1 ECONOMIC PLANTWIDE CONTROL: Control structure design for complete processing plants Sigurd Skogestad Department of Chemical Engineering Norwegian University.

Slides:



Advertisements
Similar presentations
1 Outline Control structure design (plantwide control) A procedure for control structure design I Top Down Step 1: Degrees of freedom Step 2: Operational.
Advertisements

1 CONTROLLED VARIABLE AND MEASUREMENT SELECTION Sigurd Skogestad Department of Chemical Engineering Norwegian University of Science and Technology (NTNU)
1 Outline Control structure design (plantwide control) A procedure for control structure design I Top Down Step 1: Degrees of freedom Step 2: Operational.
1 Effective Implementation of optimal operation using Self- optimizing control Sigurd Skogestad Institutt for kjemisk prosessteknologi NTNU, Trondheim.
1 M. Panahi ’Plantwide Control for Economically Optimal Operation of Chemical Plants’ Plantwide Control for Economically Optimal Operation of Chemical.
GHGT-8 Self-Optimizing and Control Structure Design for a CO 2 Capturing Plant Mehdi Panahi, Mehdi Karimi, Sigurd Skogestad, Magne Hillestad, Hallvard.
1 Self-optimizing control: Simple implementation of optimal operation Sigurd Skogestad Department of Chemical Engineering Norwegian University of Science.
1 Coordinator MPC for maximization of plant throughput Elvira Marie B. Aske* &, Stig Strand & and Sigurd Skogestad* * Department of Chemical Engineering,
Part 3: Regulatory («stabilizing») control
1 Outline Skogestad procedure for control structure design I Top Down Step S1: Define operational objective (cost) and constraints Step S2: Identify degrees.
1 Plantwide control: Towards a systematic procedure Sigurd Skogestad Department of Chemical Engineering Norwegian University of Science and Tecnology (NTNU)
1 1 Economic Plantwide Control, July 2015 ECONOMIC PLANTWIDE CONTROL Sigurd Skogestad Dept. of Chemical Engineering, Norwegian University of Science and.
Outline Skogestad procedure for control structure design I Top Down
1 1 V. Minasidis et. al. | Simple Rules for Economic Plantwide ControlSimple Rules for Economic Plantwide Control, PSE & ESCAPE 2015 SIMPLE RULES FOR ECONOMIC.
1 Structure of the process control system Benefits from MPC (Model Predictive Control) and RTO (Real Time Optimization) Sigurd Skogestad Department of.
1 A SYSTEMATIC APPROACH TO PLANTWIDE CONTROL Sigurd Skogestad Department of Chemical Engineering Norwegian University of Science and Tecnology (NTNU) Trondheim,
1 AN INTRODUCTION TO PLANTWIDE CONTROL Sigurd Skogestad Department of Chemical Engineering Norwegian University of Science and Tecnology (NTNU) Trondheim,
1 A SYSTEMATIC APPROACH TO PLANTWIDE CONTROL Sigurd Skogestad Department of Chemical Engineering Norwegian University of Science and Tecnology (NTNU) Trondheim,
1 A Plantwide Control Procedure Applied to the HDA Process Antonio Araújo and Sigurd Skogestad Department of Chemical Engineering Norwegian University.
1 ECONOMIC PLANTWIDE CONTROL: Control structure design for complete processing plants Sigurd Skogestad Department of Chemical Engineering Norwegian University.
1 Outline About Trondheim and myself Control structure design (plantwide control) A procedure for control structure design I Top Down Step 1: Degrees of.
1 E. S. Hori, Maximum Gain Rule Maximum Gain Rule for Selecting Controlled Variables Eduardo Shigueo Hori, Sigurd Skogestad Norwegian University of Science.
1 Self-optimizing control Theory. 2 Step S3: Implementation of optimal operation Optimal operation for given d * : min u J(u,x,d) subject to: Model equations:
1 Active constraint regions for economically optimal operation of distillation columns Sigurd Skogestad and Magnus G. Jacobsen Department of Chemical Engineering.
Sigurd Skogestad Department of Chemical Engineering
1 A SYSTEMATIC APPROACH TO PLANTWIDE CONTROL Sigurd Skogestad Department of Chemical Engineering Norwegian University of Science and Tecnology (NTNU) Trondheim,
1 Plantwide control: Towards a systematic procedure Sigurd Skogestad Department of Chemical Engineering Norwegian University of Science and Tecnology (NTNU)
1 Outline Control structure design (plantwide control) A procedure for control structure design I Top Down Step 1: Degrees of freedom Step 2: Operational.
1 Selv-optimaliserende regulering Anvendelser mot prosessindustrien, biologi og maratonløping Sigurd Skogestad Institutt for kjemisk prosessteknologi,
