Model-Based Split-Range Algorithm for the Temperature Control of a Batch Reactor

Abstract

In the manufacturing processes of high value-added products in the pharmaceutical, fine chemical polymer and food industry, insufficient control might produce off-grade products. This can cause significant financial losses, or in the pharmaceutical industry, it can result in an unusable batch. In these industries, batch reactors are commonly used, the control of which is essentially a problem of temperature control. In the industry, an increasing number of heating-cooling systems utilising three different temperature levels can be found, which are advantageous from an economic point of view. However, it makes the control more complicated. This paper presents a split-range designing technique using the model of the controlled system with the aim to design a split-range algorithm more specific to the actual sys- tem. The algorithm described provides high control performance when using it with classical PID-based cascade temperature control of jacketed batch reactors; however, it can be used with or as part of other types of controllers, for ex- ample, model-based temperature controllers. The algorithm can be used in the case of systems where only two as well as where three temperature levels are used for temperature control. Besides the switching between the modes of opera- tion and calculating the value of the manipulated variable, one of the most important functions of the split-range algo- rithm is to keep the sign of the gain of the controlled system unchanged. However, with a more system-specific split-range solution, not only can the sign of the gain be kept unchanged, but the gain can also be constant or less de- pendent on the state of the system. Using this solution, the design of the PID controller becomes simpler and can be implemented in existing systems without serious changes

Advances in Machine Learning for Monitoring, Control, and Optimization of Temperature of Reactors

“…Their algorithm's successful application in the hydrolysis of acetic anhydride demonstrates its versatility and potential for achieving isothermal operation and desired temperature profiles in various systems. To improve temperature control in batch reactors used in various industries, Balaton, Nagy, and Szeifert propose a model-based split-range algorithm [43]. This algorithm is specifically designed for systems with three temperature levels, offering enhanced control performance and simplifying PID controller design.…”

Best of Breed Control of Platinum Precipitation Reactors

“…For this design requirement to be correctly modeled using a PID Controller, a splitrange algorithm was implemented. The split-range algorithm is preferred in the control of cascaded reactor, to operate two actuators which control the inflow of utilities at the different times during the different phases of a single batch (Balaton et al 2012). The two actuators on the steam and cooling water inflow valve to the jacket were considered as one manipulated variable (MV) and the temperature of the reactor as the controlled variable (CV).…”

“…In many industrial applications, the temperature control of the reactor is carried out with PID controllers in a cascade structure, however rapid and precise temperature control is hard to achieve with these controllers (Stampar et al 2013). In terms of a PID controller, the two actuators on the steam and cooling inlet valve to the jacket can be considered as one manipulated variable and a split-range algorithm can be implemented as part of the controlled system (Balaton et al 2012). Using one controller as long as the system state is close to the corresponding operating point and switching to another when the operating point is sufficiently close to the next operating point gives a better controller performance (Rugh and Shamma, 2000).…”