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Overview
Introduction
Pyramid of operations
Off-line vs On-line Tasks
Steady state vs Dynamics
Enablers and open questions
On-line Issues
Model predictive control
Treatment of nonlinear model and uncertainty
Benefits and successes
Advanced Step Controller
Basic concepts and properties
Performance for examples
Future Work
Scheduling
Site-wide Optimization
Performance
Feasibility
Planning
Real-time Optimization
Model Predictive Control
Regulatory Control
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Scheduling
Site-wide Optimization
Real-time Optimization
Model Predictive Control
Performance
Feasibility
Planning
MPC APC
Regulatory Control
4
u
RTO
c(x, u, p) = 0
On line optimization
Nonlinear steady state model for
states (x)
Supply setpoints (u) to APC
(control system) with
Linear Dynamic Models
Model mismatch, measured and
unmeasured disturbances (w)
Minu F(x, u, w)
s.t. c(x, u, p, w) = 0
x X, u U
DR-PE
c(x, u, p) = 0
Data Reconciliation & Parameter
Identification
Estimation problem formulations
Steady state model
Maximum likelihood objective
functions considered to get
parameters (p)
Minp (x, y, p, w)
s.t. c(x, u, p, w) = 0
x X, p P
u
RTO
c(x, u, p) = 0
DR-PE
c(x, u, p) = 0
Batch processes
Grade transitions
Cyclic reactors (coking, regeneration)
Cyclic processes (PSA, SMB)
Continuous processes are never in steady state:
Feed changes
Nonstandard operations
Optimal disturbance rejections
Decoking scheduling
SMB optimization
PSA optimization
Productivity increases by factor of 2-3
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s.t.
dz (t )
= F (z (t ), y (t ),u (t ),t , p )
dt
G( z (t ), y(t ), u(t ), t , p ) = 0
z o = z(0)
z
t, time
z, differential variables
y, algebraic variables
z(t) z
y(t) y
u(t) u
p p
u
u
Indirect/Variational
Single Shooting
+Small NLP
- No instabilities
Bock, Plitt (1984)
Simultaneous Approach
+Handles instabilities
Sullivan (1977)
-Larger NLPs
Multiple Shooting
+Embeds DAE Solvers/Sensitivity
- Dense Sensitivity Blocks
Collocation
Large/Sparse NLP
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SQP
rSQP
Full-space
Barrier
E.g.,
IPOPT
Simultaneous
dynamic
optimization
E.g, SNOPT
NPSOL- and
Multiple
Sequential
Shooting
Dynamic
- over
100
5 variables
over
000
000
variables
and
constraints
Optimization
d.f.s 1but
over
- 10
over
100 variables
and
constraints
and constraints
Object Oriented Codes tailored to structure, sparse linear
algebra and computer architecture (e.g., IPOPT 3.2)
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Simultaneous
Full Space Formulation
Interior Point
Multiple Shooting
Adjoint Sensitivity
Direct Sensitivities
Single Shooting
rSQP
SQP
102
104
106
Variables/Constraints
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Multiple
Shooting
nw N
Simultaneous
Sensitivity
(nw N) (nu N)
N (nu + nw)
Exact Hessian
N (nu + nw)
NLP Decomposition
---
nw3 N
---
Step Determination
(nu N)
(nu N)
((nu + nw)N)
---
---
((nu + nw)N)
DAE Integration
Backsolve
O((nuN) + N2nwnu
O((nuN) + N nw3
+ N3nwnu2)
+ N nw (nw +nu)2)
---
O((nu + nw)N)
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Process
u : manipulated
variables
z : differential states
y : algebraic states
Why NMPC?
NMPC Controller
z = F ( z , y , u , p, d )
0 = G ( z , y , u , p, d )
Model Updater
z = F ( z , y , u , p, d )
0 = G ( z , y , u , p, d )
Planning
Scheduling
Site-wide Optimization
Real-time Optimization
Model Predictive Control
Regulatory Control
min
u
s .t .