1 Part 3: Regulatory («stabilizing») control Inventory (level) control structure –Location of throughput manipulator –Consistency and radiating rule Structure.
1 From process control to business control: A systematic approach for CV-selection Sigurd Skogestad Department of Chemical Engineering Norwegian University.
1 ECONOMIC PLANTWIDE CONTROL How to design the control system for a complete plant in a systematic manner Sigurd Skogestad Department of Chemical Engineering.
1 Self-optimizing control From key performance indicators to control of biological systems Sigurd Skogestad Department of Chemical Engineering Norwegian.
1 ECONOMIC PLANTWIDE CONTROL: Control structure design for complete processing plants Sigurd Skogestad Department of Chemical Engineering Norwegian University.
1 PLANTWIDE CONTROL Identifying and switching between active constraints regions Sigurd Skogestad and Magnus G. Jacobsen Department of Chemical Engineering.
1 Feedback: The simple and best solution. Applications to self-optimizing control and stabilization of new operating regimes Sigurd Skogestad Department.
1 Outline Skogestad procedure for control structure design I Top Down Step S1: Define operational objective (cost) and constraints Step S2: Identify degrees.
1 A SYSTEMATIC APPROACH TO PLANTWIDE CONTROL Sigurd Skogestad Department of Chemical Engineering Norwegian University of Science and Tecnology (NTNU) Trondheim,
1 II. Bottom-up Determine secondary controlled variables and structure (configuration) of control system (pairing) A good control configuration is insensitive.
1 PLANTWIDE CONTROL How to design the control system for a complete plant in a systematic manner Sigurd Skogestad Department of Chemical Engineering Norwegian.
1 Self-optimizing control Theory. 2 Outline Skogestad procedure for control structure design I Top Down Step S1: Define operational objective (cost) and.
1 A SYSTEMATIC APPROACH TO PLANTWIDE CONTROL ( ) Sigurd Skogestad Department of Chemical Engineering Norwegian University of Science and Tecnology.
Control Structure Design: New Developments and Future Directions Vinay Kariwala and Sigurd Skogestad Department of Chemical Engineering NTNU, Trondheim,
1 Outline About Trondheim and myself Control structure design (plantwide control) A procedure for control structure design I Top Down Step 1: Degrees of.
1 Effective Implementation of optimal operation using Self- optimizing control Sigurd Skogestad Institutt for kjemisk prosessteknologi NTNU, Trondheim.
1 Self-optimizing control From key performance indicators to control of biological systems Sigurd Skogestad Department of Chemical Engineering Norwegian.
1 ECONOMIC PLANTWIDE CONTROL: Control structure design for complete processing plants using self-optimizing control Sigurd Skogestad Department of Chemical.
1 ECONOMIC PLANTWIDE CONTROL: Control structure design for complete processing plants Sigurd Skogestad Department of Chemical Engineering Norwegian University.
1 PLANTWIDE CONTROL Sigurd Skogestad Department of Chemical Engineering Norwegian University of Science and Tecnology (NTNU) Trondheim, Norway August/September.
1 Devising control structures for complete chemical plants – from art to science Sigurd Skogestad Department of Chemical Engineering Norwegian University.
1 A SYSTEMATIC APPROACH TO PLANTWIDE CONTROL Sigurd Skogestad Department of Chemical Engineering Norwegian University of Science and Tecnology (NTNU) Trondheim,
1 A SYSTEMATIC APPROACH TO PLANTWIDE CONTROL ( ) Sigurd Skogestad Department of Chemical Engineering Norwegian University of Science and Tecnology.
Control strategies for optimal operation of complete plants Plantwide control - With focus on selecting economic controlled variables Sigurd Skogestad,
A systematic procedure for economic plantwide control
Sigurd Skogestad Department of Chemical Engineering
Self-optimizing control Theory
Sigurd Skogestad Department of Chemical Engineering
Sigurd Skogestad Institutt for kjemisk prosessteknologi
Plantwide control: Towards a systematic procedure
PLANTWIDE CONTROL Sigurd Skogestad Department of Chemical Engineering
CONTROLLED VARIABLE AND MEASUREMENT SELECTION
Outline Skogestad procedure for control structure design I Top Down
Outline Control structure design (plantwide control)
Plantwide control: Towards a systematic procedure
Example regulatory control: Distillation
Plantwide control: Towards a systematic procedure
Example regulatory control: Distillation
Example regulatory control: Distillation
Outline Control structure design (plantwide control)
Presentation transcript:

