Automated Process Control Research Articles

EXTREMUM SEEKING CONTROL OF TWO-STAGE ANAEROBIC DIGESTION SYSTEM: A MINI REVIEW

Anaerobic digestion (AD) is a biotechnological process, in which microorganisms degrade organic matter under anaerobic conditions to produce biogas. It has long been known that the two main species (acidogenic and methanogenic) in the community of microorganisms in AD differ in many aspects and the optimal conditions for their growth and development are different. Therefore, in AD in a single bioreactor (BR) (single-phase process), the optimal conditions are selected taking into account the slow-growing methanogens at the expense of fast-growing acidogens, which affects the efficiency of the whole process. This has led in recent years to the development of two-stage AD (TSAD), in which processes are divided into a cascade of two separate BRs. It is known that this division of the processes into two consecutive BRs leads to significantly higher energy yields for the two-phase system (H2 + CH4), compared to the traditional single-stage CH4 production process. In our previous studies different mathematical models of the TSAD have been developed. It was shown that in both BRs the input-output characteristics have a clear maximum, which allows the yields to increase significantly if operations are provided around the maximum points. However, in order to maintain the sustainability of the biogas plants work, it is necessary to introduce automatic control with sophisticated extremum seeking control (ESC) algorithms. This paper presents the pioneering research on ESC of AD process with production of hydrogen and methane. This research has been realized by the Department of Biotechnology at The Stephan Angeloff Institute of Microbiology (SAIM) and the French-Chinese Laboratory on Automatic Control and Signal Processing (LaFCAS), in collaboration with the Laboratory of Signals and Systems (L2S) at the French National Center of Scientific Research CNRS.

Advances in automated real-time flow cytometry for monitoring of bioreactor processes.

Flow cytometry and its technological possibilities have greatly advanced in the past decade as analysis tool for single cell properties and population distributions of different cell types in bioreactors. Along the way, some solutions for automated real‐time flow cytometry (ART‐FCM) were developed for monitoring of bioreactor processes without operator interference over extended periods with variable sampling frequency. However, there is still great potential for ART‐FCM to evolve and possibly become a standard application in bioprocess monitoring and process control. This review first addresses different components of an ART‐FCM, including the sampling device, the sample‐processing unit, the unit for sample delivery to the flow cytometer and the settings for measurement of pre‐processed samples. Also, available algorithms are presented for automated data analysis of multi‐parameter fluorescence datasets derived from ART‐FCM experiments. Furthermore, challenges are discussed for integration of fluorescence‐activated cell sorting into an ART‐FCM setup for isolation and separation of interesting subpopulations that can be further characterized by for instance omics‐methods. As the application of ART‐FCM is especially of interest for bioreactor process monitoring, including investigation of population heterogeneity and automated process control, a summary of already existing setups for these purposes is given. Additionally, the general future potential of ART‐FCM is addressed.

Automated and continuous synthesis of drug substances

A continuous synthesis line was developed integrating different common reaction steps namely nitration, substitution and hydrogenation. Mesalazine as model drug substance was produced from 2-chlorobenzoic acid in continuous flow mode. A multi-instrument PAT strategy was implemented to equip the full line with in-line monitoring capability for critical quality attributes (CQAs) at several points. While most applications of PAT in research and manufacturing of the drug substance are limited to in-process control of quality, in this study real-time process information was generated to support automated process control actions. Process models were developed for all steps of the synthesis route either mechanistic based on reaction kinetics, data driven based on process data or depicting the residence time distribution (RTD). These models facilitated the development and implementation of an automation concept. Feedback loops were established using model predictive controllers for each unit operation, with the objective to maximize yield and minimize side products. The results indicate the high potential of an advanced control concept based on process models and real-time process data.

