Process Control Technology Research Articles

High-Order Engineering Fastest Controller and Its Application in Thermal Power Units

In the domain of industrial process control, the ubiquitous proportional–integral–derivative (PID) control paradigm, while foundational, is deemed insufficient amidst evolving complexities. In alignment with China’s strategic “dual-carbon” targets, extant thermal power installations are mandated to facilitate profound peak load navigation and expedited frequency modulation services. The incumbent PID control schema is found wanting in this regard, precipitating the imperative for an innovative process control technology to supplant the conventional PID regimen. Power system engineers have consequently devised the engineering fastest controller (EFC), which has adeptly succeeded PID control in nascent applications, thereby meeting the stringent control exigencies for deep peak regulation and agile frequency modulation. Employing rigorous theoretical analysis and sophisticated simulation experiments, this investigation meticulously compares the performance attributes of high-order controllers (HOCs) with the EFC. The empirical findings underscore the EFC’s pronounced superiority over PI, PID, and SOC in regulatory performance enhancements by 122.2%, 88.0%, and 77.3%, respectively, and in mitigating disturbances by 140.0%, 80.9%, and 54.5%, respectively. This study culminates in the assertion that the EFC represents a paradigmatic advancement in industrial control technology, not only manifesting pronounced performance benefits but also furnishing a robust theoretical scaffolding that transcends the performance zeniths of traditional PID and HOC technologies.

A Multi-Objectives Optimization Model for the Joint Design of Statistical Process Control and Engineering Process Control

A Multi-Objectives Optimization Model for the Joint Design of Statistical Process Control and Engineering Process Control

GENERAL PRINCIPLES OF FORMALIZATION OF TECHNOLOGICAL PROCESS CONTROL OF MINING PRODUCTION IN A DYNAMIC DISTRIBUTED SYSTEM

Context. The problem of synthesis, modeling, and analysis of automated control of complex technological processes of mining production as a dynamic structure with distributed parameters. Objective. On the example of the technological line of ore beneficiation, the general principles of formalization of control of mining production processes as a dynamic system with distributed parameters are considered. Method. The modeling of interactions between individual components of the control system is carried out using the methods of coordinated distributed control. In accordance with this approach, the technological line is decomposed into a set of separate subsystems (technological units, enrichment cycles). Under these circumstances, the solution to the global optimization problem is also decomposed into a corresponding set of individual subproblems of optimizing the control of subsystems. To solve the global problem, this formulation uses a two-level structure with coordinating variables that are fed to the input of local control systems for technological units and cycles. At the lower level of control, sets of subtasks have independent solutions, coordinated by the coordinating variables formed at the upper level. Results. The paper proposes a method for forming control of a distributed system of technological units of an ore dressing line based on the decomposition of the dynamics of the distributed system into time and space components. In the spatial domain, the control synthesis problem is solved as a sequence of approximation problems of a set of spatial components of the dynamics of the controlled system. In the time domain, the solution of the control synthesis problem is based on the methods of synthesizing control systems with concentrated parameters. Conclusions. The use of the proposed approach to the formation of technological process management at mining enterprises of the Kryvyi Rih iron ore basin will improve the quality of iron ore concentrate supplied to metallurgical processing, increase the productivity of technological units and reduce energy consumption.

Research on manufacturing process control and analysis technology of civil aircraft

Abstract The manufacturing stage is the core link of product reliability, and the manufacturing process control is the bridge between design reliability and product reliability. In the manufacturing process, the influence of various factors on the formation of product reliability is considered and controlled. Meanwhile, the process failure mode and impact analysis (PEMEA) method is introduced to clarify its principle and method. The key processes of the manufacturing and assembly process are identified by taking the RAT system of certain aircraft as an example. Effective measures are proposed to improve the manufacturing and assembly process, ensure the manufacturing reliability of products, and provide strong support for improving the quality and reliability of civil aircraft.

