in batch process control. In M. Morari and T.J. McAvoy, editors, Chemical Process Control — CPC III, CACHE, pages 139–183. Elsevier, 1986.
R. King. Modellgestützte Überwachung kritischer Reaktionssysteme. Reihe 8: Meß-, Steuerungs-und Regelungstechnik Nr. 185. VDI-Verlag, Düsseldorf, 1989.
G. Labinaz, M.M. Bayoumi, and K. Rudie. A viable cascade controller design for a batch polymerization process. In Preprints of the IFAC Symposium AD CHEM’91, pages 195–200, Banff, Canada, 9–11 June 1997.
D.R. Lewin. Modelling and control of an industrial PVC suspension polymerization reactor. Comput. Chem. Eng., 20(Suppl.):S865–S870, 1996.
J.S. Logsdon and L.T. Biegler. Decomposition strategies for large-scale dynamic optimization problems. Chem. Eng. Sci., 47(4):851–864, 1992.
Z. Louleh, M. Cabassud, M.V. LeLann, and G. Casamatta. Experimental study of a new thermal control strategy for batch reactors. In Preprints of the IFAC Symposium ADCHEM’97, pages 119–124, Banff, Canada, 9–11 June 1997.
Z. Louleh, M.V. LeLann, A. Chamayou, and G. Casamatta. A new heating-cooling system to improve controllability of batch reactors. Chem. Eng. Sci., 51(11):3163–3168, 1996.
W. Marquardt. Towards a process modeling methodology. In R. Berber, editor, Methods of Model-Based Control, volume 293 of NATO-ASI Series, pages 3–40, Dordrecht, The Netherlands, 1995. Kluwer Press.
A. M’hamdi, A. Helbig, O. Abel, and W. Marquardt. Newton-type receding horizon control and state estimation — a case study. In J.J. Gertler, J.B. Cruz, and M. Peshkin, editors, Preprints of the 13th World Congresè of IFAC, volume M, pages 121–126, San Francisco, 30 June–5 July 1996.
M.J. Mohideen, J.D. Perkins, and E.N. Pistikopoulos. Optimal design of dynamic systems under uncertainty. AIChE J., 42(8):2251–2272, 1996.
M. Morari. Design of resilient processing plants-III. A general framework for the assessment of dynamic resilience. Chem. Eng. Sci., 38(11):1881–1891, 1983.
M. Morari and E. Zafiriou. Robust Process Control. Prentice-Hall, Englewood Cliffs, New Jersey, 1989.
Z. Nagy and Ş.. Agachi. Model predictive control of a PVC batch reactor. Comput. Chem. Eng., 21(6):571–591, 1997.
H. Nijmeijer and A.J. van der Schaft. Nonlinear Dynamical Control Systems. Springer, New York, 3. edition, 1996.
S. Palanki, C. Kravaris, and H.Y. Wang. Optimal feedback control of batch reactors with a state inequality constraint and free terminal time. Chem. Eng. Sci., 49(1):86–97, 1994.
J.D. Perkins and S.P.K. Walsh. Optimization as a tool for design/control integration. Comput. Chem. Eng., 20(4):315–323, 1996.
T. Peterson, E. Hernández, Y. Arkun, and F.J. Schork. A nonlinear DMC algorithm and its applications to a semibatch polymerization reactor. Chem. Eng. Sci., 47(4):737–753, 1992.
A.K.M.S. Rahman and S. Palanki. On-line optimization of batch processes with nonlinear manipulated input. Comput. Chem. Eng., 20(5):449–459, 1996.
S. Rahman and S. Palanki. On-line optimization of batch processes in the presence of measurable disturbances. AIChE J., 42(10):2869–2882, 1996.
G.V. Reklaitis (editor) and E. Zafiriou (guest editor). Selected Papers from the IFAC Workshop on Integration of Process Design & Control (IPDC’94). Comp. Chem. Eng., 20(4), 1996.
D.W.T. Rippin. Simulation of single-and multiproduct batch chemical plants for optimal design and operation. Comput. Chem. Eng., 7(3):137–156, 1983.
O. Rosen and R. Luus. Evaluation of gradients for piecewise constant optimal control. Comput. Chem. Eng., 15(4):273–281, 1991.
D. Ruppen. A Contribution to the Implementation of Adaptive Optimal Operation for Discontinuous Chemical Reactors. PhD thesis, ETH, No. 10634, Zürich, Switzerland, 1994.
H. Schuler. Frühzeitige Erkennung gefährlicher Reaktionszustände in chemischen Reaktoren. Regelungstechnik, 32(6):190–237, 1984.