CREATION AND ANALYSIS OF THE STRUCTURE OF INTELLECTUAL DIAGNOSTIC SYSTEM OF INDUSTRIAL ROBOTS APPLIED IN EQUIPMENT MANUFACTURING

Based on comparative analysis of the current state of the issue, the main research tasks of the study were put in order to solve the current problem. The structure of the automated diagnostics system of typical industrial robots applied in flexible manufacturing systems of the appliance industry has been proposed. , The scheme of stable diagnostics of industrial robots applied in the flexible manufacturing system and also their mechatronics parts was proposed. To ensure the sustainability of the automated diagnostics of the industrial robot operating in the robotics complex, a scheme consisting of general diagnostic testing tools of the automated process control system, means of replacing faulty elements and diagnostic decision-making subsystem has been proposed. The automation scheme of the diagnostic system of technological equipment controlled by digital software, which is serviced by industrial robots in the flexible manufacturing system under study, has been proposed. The analysis of the proposed architecture of the industrial robot and its mechatronics diagnostic system was carried out. In one work turn, for the automated diagnosis of mechatronic parts of an industrial robot, the accuracy of its operations, hardness, power supply, oil content of mechanical parts, etc. requirements for verification of technical procedures have been identified. For the analysis of the architecture of the control and diagnostic system of the research object, the regulation of linear and angular displacements of the industrial robot at hierarchical levels (level 1), software testing of the current state of its execution mechanisms (level 2), automated workstation and control node connection is provided (level 3). For the automatic diagnostics of the industrial robot, the requirements for the sounds generated between the kinematic displacement points are in the accepted sound range, the vibrations in the kinematic displacement points are in the required range, and the power supply is in the required range. Automation of control and monitoring functions of the diagnostic system with the help of the server of the local industrial network of the industrial robot performing service functions in production is provided by SCADA. Keywords: instrumentation industry, flexible manufacturing system, diagnostic system, industrial robot, mechatronics part.

Research aspects of modeling and automated process control photopolymerization

This paper provides an overview of the state of existing systems of predictable control of the polymerization process. It includes a literature and patent survey of the presented mathematical models of the processes that occur during chemical polymerization reactions and analyzes techniques of controlling the processes of designing, manufacturing, modeling and construction of automated control systems. A critical analysis of existing modeling and control systems is given. The most promising software complexes ready for use in the process of designing of materials and products from photopolymers with predetermined structural properties have been identified. The analysis of a standard technological process as an object of control, by the example of the presented algorithm of the functioning of a particular production unit, showed the possibility of improving the existing automated systems of its control. By this example the authors prove the possibility of constructing automated process control systems, as well as those of photopolymerization, which will stabilize physical and chemical processes when manufacturing products from photopolymers. At the end of the research it was made possible to determine the purpose and objectives of further research of the authors aimed at creating the following complex: a software for the development of materials with specified structural properties; development of mathematical tools for calculation and modeling of photopolymerization processes; construction of automated control systems for technological processes of manufacturing products from photopolymer structural materials.

Automatic control of the sand granulation process to improve homogeneity in the manufacture of ceramic tiles

The purpose of this article is to quantify to what extent the design of an automatic control system for the clay sand granulation process will improve the percentage of homogeneity in the manufacture of ceramic tiles, through the analysis of the percentage of dust moisture. For which the process under study is initially described, identifying its stages, the control strategy to be used and its main characteristics. After conducting the research, it was determined that from the proposed control strategy, in which the flow of clay sand is controlled through frequency variators and the sequential injection of water spray through electric nozzles, it was achieved improve the homogeneity percentage by 94.78%, achieving that the error between the desired value and the present value of the humidity percentage is 0.015%, the approximation to the desired value or setpoint value being significant. Thus, it was also possible to determine that through an analysis of the dispersion model, that the collected data respond to a constant; evidencing that there is no sudden variation in the percentage of homogeneity during the automated operation of the process, which validates the improvement of homogeneity in the manufacture of ceramic tiles.

