This study explores controlling a first- and second-generation alcoholic fermentation process with cell recycling, modeled through algebraic differential equations (DAE) with constraints. It evaluates seven controller types: PI, PID, Model Predictive Control (MPC), Neural Network Model Predictive Control (NNMPC), Mixed Model Predictive Control (MMPC), Internal Model Control (IMC), and Linear Quadratic Regulator (LQR). Results show that, while PI and PID controllers can track setpoints, they exhibit slow responses and oscillations. In contrast, MPC controllers respond faster, with both MPC and MMPC demonstrating more robust dynamics, achieving a significant reduction in Integral of the Absolute Error (IAE) across various disturbances, notably an 87% reduction in regulatory scenarios. NNMPC outperforms PI and PID but exhibits overshoot and oscillations, and lacks robustness for servo-type problems. However, MMPC showcases comparable or superior performance to MPC, surpassing other controllers in robustness, especially the IMC and LQR in the regulatory problems. NNMPC maintains a simulation time of under 4 seconds, whereas MPC incurs a computational cost 1,000 times higher. Integrating NNMPC’s optimal increment as an initial estimate in MPC reduces computational time by up to 79.7%. These findings highlight the ANN’s effectiveness in addressing complex control challenges, especially when integrated with MPC. MMPC offers a superior balance between accuracy, robustness, and computational efficiency, serving as a promising solution for reducing computational costs in MPC-type controllers.
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