NMPC Subproblem
J ( x ( k )) =
( z , u )+ E ( z
l
l =0
z l +1 = f ( z l , u l ))
z0 = x (k )
Bounds
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MPC - Background
Motivate: embed dynamic model in moving horizon framework to drive
process to desired state
Generic MIMO controller
Direct handling of input and output constraints
Slow time-scales in chemical processes consistent with dynamic
operating policies
Different types
Linear Models: Step Response (DMC) and State-space
Empirical Models: Neural Nets, Volterra Series
Hybrid Models: linear with binary variables, multi-models
First Principle Models direct link to off-line planning
Stability properties
Nominal remain bounded and eventually achieve desired state
without noise and with perfect model
Robust remain stable with model mismatch and noise
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s .t .
Jk =
( z , u )+ E ( z
l
l =0
z l +1 = f ( z l , u l ))
z0 = x ( k )
Bounds
J k 1 J k ( x ( k 1), u( k 1)) + {E ( z N |k 1 ) ( z N |k , v N |k ) E ( z N |k )}
( x ( k 1), u( k 1))
J0
(J
k =1
k 1
Jk ) =
x ( k ) 0, u( k ) 0
Discrete Lyapunov stability proof
Nominal case no noise: perfect model
General formulation with local asymptotic controller for t
Robust case keep (Jk-1 Jk) sufficiently positive in presence of noise/mismatch
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Unstable Reactor
After discretization
10920 variables
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(2007)
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NLP Sensitivity
Parametric Programming
Solution Triplet
Optimality Conditions
and find
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NLP Sensitivity
Obtaining
Optimality Conditions of
around
Assume:
Optimal Solution
Optimal Solution
Approximate
by Perturbing
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___ Ideal
____ Adv. Step NMPC
- - - - Direct Variant
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Simultaneous Collocation-Based
Approach
Optimal Policy vs. NLP Sensitivity -Shifted (On-line Computation 1.04 CPU s)
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DAE Model
Stage Transitions
Bounds
Path Constraints
Boundary Conditions
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Multi-stage Optimization
Determine Off-line policy
Tracking problem for NMPC
Nominal policy or incorporate uncertainty in conservative
optimization
u : manipulated
variables
Process
z : differential states
y : algebraic states
NMPC Controller
z = F (z , y , u , p , d )
0 = G (z , y , u , p , d )
Model Updater
z = F (z , y , u , p , d )
0 = G (z , y , u , p , d )
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On-Line Calculation
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On-Line Calculation
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Summary
RTO and MPC widely used for refineries, ethylene and,
more recently, chemical plants
Inconsistency in models
Can lead to operating problems
References
F. Allgwer and A. Zheng (eds.), Nonlinear Model Predictive Control, Birkhaeuser, Basel (2000)
R. D. Bartusiak, NLMPC: A platform for optimal control of feed- or product-flexible
manufacturing, in Nonlinear Model Predictive Control 05, Allgower, Findeisen, Biegler (eds.),
Springer, to appear
Biegler Homepage: http://dynopt.cheme.cmu.edu/papers.htm
Forbes, J. F. and Marlin, T. E.. Model Accuracy for Economic Optimizing Controllers: The Bias
Update Case. Ind.Eng.Chem.Res. 33, 1919-1929. 1994
Forbes, J. F. and Marlin, T. E.. Design Cost: A Systematic Approach to Technology Selection for
Model-Based Real-Time Optimization Systems, Computers Chem.Engng. 20[6/7], 717-734. 1996
Grossmann Homepage: http://egon.cheme.cmu.edu/papers.html
M. Grtschel, S. Krumke, J. Rambau (eds.), Online Optimization of Large Systems, Springer,
Berlin (2001)
K. Naidoo, J. Guiver, P. Turner, M. Keenan, M. Harmse Experiences with Nonlinear MPC in
Polymer Manufacturing, in Nonlinear Model Predictive Control 05, Allgower, Findeisen, Biegler
(eds.), Springer, to appear
Yip, W. S. and Marlin, T. E. Multiple Data Sets for Model Updating in Real-Time Operations
Optimization, Computers Chem.Engng. 26[10], 1345-1362. 2002.
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