Methodological Bases of Optimal Load Distribution at a Thermal Power Plant with a Complex Composition of Equipment, Taking into Account Market Requirements

The features of a mathematical model for optimizing the distribution of heat and electricity at a large thermal power plant with a complex composition of equipment as part of traditional heating units and a heating CCGT are considered. The selection and justification of optimization criteria at different stages of preparation and entry of the station to the electricity and capacity market is given. The disadvantages of the previously proposed optimal distribution algorithms are analyzed in relation to thermal power plants with a complex composition of equipment and with a complex scheme for the supply of electricity and heat. A method and algorithm for solving the problem are proposed based on the equivalence of the CHP equipment and the decomposition of the problem taking into account the schemes of electricity and heat output. The description of mathematical optimization methods is given, taking into account the peculiarities of the CCGT operating modes at reduced loads. The requirements for information support when integrating the developed algorithm into the application software of the automated process control system based on the PTC are given.

PGU-450 network heaters modes modelling with CCGT participation in regulating the electrical load in the heating mode

The features of a mathematical model for optimizing the distribution of heat and electricity at a large thermal power plant with a complex composition of equipment as part of traditional heating units and a heating CCGT are considered. The selection and justification of optimization criteria at different stages of preparation and entry of the station to the electricity and capacity market is given. The disadvantages of the previously proposed optimal distribution algorithms are analyzed in relation to thermal power plants with a complex composition of equipment and with a complex scheme for the supply of electricity and heat. A method and algorithm for solving the problem are proposed based on the equivalence of the CHP equipment and the decomposition of the problem taking into account the schemes of electricity and heat output. The description of mathematical optimization methods is given, taking into account the peculiarities of the CCGT operating modes at reduced loads. The requirements for information support when integrating the developed algorithm into the application software of the automated process control system based on the PTC are given.

Combined architecture of an intelligent agent using models

The article considers the problem of building a multi-agent system for solving information security problems of automated process control systems. The architecture of an intelligent agent is proposed and studied, the features of which are the presence of a set of models used both for assessing the security of a certain node of the security object – an automated system, and for making decisions aimed at increasing the level of security. The results obtained in the course of research improve both the scientific and methodological apparatus for integrating methods of multi-agent technologies, and expand the areas of its practical application.

Improving the Efficiency of a Blast Furnace and Increasing its Campaign with Mathematical Models Run in Real Time as Part of the Automatic Process Control System

Improving the Efficiency of a Blast Furnace and Increasing its Campaign with Mathematical Models Run in Real Time as Part of the Automatic Process Control System

CFTR modulation with elexacaftor-tezacaftor-ivacaftor in people with cystic fibrosis assessed by the β-adrenergic sweat rate assay

Background: The cystic fibrosis (CF) sweat gland is defective in β-adrenergically-stimulated sweat secretion in the coil and chloride reabsorption in the duct. Whereas chloride reabsorption is regularly assessed by quantitative pilocarpine iontophoresis (QPIT), the measurement of β-adrenergic sweat secretion is not yet established in clinical practice. Methods: A novel sweat bubble imaging protocol was developed that determines sweat secretion rates by automatic recording, processing and quality control of the kinetics of sweat droplet formation. Results: Treatment of CF patients with the CFTR modulators elexacaftor, tezacaftor and ivacaftor reduced the sweat chloride concentration measured in QPIT in the majority of patients to values in the intermediate or normal range. In contrast, the β-adrenergically-stimulated sweat secretion rate assayed by the automated bubble sweat test was normalized in only 3 patients, slightly increased in 12 patients and remained undetectable in 8 patients. Conclusions: β-adrenergic sweat stimulation in the coil is apparently rather stringent in its requirements for a wild type CFTR conformation whereas chloride reabsorption in the duct tolerates residual structural and functional deficits of native or pharmacologically rescued mutant CFTR in the apical membrane.

