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281436, 1995
Copyright 0 1995 Elswier Science Ltd
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Brief Paper
Key Words-Process control; chemical industry; model reference control; nonlinear control systems;
nonlinear programming; quadratic programming.
Abstract-This study extends the multistep, Newton-type properties under appropriate conditions. An additional
formulation [Li and Biegler (1989) C/tern. Eng. Res. Des., 67, advantage of the method is that it provides a consistent
562-5771 for nonlinear constrained process control. The treatment of both linear and nonlinear models.
computation of the control law is based on an augmented The next two sections describe the computational
performance index, which improves the performance of the formulation with a review of the stability properties in
method over the original formulation. A number of Section 3. In particular, we show that in the absence of active
modifications are also introduced in the computational constraints, the method becomes a nonlinear extension of the
algorithm to extend the range of problems, eliminate linear quadratic regulator, which guarantees closed-loop
steady-state offsets, and extend the output predictive horizon stability for a large range of tuning parameters. Finally, the
to infinity. We show that the global stability properties of the application of this algorithm to various process examples is
original Newton controller are preserved by the present considered in Section 4.
modifications. Moreover in the absence of active constraints,
the method behaves as an extension of the linear quadratic
regulator for, exhibiting therefore excellent stability pro- 2. Computational framework
perties for a large range of tuning parameters. The The use of operator theory for the synthesis of nonlinear
capabilities of the method are illustrated by application to control systems was first suggested by Economou (1985).
various process examples. This proposed Newton approach was later generalized by Li
and Biegler (1989) to an SQP algorithm, in order to allow the
inclusion of process constraints, and the consideration of a
1. Introduction multistep predictive horizon. Here, we consider in this
In the last decade, a substantial increase in the use of section a modified multistep Newton-type formulation based
optimization based predictive algorithms for process control on a more general quadratic performance index, for a
was observed. Model predictive control methods based on process model of the form
linear models have been tested extensively, and are presently
well-accepted in industrial practice; they are seen to provide
2 =&(x, u, d), (la)
control systems with relatively high performance and
reliability (Garcia et al, 1989). Alternative formulations for Y = g,(x). (Lb)
predictive control using nonlinear process models have also
been considered. These extensions have been recently where u E R”e represents the vector of system inputs
reviewed by Bequette (1991). Nonlinear model predictive (manipulations), x E Iw”s is the vector of state variables,
control (MPC) algorithms are advantageous in situations y E lR”o is the vector of system outputs, and d E LW is a
where substantial incentives for improved control quality vector of disturbances. It is assumed that n, s ni, that f, and
exist, due to the strong nonlinear nature of the system itself g, are continuously differentiable functions.
or when large changes in the operating conditions can be In order to simplify the determination of the optimal
anticipated during routine operation, such as in batch control laws, a discrete-time framework is used. Denoting the
processes, or during the start-up and shutdown of continuous present sampling instant by tk, the correspondent input and
processes. output predictive horizons are designated by %$ = [tk, tk +
This paper describes a nonlinear control algorithm that rik] and %& = [tk, cl, + t,J, respectively. This allows the
extends the basic Newton formalism of Li and Biegler (1989). correspondent predictive problem at tk to be formulated as
A number of important characteristics demonstrated by this
approach make the algorithm particularly attractive for
process control. These include a computationally efficient minJZi("7Y) =
u* I,%
2 (Yk+i- Y,p,k+i)TQyi(Yk+i-Ysp,k+i)
i=l
method for the determination of the model sensitivities and
the successive quadratic programming (SQP) nature of the + hk+i-I - u,,k+,-dTQui(Uk+r-,
- u,.k+i--l),
algorithm, together with the existence of global convergence
(24
* Received 25 April 1993; revised 10 January 1994; revised i= fp(x,u, 4, PI
20 March 1994; received in final form 14 April 1994. This
paper was not presented at any IFAC meeting. This paper Y = &Ax). (2c)
was recommended for publication in revised form by
Associate Editor B. Wayne Bequette under the direction of
Y/SY 'Y"? (24
Editor Yaman Arkun. Corresponding author Professor L. T. U,5U~U, and u(t) = u(rk + r,, - T);
Biegler. Tel. +I 412 268 2232; Fax +l 412 268 7139.
t Department of Chemical Engineering, Carnegie Mellon t E [zk + tih, rk + tohI. (2e)
University, Pittsburgh, PA 15213, U.S.A.