S. Skogestad and I. Postlethwaite. Multivariable Feedback Control. John Wiley & Sons, Chicester, England, 1996.
E. Sørensen. Studies on Optimal Operation and Control of Batch Distillation Columns. PhD thesis, NTU, Trondheim, Norway, 1994.
E. Sørensen and S. Skogestad. Control strategies for reactive batch distillation. J. Proc. Cont., 4(4):205–217, 1994.
M. Soroush and C. Kravaris. Optimal design and operation of batch reactors. 1. Theoretical framework. Ind. Eng. Chem. Res., 32:866–881, 1993.
M. Soroush and C. Kravaris. Optimal design and operation of batch reactors. 2. A case study. Ind. Eng. Chem. Res., 32:882–893, 1993.
A.J. Stack and F.J. Doyle III. Application of a control-law nonlinearity measure to the chemical reactor analysis. AIChE J., 43(2):425–439, 1997.
A.J. Stack and F.J. Doyle III. The optimal control structure: an approach to measuring control-law nonlinearity. Comput. Chem. Eng., 21(9):1009–1019, 1997.
J. Steinbach. Praxisorientierte Darstellung von Auslegungskriterien für Semibatch — Reaktoren. In Dechema — Monographien Band 107, pages 133–152. VCH Verlagsgesellschaft, 1987.
F. Stoessel. Design thermally safe semibatch reactors. Chem. Eng. Progr., pages 46–53, September 1995.
F. Strozzi and J.M. Zaldivar. A general method for assessing the thermal stability of batch chemical reactors by sensitivity calculation based on Lyapunov exponents. Chem. Eng. Sci., 49(16):2681–2688, 1994.
P. Tanartkit and L.T. Biegler. Stable decomposition for dynamic optimization. Ind. Eng. Chem. Res., 34(4):1253–1266, 1995.
P. Tanartkit and L.T. Biegler. A nested, simultanous approach for dynamic optimization problems — I. Comput. Chem. Eng., 20(6/7):735–741, 1996.
P. Terwiesch. Dynamic Optimization of Batch Process Operations with Imperfect Modeling. PhD thesis, ETH, No. 10857, Zürich, Switzerland, 1994.
P. Terwiesch. Cautious on-line correction of batch process operation. AIChE J., 41(5):1337–1340, 1995.
P. Terwiesch and M. Agarwal. Robust input policies for batch reactors under parametric uncertainty. Comput. Chem. Eng., 131:33–52, 1995.
P. Terwiesch, M. Agarwal, and D.W.T. Rippin. Batch unit optimization with imperfect modelling: A survey. J. Proc. Cont., 4(4):238–258, 1994.
P. Terwiesch, D. Ravemark, and D.W.T. Rippin. Risk-cautious operation of batch processes. In J.B. Rawlings, editor, Proc. of the IFAC Symposium DYCORD+’95, pages 409–414, Helsingør, Denmark, 7–9 June 1995.
C. Toulouse, J. Cezerac, M. Cabassud, M.-V. LeLann, and G. Casamatta. Optimisation and scale-up of batch chemical reactors: Impact of safety constraints. Chem. Eng. Sci., 51(10):2243–2252, 1996.
V.S. Vassiliadis, R.W.H. Sargent, and C.C. Pantelides. Solution of a class of multistage dynamic optimization problems. 1. Problems without path constraints. Ind. Eng. Chem. Res., 33(9):2111–2122, 1994.
V.S. Vassiliadis, R.W.H. Sargent, and C.C. Pantelides. Solution of a class of multistage dynamic optimization problems. 2. Problems with path constraints. Ind. Eng. Chem. Res., 33(9):2123–2133, 1994.
Author information
Authors and Affiliations
Corresponding author
Editor information
Editors and Affiliations
Rights and permissions
Copyright information
© 1998 Springer Science+Business Media Dordrecht
About this chapter
Cite this chapter
Abel, O., Helbig, A., Marquardt, W. (1998). Optimization Approaches to Control-Integrated Design of Industrial Batch Reactors. In: Berber, R., Kravaris, C. (eds) Nonlinear Model Based Process Control. NATO ASI Series, vol 353. Springer, Dordrecht. https://doi.org/10.1007/978-94-011-5094-1_18
Download citation
DOI: https://doi.org/10.1007/978-94-011-5094-1_18
Publisher Name: Springer, Dordrecht
Print ISBN: 978-94-010-6140-7
Online ISBN: 978-94-011-5094-1
eBook Packages: Springer Book Archive