THE APPLICATION OF COMPUTER VISION FOR THE ESTIMATION OF SHRINKAGE AND DEFORMATION OF THIN MANGO SLICES DURING AIR DRYING PROCESS

Computer vision has been currently a new trend in developing new tools for automatic real-time quality control process in food drying. During drying process, the size and shape of mango slides are critically changed. These changes usually determine the sensorial value of products, as well as which drying conditions would be needed to obtain the highest quality of dried products. In this study, we report on the development of a computer vision tool, requiring a normal digital camera installed, to evaluate the changes in size and shape of mango slides during the drying process. The technique is expected to replace the observation with human eyes to evaluate the changes of food products during the drying process, which might not be able to provide reliable and consistent judgements all the time. Image of drying mango slide is taken by a digital camera, then the feature extraction is implemented. The area of mango slice is determined by the area ratio via the pixel number counting and the comparison to an original sample with predefined reference size. The shrinkage deformation is evaluated by elliptical fitting to develop the automated utility. The utility is built on MATLAB platform. The variations in size and shape of the mango slices during a convective drying process with different processing conditions are examined and acquired by the built software which achieves real-time performance on the personal laptop.

APPLICATION OF INTERNET ARCHITECTURE IN CENTRALIZED AUTOMATED PROCESS CONTROL SYSTEMS

This article discusses the use of Internet architecture in centralized automated process control systems for the purpose of monitoring and managing geographically distributed objects. The hardware components of the proposed architecture are described and the required functions are formulated. The methods of implementing these functions of centralized control systems based on this architecture are proposed: using internal algorithms of SCADA systems, or using microprocessor subsystems. The difficulties that are likely to be encountered when implementing all the required functions in the system being developed are described.

TECHNOLOGY OF COMPLEX SORPTION TREATMENT OF INDUSTRIAL WASTEWATER FROM SULPHIDE AND COPPER(II)–IONES

Complex processing of industrial waste of individual industries, including wastewater treatment, containing sulfur anions and cations of heavy metals, in order to obtain both purified water and finished industrial products is an urgent task for today. The possibility of efficient use of regenerated mixed sorbent (AC+K), containing activated carbon (AC) and diatomaceous earth (K), for wastewater treatment of certain technological processes of chemical (petrochemical) industry and galvanic industries has been shown. The sorbent with the removed contaminants was offered to be utilized as a part of plastic lubricants of special purpose. The technological process of complex sorption treatment of industrial wastewater from sulfide and copper (II) ions includes the following main stages: sorbent regeneration; purification of sulfide-alkaline solutions; purification of washing waters of galvanic productions; obtaining plastic oils. The basic technological scheme of the site of regeneration of the spent mixed sorbent (AC+K) and purification of water-sugar solutions from organic impurities was developed. The material balance of regeneration of the spent mixed sorbent was calculated. The basic technological scheme of the site of combined treatment of industrial wastewater from sulfide and copper (II) ions, regeneration of spent industrial oils with regenerated sorbent (AC+K) and production of plastic oils has been developed. It was shown that the technology of complex sorption wastewater treatment is based on the most common technological processes - heating, cooling, adsorption and filtration and does not require complex schemes of automatic process control, and chemical equipment is typical for chemical enterprises in Ukraine. The economic effect of production of special purpose plastic oils was calculated.

Design and application of sewage treatment technology in fieldbus control system

At present, most sewage treatment plants in China generally have low sewage treatment automation and low operating efficiency. In order to solve this problem, this article takes a sewage treatment plant in Hangzhou as an example to analyze the functions and control requirements of each process in detail. Adopting three-level sewage treatment process and multiple disinfection technology at the same time, a set of sewage treatment field bus automatic monitoring system for SBR comprehensive process is designed, and the overall structure of the control system, control system hardware, control program and host computer monitoring system are given. The system adopts siemens S7-300 as the main control station, and uses industrial ethernet to complete the data exchange between the bus control and the control station on the network configuration. With various testing equipment, the inverter and MCC serve as the slave stations form a profibus control network, and complete functions such as automatic control of sewage treatment equipment and dynamic process monitoring through Wincc7.4 and Step7 V5.5. At the same time, automatic online monitoring and sampling are adopted, and video monitoring replaces manual inspection. Practice shows that the system The operation is in good condition, the effluent indicators, reliability, safety, etc. have reached the design requirements, and good economic and social benefits have been achieved. It is an integrated control system with strong practicability and high degree of automation, which is useful for further improving the automation of sewage treatment. The degree has important reference value. At the same time, the technical achievements of automatic sewage control and comprehensive treatment can fully support the sewage treatment needs during the new coronavirus epidemic, and have a wide range of application prospects.