Economical management of diesel generator sets by means of MATLAB digital technologies

A numerical algorithm for optimizing the technological processes of diesel generator sets operating on various grades of fuel, implemented by means of CVX-technologies, is considered. Traditional algorithms have generally proven to be positive, but can be problematic for optimization due to the large number of variables and the nonlinearity of the model. In addition, due to the huge computational load, they can “stall” or become damaged when used to search for non-standard designs, such as asymmetric D-optimal and large-dimensional spatial structures. It is noted that an alternative to them is calculations in the CVX format, which are widespread and available for solving convex optimization problems. However, their application for the control of technological processes of energy saving in autonomous electric power complexes in transport is still limited. Based on the tools of the CVX package in MATLAB, using their usefulness and flexibility in comparison with traditional optimization methods, this paper proposes technical solutions aimed at developing energy-saving technologies for energy complexes of autonomous systems in the context of digital transformation. The application of energy saving management methods is presented in this study on the example of fuel consumption management by a group of diesel generators with different consumption characteristics of primary engines, for which optimal modes have been obtained at various options of active power consumption by the network. An example of calculating optimal modes in parallel operation of five DGA with CVX program codes is given, confirming the correctness of the proposed solutions. It is shown that the use of CVX programs in MATLAB demonstrates their usefulness and flexibility in comparison with traditional algorithms in the statistics of searching for various types of optimal approximate constructions by convex criterion for nonlinear models.

OPTIMIZATION PROBLEM FOR PROPYLENE GLYCOL PRODUCTION

Currently, in the rapid development era of new technologies and in order to increase the economic efficiency of production, more and more attention is paid to the current automation, control, and optimization problems of technological processes in the oil refining, petrochemical, and chemical industries [1-11]. It is known that the production of commercial propylene glycol is one of the most important industries in modern chemical technology. Propylene glycol can act as one of the components in the obtaining drug's process. In addition, it is used for lubrication and preservation of food packaging machines, is used as a plasticizer in the production of cellophane and polyvinyl chloride films, as a solvent for natural and synthetic substances in the preparation of ointments, pastes, creams, shampoos, etc., in the pharmaceutical and cosmetic industries, in the food industry as a solvent for food additives and a tobacco humectant, etc. Based on the relevance of the above, this article, based on a comprehensive study of the features of the chemical-technological process for obtaining propylene glycol, in particular, the chemical reaction of obtaining commercial propylene glycol in one of the main apparatuses for the studied block - the hydrator, a physically substantiated mathematical statement of the optimal control problem of this apparatus is formulated. The optimal control problem of the studied technological apparatus is reduced to obtaining the maximum amount of the target product, considering the restrictions imposed on the control parameters. It is established that by its nature and specificity, it is a nonlinear programming problem, for the solution of which in the presented article an algorithm for optimizing the modes of the technological process is proposed, based on the use of the Lagrange multiplier method. An analysis of the results for solving the optimal control problem of the obtaining propylene glycol process showed that when maintaining the optimal values of the control parameters obtained by us, the amount of propylene glycol obtained increases by 3.5% compared to the actual amount. Keywords: technological process, commercial propylene glycol, optimal control problem, control parameters, Lagrange multiplier method, technological apparatus.

A Review of Model Predictive Control for the Municipal Solid Waste Incineration Process

Municipal solid waste incineration (MSWI) is essential for tackling urban environmental challenges and facilitating renewable energy recycling. The MSWI process has characteristics of multiple variables, strong coupling, and complex nonlinearity, requiring advanced process control (APC) technology. Although there have been several reviews on the modeling and control of the MSWI process, there is a lack of focus on model predictive control (MPC), a widely used APC technology. This article aims to comprehensively review MPC strategies in the MSWI process. First, it describes MSWI process technology in detail, examining control issues and objectives to highlight the complexity and challenges in controller design while providing an overview of MPC methods and their benefits. Second, it reviews incinerator modeling for control, including traditional modeling techniques and machine learning technologies such as fuzzy neural networks. Third, it reviews the controllers used for MSWI process, emphasizing the advantages of MPC over existing control methods. Fourth, it discusses the current status of MPC design and online updates, covering the need for an accurate dynamic predictive model and objective function and the online updates components such as predictive modeling, rolling optimization, and feedback correction. Finally, the study concludes with a summary of the findings.

DEVELOPMENT OF A COMPUTERIZED FLOUR ACCOUNTING SYSTEM AT A BAKERY ENTERPRISE USING SCADA

The modern stage of the development of branches of the national economy, where automatic control and control systems are actively used, is marked by the increasing penetration of microcontroller technology, methods of control and management of technological processes are constantly being improved. In general, the development of semiconductor technology and achievements in the field of automation led to the use of devices made on integrated microcircuits, which, due to high manufacturability, small size, weight and energy consumption, became very popular. The most accurate and effective accounting of flour can be carried out with the help of an automated system based on modern software and technical tools. The work, durability and quality of any system is determined not only by the novelty of the information it carries, but also by its operating characteristics, such as the speed of obtaining this information and its structure, the quality of all its component subsystems. All this fundamentally changes the properties of many systems, giving them new functions and opening up new possibilities for use. A more detailed consideration of the functions of such systems shows their following advantages: - multi-functionality of devices; - ease of system control; - control automation; - the ability to perform quick mathematical calculations; - miniaturization and efficiency of equipment; - increase in reliability; - the possibility of creating databases of information archives; - reduction of system development time. The creation of means of measurement, control and management of equipment and technological processes is characterized by the transition from the solution of separate, relatively simple tasks of automation to the creation on the basis of microprocessor circuits and other microelectronic elemental base of automation devices with software control from SCADA systems, which provide distributed automated control of technological processes of the entire enterprise as a whole.

