Abstract
A novel formulation for combined scheduling and control of multi-product, continuous chemical processes is introduced in which nonlinear model predictive control (NMPC) and noncyclic continuous-time scheduling are efficiently combined. A decomposition into nonlinear programming (NLP) dynamic optimization problems and mixed-integer linear programming (MILP) problems, without iterative alternation, allows for computationally light solution. An iterative method is introduced to determine the number of production slots for a noncyclic schedule during a prediction horizon. A filter method is introduced to reduce the number of MILP problems required. The formulation’s closed-loop performance with both process disturbances and updated market conditions is demonstrated through multiple scenarios on a benchmark continuously stirred tank reactor (CSTR) application with fluctuations in market demand and price for multiple products. Economic performance surpasses cyclic scheduling in all scenarios presented. Computational performance is sufficiently light to enable online operation in a dual-loop feedback structure.
Highlights
Production scheduling and advanced control are terms which describe efforts to optimize chemical manufacturing operations
The results for closed-loop combined noncyclic scheduling and advanced control are compared to results for open-loop combined cyclic scheduling and advanced control
This work demonstrates the flexibility of a noncyclic combined scheduling and advanced control framework
Summary
Production scheduling and advanced control are terms which describe efforts to optimize chemical manufacturing operations. Model predictive advanced controls use process models to make predictions into a future horizon based on possible control moves to determine the optimal sequence of control moves to meet an objective, such as reaching an operational set point. In a multi-product continuous chemical process, steady-state operational set points or desired operational conditions over a future time horizon are determined by the production schedule, determining at which times, in what amounts, and in which sequence certain products should be produced. As scheduling and advanced control are closely interrelated, both seeking to optimize chemical manufacturing efficiency over future time horizons, their integration has been the subject of significant recent investigation. When scheduling and advanced control are separated, coordination of closed-loop responses to process disturbances is lost, unrealistic set points may be passed from scheduling to advanced controls, and advanced control may seek to drive the process
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