Sensor fusion based on Extended and Unscented Kalman Filter for bioprocess monitoring

Availability of measurements of key process variables is of great importance to allow real time monitoring and control applications. However, in microbial fermentation processes, the unavailability of sensors or their high cost is a major barrier in automated process control applications. In this study, we implemented an Extended Kalman Filter (EKF) and an Unscented Kalman Filter (UKF), both augmented to take state constraints into account, in order to estimate biomass formation, sugar consumption and CO2 formation in a fed-batch bacterial cultivation process. The filters use a simple monod-growth model combined with an in-situ absorbance probe and an infrared off-gas measurements device for monitoring of biomass production and substrate consumption. We tuned the covariance matrices of the filters by a dedicated experiment, and tested their performance on independent set of experiments. Our results demonstrate precise estimation of the biomass and glucose consumption during the batch and the feeding phases, particularly when the process covariance matrix is adapted to the phases to account for model inaccuracies during the feeding phase.

Automated technology for the production of nanosized silicon dioxide and carbon

The article presents the results of the development of an automated process control system for the production of nanosized silicon and carbon for use in construction in the Arctic zone. The logical and organizational structures have been implemented; measuring instruments and a rational coding classification system have been selected. The machine and non-machine information bases have been worked out.

Дистанционный лабораторный комплекс «АСУ ТП тепломеханическим оборудованием электростанций» А. В. Трофимов,

Most industrial automation and control systems are remotely operated and monitored. We present the novel remote complex developed for educational purposes – to train engineering students in operating IACS intended for thermal mechanical equipment of power plants. Development of this remote training complex had multiple goals such as displaying all IACS components, operating real industrial equipment, simplicity, portability, and remote access. The typical structure of the automated process control system has been described. We have built a training stand in accordance with this structure, including all technology parts and connection of all sensors and equipment.

Data-Driven Consumption Load Monitoring and Adjustment Strategy in Smart Grid

The enhancement of the intelligent construction of the power grid and widespread popularity of smart meters enable large amounts of electrical energy consumption data to be collected and analyzed. Based on the data, the energy provider gives a guiding price in the future periods to users. It encourages users to be more economical and smarter in the process of using electricity. By applying the social welfare model to equate demand and supply in every time interval, we gain the optimal prices and generation capacity. Nevertheless, the truth is that there is a great gap between the consumers’ booked electrical energy consumption and the optimal generation capacity, causing the power system overload and even outage. This article puts forward a novel automatic process control strategy in order to monitor the gap between the consumers’ booked electrical energy consumption and optimal generation capacity by using statistical method to predict the future one. When the predicted value exceeds the boundary, the energy provider adopts the changeable electricity price to stimulate consumers to adjust their electrical energy demands so that it can have smoothly actual electrical energy consumption. Our adjustment method is data-driven exponential function-based adjustment. Case study results show that the strategy can obtain small adjustment times, stable actual consumption load, and controllable prediction errors. Different from the linear monitoring and adjustment strategy, our approach obtains almost the same adjustment frequency, less standard deviation of residuals, and higher total social welfare and energy provider profit.

Electrical Impedance Spectroscopy

The electrical impedance measurement of a suspension is a valid method to monitor crystallization processes. As it allows measurement of conductivity and permittivity it enables the characterization of non-conductive suspensions. The results obtained show that the concentration of an organic compound of interest can be determined by evaluating its electrical and thermal properties. As the analytical analysis of independent process parameters is a challenging task, a machine learning approach is investigated to extract essential parameter dependency for automated process control purposes.