Computer Aided Tools for Designing Plant-Wide Control Structures for Large-Scale Industrial Processes

Abstract

In this work a systematic design procedure of a plant-wide control structure is applied to a well known benchmark problem of a large-scale pulp mill process (CASTRO; DOYLE, 2004a). Because of the high dimension of this system it was necessary to develop some additional computer aided tools for support calculations. It is based on the minimization of the sum of squared deviations (SSD index) (ZUMOFFEN; BASUALDO, 2010) which is done via the use of genetic algorithm. It represents a good trade-off between achieve acceptable results with less computational effort. Previous works presented alternative solutions but using several heuristic considerations for reducing the problem dimensionality. The obtained performance with the selected control structure and the decentralized strategy, presented previously by Castro and Doyle (2004b), are compared. Several closed-loop simulations for critical set point changes are rigorously evaluated here.

Plantwide Control: A Review of Design Techniques, Benchmarks, and Challenges

“…In another work, these authors used IMC and autorelay rules to tune the PID controllers. Later, Luppi and co-workers , published works using IMC and a modified IMC tuning rule to tune PID controllers. In the Tennessee Eastman (TE) case, Molina and co-workers used the IMC rules to tune the PID controllers in a designed plantwide control system, and Tian and Hoo designed and manually tuned an MPC to control the process.…”

Plantwide control: a review and proposal of an augmented hierarchical plantwide control design technique.

“…Methyl Ether (TAME) Process Benchmark (Castro & Doyle, 2002), (Castro & Doyle, 2004a), (Castro & Doyle, 2004b) (Mercangöz & Doyle, 2006), (Marcangöz & Doyle, 2008), (Luppi, et al, 2011), (Luppi, et al, 2013) Of the seven plantwide control methods described in Section 2.3, none specify control tuning methods for the overall plant. The authors who designed plantwide control systems for the benchmarks cited in Table 2.3 had to tune the PID or MPC controllers.…”

“…In (Castro & Doyle, 2004a), the authors used IMC and autorelay rules to tune the PID controllers. Later, (Luppi, et al, 2011) and (Luppi, et al, 2013) used IMC and a modified IMC tuning rule to tune PID controllers. In the Tennessee Eastman (TE) case, (Molina, et al, 2011) used the IMC rules to tune the PID controllers in a designed plantwide control system, and (Tian & Hoo, 2005) designed and manually tuned an MPC to control the process.…”