Water-Coal Ratio Control Strategy of Ultra Supercritical Unit Based on Neural Network Inverse Model

Since the boiler water-coal ratio control system is a complex system with the characteristics of non-linearity and strong coupling, water-coal ratio control is one of the most difficult problems in the coal-fired power generation process control engineering, whose control strategy is of great importance. While, in order to achieve the control of water-coal ratio effectively during the coal-fired power generation process, the neural network inverse system scheme is proposed for the control of the water-coal ratio of ultra-supercritical units. Firstly, the model for the water-coal ratio system of an ultra-supercritical unit is presented in allusion to the characteristics of the water-coal ratio control system. Then the concept of the neural network based inverse system, the principle and method of the design of the neural network inverse controller are discussed. Finally, the control scheme is verified by establishing neural network inverse system on MATLAB toolbox. The experimental results show that the neural network based inverse system models has better control effect in terms of anti-interference ability, stability time than that of PID control system.

Unveiling the common laws of extracellular polymeric substances (EPS) properties on short-chain fatty acids production from sludge by EPS disintegration pretreatment

The production of short-chain fatty acids (SCFAs) from sludge is promising, but the efficiency and product quality often vary because of extracellular polymeric substances (EPS) characteristics and pretreatment principles. This study adopted specific EPS disintegration pretreatment to treat different types of sludge. By correlation coefficient matrix analysis and correlation dynamics change resolution, the intrinsic relationships between the nature of EPS and the production of SCFAs from sludge was unveiled. We demonstrate that tight-bound EPS (TB-EPS) is a principal carbon reservoir, positively impacting SCFAs yields, in the fermentation system with EPS as the main fermentation substrate, it can contribute about 29.2 % for SCFAs growth during fermentation. Conversely, TB-EPS exhibits a negative correlation during fermentation due to EPS-SCFAs interconversion, while loosely bound EPS (LB-EPS) correlates positively. Proteins and polysaccharides in TB-EPS, especially proteins, significantly enhance individual SCFAs yields, predominantly acetic, propionic, and isovaleric acids. The findings would provide a theoretical basis for developing pretreatments and process-control technologies aimed at improving SCFAs production efficiency and quality.

Framework for ergonomic design of control centres in underground coal mines - A Serbian experience

We present a framework for solving the problem of functional compatibility between process control equipment in control centres at underground mines and operator capabilities. The equipment incorporates displays of current ventilation, gas, and fire hazard data, status of alarm and early warning systems, a voice communication subsystem, and facilities for recording and printing of data and reports. The layout of the existing control panel is compared with a recommended design. The basic principles of ergonomic design and arrangement of the controls and indicators, as well as ease of use, type of operations carried out with these controls, and operators' viewing angles are discussed. The objective is to improve the usability of control panels, display boards, and graphic screens so as to enhance the functioning of control centres and optimize control of technological processes in coal mines.

Создание и развитие высоконадежных информационно-управляющих систем с элементами искусственного интеллекта для перспективных технологических комплексов

Methods and means of improving complex technological equipment are shown through the operational assessment of the quality of implemented technologies realtime. This is proved by the fact that implementing technological operations on universal equipment each time requires modeling dynamic processes and taking into account a large number of uncertainty factors that affect the geometry generation quality. It is not possible to be a priori aware of these factors. There is a need to create new information technologies with the possibilities of universal application for immediate understanding of various dynamic processes in diagnostic, identification and control systems. Standard computer systems for statistical analysis and optimization of dynamic processes with the possibilities of universal application for various implementations of modern technologies have been introduced. The possibility of using integrative criteria and methods of artificial intelligence for diagnostic systems, identification and control of advanced technological complexes is shown. The implementation of information systems for the management of complex objects of various technological purposes is presented. The proposed modeling methods and approaches have been tested at various machine-building enterprises when processing parts on turning, milling and grinding machines, both universal and CNC. The research results made it possible to implement new principles of automated control and optimal adjustment of technological processes in real time and create an automated system for evaluating their quality, which allows increasing the efficiency and reliability of management decisions by conducting optimization directly on operating equipment. Based on the methods and approaches described above, new results have been obtained in the implementation of plasma technologies for the modification of geometrically complex surfaces of mechanical engineering products aimed at increasing wear resistance, hardness and other technical characteristics of the working surfaces of precision engineering products. A fairly complete approbation of methods, approaches, procedures and decision-making criteria for various technologies allows them to be recommended for universal applicability.