$ Present address: Department of Chemical Engineering, Here, u, E R”a represents a reference input trajectory,
Universidade de Coimbra, Large Marques de Pombal, 3000 accomplishing the same role as y,, for the outputs, and
Coimbra, Portugal. compatible to these set-points. The notation can be simplified
281
282 Brief Papers
by de&ring the augmented input and output vectors for a been satisfied. If so, implement uk = V,, and update ii for
predictive trajectory, as the next interval as
Hessian block elements of (6a), respectively. Here S,, The first one is a Continuous Stirred-tank Reactor (CSTR),
corresponds to the Kronecker delta and the second is a Fluid Catalytic Cracking (FCC) unit.
Both of these examples exhibit interesting characteristics in
terms of nonlinear behavior over an extended range of
operating conditions.
4.1. CSTR example. The system considered here consists
while Sjj is given by (5). A more detailed treatment of this of an ideal CSTR with an isothermal pseudo first-order
issue is given in Oliveira (1994). reaction A + B +P, in the presence of an excess
concentration of A (Oliveira, 1994). The corresponding
3. Stability properties process model is
Results in this section comprise a generalization of the
stability results of Li and Biegler (1989) for OL-stable
systems and a general unconstrained treatment. The effects
of the presence of active constraints on the closed-loop
stability, including some soft-constraint handling strategies
~=(c,,-**)~+(c”‘-“~)~-~. (W
are presented in Oliveira and Biegler (1994). For open-loop
asymptotically stable systems, Li and Biegler (1989) We assume that both state variables are measured and that
demonstrate that with Q, = Z, Qz = 0 the controller can be the process output is given by {x1, x2}. The vector of
made globally stable, by choosing a sufficiently long sampling manipulated variables is {u,, uZ}, while Car and Ca,
time, and using a line-search algorithm to enforce a descent constitute potential input disturbances. Under nominal
property. The next theorem shows that similar properties operating conditions this model can be shown to have three
exist for the formulation presented in the last section. possible equilibrium points, with the middle one being
OL-unstable.
Theorem 1. Assume that the open-loop nonlinear system For simulation, we used a sampling time T = 1, predictive
described by (1) is largely asymptotically stable, and that a horizons with 10 sampling intervals and Q, = diag{l, l},
constant set-point y,, = y* is used. For (1y, - y*llo, 2 6 > 0, Q, = diag (0.01, 0.01).Figures 1 and 2 illustrate the response
the application of the multistep Newton-type controller of the closed-loop system to a +lO% step change in C,,, at
correspondent to the previous algorithm with m,p > 1 t = 1. Despite being unmeasured and unpredicted by the
converges monotonically for sampling times T > T*, where control algorithm, this disturbance is well rejected; for
T* is finite. Therefore we have comparison the correspondent open-loop response goes to a
steady state of x~,+~= 9.4. Since the disturbance is not
II Ys+I -Y*l12a,<IlYs-Y*ll$y. explicitly accounted for by the controller, the final steady
states of the output variables exhibit a small offset when no
The proof for this theorem can be found in the Appendix.
integral action is used (about 0.4%). This offset is, however,
It relies on the fact that for open-loop asymptotically stable
eliminated when integral action is added, as can be observed
systems, a sufficiently large but finite T can be found such
from the corresponding output profiles. Using a tolerance
that 119115l, for any small predetermined E. Therefore
Ed” = 0.5 X 10w3, the number of iterations required reached a
choosing T > T*, where
maximum of five or six during the sampling times where the
major change (disturbance or set-point change) occurred,
and was typically smaller after that (around two). This
resulted in a total computational time of about 1 minute of
guarantees the stability of the Newton controller with CPU time for each case, using a mixture of ‘Mathematics’
open-loop asymptotically stable systems. This situation is (Wolfram, 1988) and Fortran code, on DecStation 5ooO/240.
representative of the characteristics of the majority of 4.2. FCC example. Next we consider the control of a FCC
chemical processes. However, since the above results rely on
the boundedness of the sensitivity coefficients, they do not
extend to the OL-unstable case. In fact, a strong statement I.
