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Department of Systems Engineering and Control, Universidad Politcnica de Valencia, Camino de Vera, 14, 46022 Valencia, Spain
Department of Chemical and Nuclear Engineering, Universidad Politcnica de Valencia, Camino de Vera, 14, 46022 Valencia, Spain
a b s t r a c t
This paper presents a methodology for the design of a fuzzy controller applicable to continuous processes based on
local fuzzy models and velocity linearizations. It has been applied to the implementation of a fuzzy controller for a
continuous distillation tower. Continuous distillation towers can be subjected to variations in feed characteristics that
cause loss of product quality or excessive energy consumption. Therefore, the use of a fuzzy controller is interesting
to control process performance.
A dynamic model for continuous distillation was implemented and used to obtain data to develop the fuzzy controller at different operating points. The fuzzy controller was built by integration of linear controllers obtained for each
linearization of the system. Simulation of the model with controller was used to validate the controller effectiveness
under different scenarios, including a study of the sensibility of some parameters to the control.
The results showed that the fuzzy controller was able to keep the target output in the desired range for different
inputs disturbances, changing smoothly from a predened target output to another. The developed techniques are
applicable to more complex distillation systems including more operating variables.
2010 The Institution of Chemical Engineers. Published by Elsevier B.V. All rights reserved.
Keywords: Fuzzy; Distillation tower; Gain scheduling; Control
1.
Introduction
Corresponding author.
E-mail addresses: fabarri@upv.com (F. Barcel-Rico), jmgz@iqn.upv.es (J.M. Gozlvez-Zafrilla).
Received 23 December 2009; Received in revised form 30 March 2010; Accepted 15 April 2010
0263-8762/$ see front matter 2010 The Institution of Chemical Engineers. Published by Elsevier B.V. All rights reserved.
doi:10.1016/j.cherd.2010.04.015
108
Nomenclature
Ai
ai
bi
aen
avn
D
Fi
G
hF
hL
hV
k0
Li
mi
p
qi
R
Ri
t
u
W
x
xij
yij
y
Vi
i
zij
Rules antecedent
Regression coefcients of rules consequent
Independent term of rules consequent
Coefcient of the linear system (from energy
equation)
Coefcient of the linear system (from constant
volume condition)
Flow of top product (kmol s1 )
Feed ow to stage i (kmol s1 )
General system (in control terms)
Enthalpy of feed (kJ kmol1 )
Enthalpy of liquid (kJ kmol1 )
Enthalpy of vapour (kJ kmol1 )
Gain of the system
Flow of liquid stream exiting from stage i
(kmol s1 )
Total amount of moles in stage i
Desired pole of the controller
Heat duty input to stage i
Reux ratio
Rule number i
Time (s)
Generic input variable
Vector representing all internal ows
Generic input variable for the consequent of the
rules
Average fraction of component j in the liquid of
stage i
Average fraction of component j in the vapour
of stage i
Generic output variable of the system/controller
Flow of vapour stream exiting from stage i
(kmol s1 )
Volume of stage i (m3 )
Fraction of component j in feed Fi
Greek letters
i
Membership function value for rule i
Molar density (kmol m3 )
Time constant of the system
Subscripts
i
Number of stage
i
Number of rule
j
Component
k
Index for stream
k
Specic time instant in the controlling process
n(i, k)
Index operator for vector W
N
Last stage (reboiler)
2.
Dynamic model for continuous
distillation
Distillation towers are multi-stage separation units conceived
to separate feeds into streams enriched in components of different volatility. The separation is achieved when a vapour and
a liquid stream tend to thermodynamic equilibrium when are
put in contact in the separation stages (trays).
Fig. 1 shows a schematic representation of the tower and
the streams ows between its different stages i. The stages are
numbered increasingly from top to bottom: 1 is the condenser,
2 to N 1 are the trays and N is the reboiler. Every stream
is dened by their ow, molar fractions of j components and
enthalpy. Thus, a feed entering to stage i is dened by Fi , zi,j
and hFi . The liquid and vapour streams exiting from the stage
i are dened by Li , xij , hLi and Vi , yi,j , hVi respectively. A duty
heat, qN , is supplied to the reboiler in order to generate the
vapour stream. The vapour stream moves upwards exchanging components with the descending liquid stream, and the
vapour is progressively enriched in the most volatile components. Consequently, the liquid stream will be enriched in the
less volatile ones. To generate a saturated liquid stream, a heat
duty q1 must be removed from the vapour in the condenser.
