A hierarchical multi-parametric programming approach for dynamic risk-based model predictive quality control

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In this work, we present a hierarchical batch quality control strategy with real-time process safety management. It features a multi-time-scale decision-making framework augmenting: (i) Risk-aware model predictive controller for short-term set point tracking and dynamic risk control under disturbances; (ii) Control-aware optimizer for long-term quality and safety optimization over the entire batch operation; (iii) Intermediate surrogate model to bridge the timescale gap by readjusting the optimizer operating decisions for the controller. All of the above problems are solved via multi-parametric mixed-integer quadratic programming with a key advantage to generate offline explicit control/optimization laws as affine functions of process and risk variables. This allows for the design of a fit-for-purpose risk management plan prior to real-time implementation, while reducing the need for repetitive online dynamic optimization. A unified process model is used to underpin the consistency of hierarchical operational optimization. The proposed approach offers a flexible strategy to integrate distinct decision-making time scales which can be selected separately tailored to the process-specific need of control, fault prognosis, and end-batch quality control. A T2 batch reactor case study is presented to showcase this approach to systematically address the interactions and trade-offs of multiple decision layers toward improving process efficiency and safety.