(4 (b)
Steady state values Unstable Stable
1200
722500
1150
722000
1100
,K d 721500
+
1050
721000
1000 720500
950 J
0 I 2 3 4 5 I 2 3 4 5
t t
0.0025
9.70 106
0.0020
9.65 IO6
p 0.0015
v z 9.60 lo6
Fig. 3. System response to an unanticipated set-point change Fig. 4. Input profiles for an unanticipated set-point change
from the operating point (a) to (b). from (a) to (b).
Brief Papers 285
proposed approach is based on the use of an augmented From (A.l) and (A.2)
quadratic performance index and leads to a computationally
efficient framework for nonlinear model predictive control. J2W = II%+, - Y*IIzp~ IIYk -y*112py+ O(a). (A.3)
In addition, the inclusion of an integral term to eliminate Assuming now that O< 6 <Jz(O) -&(Au~), where 6 is a
steady-state offsets, and the possibility of extending the small positive number, and because Js(Au,.) only involves
predictive horizon to infinity are considered. 9*+,, we have from the convexity of Jz
The stability properties of the method are considerably
improved by the extended formulation. In the unconstrained J2(AAuk) - J2(0) 5 A(Js(Auk) -12(O)) < -Aa. (A.4)
case, the controller becomes a nonlinear extension of LQR,
which guarantees good stability properties with a large range Now substituting (A.3) into (A.4) and for E sufficiently small
of tuning parameters. that O(c) < 612, we have
The algorithm was successfully applied with two nonlinear
models. In particular, the behavior demonstrated with the J2(A~~)~Ily~-~*ll1p,+~~~)-~A~ll~~-~*ll~~-~.
FCC model illustrates the efficacy of the method for
challenging nonlinear systems. Simultaneously, the small (A.5)
computational times required with both examples demonstr-
ate the feasibility of the on-line implementation of this Also
nonlinear strategy. llyk+i -y*ll’p+ A2 IlAu~ll&~Jz(AW + WA*). 64.6)
processes-a review. Ind. Eng. Chem. Res., 30,1391-1413. + (Au,, - Au/) + %(A,, - Ay,) = 0, (A.7a)
Economou, C. G. (1985). An Operator Theory Approach to A:u(AU - U,) = 0, A:,(-AU + U,J = 0, (A.7b)
Nonlinear Controller Desian. Ph.D. Thesis. California
AT&&AU - Y&) = 0, A;,(-&AU + Y,‘,)= 0, (A.7c)
Institute of Technology, Pasadena, CA.
Garcia, C. E., D. M. Prett and M. Morari (1989). Model A,ZO, (A.7d)
predictive control: theory and practice-a survey. AU E ]I&, U,], X,AU l [Y/d, Y&l. (A.7e)
Automatica, 25,335-348.
Lee, W. and A. M. Kugelman (1973). Number of steady-state Also for large but finite T such that ]]ek ]I = O(e), the matrix
operating points and local stability of open-loop fluid 9, becomes
catalytic cracker. Ind. Eng. Chem. Process Des. Develop.,
l2,197-204.
Li, W. C. and L. T. Biegler (1989). Multistep, Newton-type
control strategies for constrained nonlinear processes.
Chem. Eng. R& Des., 67, 562-577.
Oliveira. N. M. C. and L. T. Biealer (1994). Constraint
handling and stability propertie: of ‘model predictive
control. AIChE. J., 40, 1138-1155.
Oliveira, N. M. C. (1994). Newton-type algorithms for
Nonlinear Constrained Chemical Process Control. Ph.D.
Thesis, Carnegie Mellon University, Pittsburgh, PA.
Sontag, E. D. (1984). An algebraic approach to bounded (‘4.8)
=
2
Au* + O(c), (A.9)
Brief Papers
where Au* represents the solution of the single step J,(hAu,) < jlyk -y*l&+ O(e) - Sh + O(e*).
controller. A large T, therefore, has a decoupling effect in
the computation of the control law (6), and thus Hence, for sufficiently small E, such that O(r) < 6A/2, the
yk+, =yz+, + O(e). Clearly J2(Auk) =&(A@) + O(8), and remainder of the previous proof applies, and we have the
from (AS) desired result from (A.6). 0