This stream is divided into a product stream and a stream
recycled back to the column. The recirculation is determined
by the reux ratio, R, dened in (1), which constitutes one of
the main operation variables.
R=
L1
D
(1)
109
express:
hL
dhLi
=
dt
xj
j
dxi,j
xi,j
(7)
dt
Our aim is to relate the stream ows and the molar fractions in the liquid that remain as the only state-variables of
the problem. To have a unique vector W representing all the
unknown internal ows, an index operator n(i, k) is dened for
each stage i so that for indices k = 04 stand for the streams
Fi , Gi , Li1 , Gi+1 and Li respectively.
n(i, k) = 4 (i 1) + k
(8)
(9)
k=1
where
aen(i,k)
hL
= hn(i,4) hn(i,k) + sign(k)
xj
j
dMi
= Li1 Li + Vi+1 Vi + Fi
dt
d(Mi xi,j )
dt
(2)
dMi
d
= i
= i
dt
dt
xj
+ Fi hFi + qi
(4)
k=1
dxi,j
where
(5)
dhL,i
= Mi1 [Li1 hL,i1 + Fi hF,i Li hL,i + Vi+1 hV,i+1
dt
+ qi Vi hV,i + hL,i (Li1 + Fi1 Li + Vi1 Vi )]
(6)
xi,j
dxi,j
(11)
dt
Substitution of (2) into (3) and (4) leads to the time derivatives of composition and enthalpy ((5) and (6)).
dt
(10)
(xn(i,k),j xi,j )
xi,j
Additional equations are necessary to completely determine the stream ows. These equations can be obtained by
expressing the liquid density as a function of the liquid composition and considering constant volume of liquid i as the
liquid overows in each stage:
(3)
d(Mi hLi )
= Li1 hLi1 Li hLi + Vi+1 hVi+1 Vi hVi
dt
avn(i,k)
= 1 +
sign(k)
x n(i,4)
j
(12)
xn(i,k),j xi,j
xj
(13)
xi,j
110
3.
Velocity-based fuzzy control of a
continuous distillation process
A suitable modelling and identication of a system is essential
for controller design. In our case, fuzzy identication adjusts
those models to available data sets, and the local error of a
number of local models that represent the system in a region
is preferred to the usual approach of minimizing the global
prediction error (Sala et al., 2006).
The identication of fuzzy models needs to establish a
model structure for a subsequent parameter identication
step (Wang, 1997), as occurs in all identication procedures.
This second identication step can be easily done, for example, by least mean squares if the system is linear in parameters
(Babuska, 1996). This is our case, because input and output variables, and antecedent fuzzy membership functions
A (interpretable as validity regions for local descriptions in a
set of operating points) will be provided by experts, and rule
consequents will be afne models following TakagiSugeno
structure described by:
Ri : If (x is Ai )
i = 1, 2, . . . , k
(14)
y=
i (x) yi
i=1
k
(15)
i (x)
i=1
4.
The control system can be built using data from a real system.
However, dynamic distillation models are accurate enough
(16)
111
Nomenclature
Value (unities)
N
Fi
i
C
R
10
6
0.064 (m3 )
0.4 (m3 )
0.4 (m3 )
Number of trays
Feed tray position
Tray volumen
Condenser volumen
Reboiler volumen
Nomenclature
Small step
qN
hF
R
7.5%
7.5%
2.5%
Heat of reboiler
Enthalpy
Reux
Big step
15%
15%
5%
F (kmol s1 )
0.217
0.217
0.217
0.217
0.217
0.217
zF
hF (kJ kmol1 )
qN (kJ s1 )
0.36
0.46
0.26
0.36
0.36
0.36
11,000
11,000
11,000
20,000
11,000
11,000
1878
1878
1878
1878
2744
1100
1
1
1
1
1
1
Point
OP1
OP2
OP3
OP4
F (kmol s1 )
0.217
0.217
0.217
0.217
zF
hF (kJ kmol1 )
qN (kJ s1 )
0.43
0.32
0.28
0.36
15,000
12,000
19,000
14,000
2079
2426
1473
1600
1
1
1
1
small models is devised in Fig. 4. This set of rst order systems will be integrated with the fuzzy structure proposed in
the previous section.