Development of farming systems in the Prienisey Siberia

The paper presents the results of research conducted to assess the development of farming systems in the Prienisei Siberia over a long period of time as a basis for identifying factors determining crop productivity, and as an information basis for forecasting crop yields by 2030. The work provides information covering more than two hundred years of land practice in the Prienisei Siberia. It was found that in all the periods of agricultural production, each of which corresponds to a certain farming system, the trend of yield change was positive. Each successive period was shorter than the previous one, with yields increasing significantly. The period of extensive technologies application in farming lasted more than 140 years. At this time, yields increased by 0.0018 t/ha per year. The period of use of the ordinal (low-intensity) farming system lasted approximately 50 years. The yields then increased by 0.0204 t/ha per year. During the period of intensification of the farming system, which took about 30 years, the yields increased by 0.0212 t/ha per year and reached about 2.1 t/ha by the end of the period. The period of formation of high-intensity farming system is the shortest, characterized by the highest productivity growth rates – 0.0639 t/ha per year. If this trend is maintained, the long-term average yield of 3.0–3.5 t/ha will be reached approximately by 2030. For each soil-climatic zone it is advisable to have its own, original farming system, developed taking into account soil-agrochemical properties, landscape and climatic peculiarities, characterized by more in-depth differentiation of individual working area. It should present digital technologies using modern electronic means of informatization, geoinformation systems, remote methods and means of technological processes control, aerial and space methods of agro-ecosystems diagnostics.

Blend uniformity monitoring in a continuous manufacturing mixing process for a low-dosage formulation using a stream sampler and near infrared spectroscopy

Continuous manufacturing has the potential to offer several benefits for the production of oral solid dosage forms, including reduced costs, low-scale equipment, and the application of process analytical technology (PAT) for real-time process control. This study focuses on the implementation of a stream sampler to develop a near infrared (NIR) calibration model for blend uniformity monitoring in a continuous manufacturing mixing process. Feeding and mixing characterizations were performed for three loss-in-weight feeders and a commercial continuous mixer to prepare powder blends of 2.5–7.5 % w/w ibuprofen DC 85 W with a total throughput of 33 kg/h. The NIR spectral acquisition was performed after the mixing stage using a stream sampler for flowing powders. A continuous mixer shaft speed of 250 RPM was selected to operate the mixing process based on a variability analysis developed with in-line spectral data acquired using the stream sampler at 6 RPM. A partial least squares regression (PLS-R) model was performed and evaluated, yielding a root-mean-square error of prediction (RMSEP) of 0.39 % w/w and a bias of 0.05 % w/w. An independent experimental run conducted two days later revealed that the continuous mixing process and the NIR calibration model presented low day-to-day variation. The minimum practical error (MPE) and sill values through variographic analysis showed low variance associated with the sampling process using the stream sampler. Results demonstrated the promising capacity of the stream sampler coupled to an NIR probe to be implemented within continuous manufacturing processes for the real-time determination of API concentration.

Machine learning & conventional approaches to process control & optimization: Industrial applications & perspectives

Technologies based on Artificial Intelligence (AI) and Machine Learning (ML) concepts are advancing at a rapid pace. The new paradigms are challenging the status-quo of mature automation and control technologies in industry. Autonomous operation is a frequently stated goal of AI evangelists and technology providers. This white paper gives an overview of the current state of art of advanced process control and optimization technologies. It also provides a brief summary of the AI and ML-based approaches that address the closed-loop control and optimization space. Some results from industrial implementations are shared for both conventional and AI/ML-based approaches. Experience from four industrial applications is shared, covering rigorous model-based, machine learning and hybrid approaches to real-time optimization and control problems. The applications range from unit-based control & optimization to refinery & network wide optimization. A set of high-level requirements that need to be satisfied regardless of the underlying technology for closed-loop autonomous operations is reviewed. The article concludes with some future directions and perspectives highlighting areas where the emerging technologies may have significant impact in industry.