Eq. (17) shows the G general single input single output linear discrete rst order system (input u, output y, and instant
k) placed at the consequent of each rule:
G=
k0
yk = yk1 + k0 uk
z
(17)
(18)
p
1p
yk +
rk
k0
k0
(19)
112
Fig. 5 Models of molar fraction x1 versus time (in s) at the operating point 5. From top left to bottom right, variations of x1
for disturbances in F, zF , hF , q, and R.
rately enough even in points that are not exactly the operating
points for which the controllers were designed. This is a good
property of this type of controllers.
The advantage of having different control variables meeting the same requirements is that its effectiveness can be
checked from different points of view (for example: economical, resources availability, etc.) and the decision on what
control variable must be used can change from time to time
depending on external factors.
Fig. 6 Control of molar fraction x1 versus time (in s) for different positive and negative steps using hF as control variable.
113
Fig. 7 Control of molar fraction x1 versus time (in s) for different positive and negative steps using qN as control variable.
5.
Once the set of models has been built and the set of controllers tested with the models and proved their performance,
the next step is to apply the set of fuzzy controllers to the simulator of the plant, as this has a slightly different behaviour of
the model built and therefore, the performance of the controller might be different over the simulator than over the
model.
To apply the controller to the simulator it has to be taken
into account that the output and inputs for this are absolute
and not by increments as they were for the model (velocitybased model and controller, Eq. (16)).
Fig. 9 shows the control applied to the simulator in operating point PC1 = [0.217,0.36, 15, 000, 1878, 1], which is a point
between P1 and P4. It can be seen how the control performs
very well in spite of the speed and dynamics of the controlled
signal x1 .
It has been said that the speed of feeding is constant as well
as the composition of this feeding in this kind of processes.
Nevertheless, it can happen that the composition has some
perturbations due to small impurities of the product. This can
highly modify the effects of the control. Thus, to check the
performance of the fuzzy controller when perturbations are
present in the composition different variations in composition C0 have been introduced. Fig. 10 shows how the control
makes the signal come back to the reference, even when a
perturbation of 10% is present in C0 .
It has to be said that control variables hF and qN are not suitable to control the composition of x1 when big perturbations
are present in C0 . They can only control up to perturbations of
0.1%. This is due to dynamics of the composition of the products when this variables are modied. On the other hand, the
modication of the variable R has an immediate response on
6.
Study of the sensibility of the control to
the selected input
As shown in Fig. 4 and described through all the text, the control can be performed by 3 different inputs. That allows the
election of one of them attending to the chosen criteria.
These criteria could be imposed by two methods. One is
the consideration of the availability of the resources needed to
perform the control. The other is by the reach of each variable
in the output level. For the hF and qN , variables a heat source is
needed, whereas a cooling source is needed for the R control
input case.
As well as the reach of the qN is the smallest one (0.05%
in the example described here) it limits the control by means
of this variable. The reach of the control by the other two
variables is bigger (0.5%), allowing a big performance zone.
However, given that all the resources are available and the
control could be built by any of the three control input, the
selection criterion is, industrially attending, economic. As far
as all the controls perform well, the cheapest one will be the
chosen. Anyway, it is not only the cost of the application what
should be studied, but also the benets from production.
114
Fig. 8 Control of molar fraction x1 versus time (in s) for different positive and negative steps using R as control variable.
To apply heat to the stream feed or to the reboiler is more
expensive than to subtract heat from the condenser, but the
amount of product decreases when R input gets reduced.
The prices of fuel to get a heat source or the cooling water
to perform the refrigeration must be updated from the market,
as well as the price of the distillate to be sold. Therefore, not
too many results can be exposed, but several conclusions can
be drawn:
7.
Conclusions
Acknowledgements
The authors acknowledge the partial funding of this work by
the projects: Regional Government Project GVPRE/2008/108,
and National Projects DPI2007-66728-C02-01 and DPI200806737-C02-01.
References
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310322.
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115