An intelligent system for high-quality automated control of multi-connected technological processes in mechanical engineering

An intelligent system for high-quality automated control of multi-connected technological processes in mechanical engineering

Application of Finite Element Simulation Technology in the Teaching of Process Equipment and Control Engineering

Improving the teaching level of the professional courses of Process Equipment and Control Engineering has an important role in promoting the cultivation of compound and applied equipment talents. In this paper, finite element simulation technology is introduced into the teaching of Process Equipment and Control Engineering. Taking the finite element analyses of truss beam in the filled tower and fixed tube-sheet heat exchanger as examples, the complementary role of finite element simulation technology for the theoretical and practical teaching of professional courses was introduced. Teaching practice shows that the visualization of finite element analysis results can effectively stimulate the interest of students in learning, deepen their understanding and mastery of theoretical knowledge, improve the ability of students to use finite element simulation technology to solve practical engineering problems, and achieve the unity of teaching and learning in professional courses.

Challenges for Leading Edge node FINFET

The primary focus of this work is to find out the challenges associated with 7nm node finFET. To enable the current generation of gadgets/instruments, foundries are going toward smaller geometries (FinFET 7nm, 5nm, etc.) for manufacturing SOC/ASIC. To support the 7nm technology node without EUV, the Layout Design Rules have been scaled quite aggressively. As a result, obtaining satisfactory performance and yield in High Volume Manufacturing (HVM) has become a difficult undertaking. The gains in terms of power, performance, and other characteristics that become available with reduced geometries are the main drivers driving this movement. Analog/mixed-signal circuits, on the other hand, do not fully achieve these gains. They get increasingly difficult to design, with higher parasitic resistance and capacitance, more layout-dependent effects, and, in certain cases, layout growth. While in terms of fabrication the challenges are in node and cost, mask making, patterning, transistor formation, BEOL, MEOL, Technology parasitic elements and process control etc. This indicate what are the challenges for design of 7nm node FinFET.

Повышение ресурса рабочих колес центробежных насосов шахтного водоотлива

Mining The article discusses the main failure causes of centrifugal pumps used in the mine dewatering plants. The factors causing intensive wear of the impellers used in centrifugal pumps of the CNS-33-66...330 type are analysed, as well as the ways of increasing their serviceability. The gas dynamic cold spraying is recognized as the most promising and efficient method of applying functional coatings, which makes it possible to improve the condition of the surface layer and eliminate surface defects of the initial impeller blanks, which have a significant impact on the serviceability of the parts. The main research trends are outlined in the studied area, and practical recommendations are provided on using the gas dynamic cold spraying methid both in the pump manufacturing process and in their overhaul. It is shown that one of the promising trends in development the gas dynamic cold spraying applications is the creation of multilayer coatings on the impeller blades based on compositions of various metal-ceramic powders. Along with the hardening treatment, this combination will allow to provide the impellers with a set of necessary functional characteristics for the hydro-abrasive wear conditions. technological process as a sequence of changing the natural state of the Earth's subsoil to obtain a certain quantity and quality of mineral products is characterized by departures from the specified normative parameter values, which is due to causes of different nature. Most of these causes are man-made, anf they are created during the performance of specific process operations by the personnel. The article presents an original approach to managing the control over the technological process parameters in a coal strip mine. To reduce the magnitude and probability of the process departures from the normative values, the authors propose to create technical and organizational control loops. Each loop is a closed chain of technical means and organizational tools, which secures up-keeping of the normative technological process state. Production risk is proposed to be used as a criterion to assess the efficiency of the control loops. The methodology allowing to calculate the risk is described. The results of the contour approach application to the technological process control at the Solntsevsky coal strip mine are presented.

Формирование контуров контроля технологического процесса угольного разреза

Mining technological process as a sequence of changing the natural state of the Earth's subsoil to obtain a certain quantity and quality of mineral products is characterized by departures from the specified normative parameter values, which is due to causes of different nature. Most of these causes are man-made, anf they are created during the performance of specific process operations by the personnel. The article presents an original approach to managing the control over the technological process parameters in a coal strip mine. To reduce the magnitude and probability of the process departures from the normative values, the authors propose to create technical and organizational control loops. Each loop is a closed chain of technical means and organizational tools, which secures up-keeping of the normative technological process state. Production risk is proposed to be used as a criterion to assess the efficiency of the control loops. The methodology allowing to calculate the risk is described. The results of the contour approach application to the technological process control at the Solntsevsky coal strip mine are presented.