1 ECONOMIC PLANTWIDE CONTROL: Control structure design for complete processing plants Sigurd Skogestad Department of Chemical Engineering Norwegian University of Science and Tecnology (NTNU) Trondheim, Norway Mexico, 01 May 2012

2 Abstract and bio ECONOMIC PLANTWIDE CONTROL: Control structure design for complete processing plants. Sigurd Skogestad, Department of Chemical Engineering, Norwegian University of Science and Technology (NTNU), Trondheim, Norway Abstract: A chemical plant may have thousands of measurements and control loops. By the term plantwide control it is not meant the tuning and behavior of each of these loops, but rather the control philosophy of the overall plant with emphasis on the structural decisions. In practice, the control system is usually divided into several layers, separated by time scale: scheduling (weeks), site-wide optimization (day), local optimization (hour), supervisory (predictive, advanced) control (minutes) and regulatory control (seconds). Such a hiearchical (cascade) decomposition with layers operating on different time scale is used in the control of all real (complex) systems including biological systems and airplanes, so the issues in this section are not limited to process control. In the talk the most important issues are discussed, especially related to the choice of variables that provide the link the control layers. Bio: Sigurd Skogestad received his Ph.D. degree from the California Institute of Technology, Pasadena, USA in He has been a full professor at Norwegian University of Science and Technology (NTNU), Trondheim, Norway since 1987 and he was Head of the Department of Chemical Engineering from 1999 to He is the principal author, together with Prof. Ian Postlethwaite, of the book "Multivariable feedback control" published by Wiley in 1996 (first edition) and 2005 (second edition). He received the Ted Peterson Award from AIChE in 1989, the George S. Axelby Outstanding Paper Award from IEEE in 1990, the O. Hugo Schuck Best Paper Award from the American Automatic Control Council in 1992, and the Best Paper Award 2004 from Computers and Chemical Engineering. He was an Editor of Automatica during the period His research interests include the use of feedback as a tool to make the system well-behaved (including self- optimizing control), limitations on performance in linear systems, control structure design and plantwide control, interactions between process design and control, and distillation column design, control and dynamics.

3 Trondheim, Norway Mexico

4 Trondheim Oslo UK NORWAY DENMARK GERMANY North Sea SWEDEN Arctic circle

5 NTNU, Trondheim

6 Outline 1. Introduction plantwide control (control structure design) 2. Plantwide control procedure I Top Down –Step 1: Define optimal operation –Step 2: Optimize for expected disturbances –Step 3: Select primary controlled variables c=y 1 (CVs) –Step 4: Where set the production rate? (Inventory control) II Bottom Up –Step 5: Regulatory / stabilizing control (PID layer) What more to control (y 2 )? Pairing of inputs and outputs –Step 6: Supervisory control (MPC layer) –Step 7: Real-time optimization (Do we need it?) y1y1 y2y2 Process MVs

7 Idealized view of control (“PhD control”)

8 Practice: Tennessee Eastman challenge problem (Downs, 1991) (“PID control”) TCPCLCACxSRC Where place??

9 How do we get from PID to PhD control? How we design a control system for a complete chemical plant? Where do we start? What should we control? and why? etc.

10 How we design a control system for a complete chemical plant? Where do we start? What should we control? and why? etc.

11 Example: Tennessee Eastman challenge problem (Downs, 1991) TCPCLCACxSRC Where place??

12 Alan Foss (“Critique of chemical process control theory”, AIChE Journal,1973): The central issue to be resolved... is the determination of control system structure. Which variables should be measured, which inputs should be manipulated and which links should be made between the two sets? There is more than a suspicion that the work of a genius is needed here, for without it the control configuration problem will likely remain in a primitive, hazily stated and wholly unmanageable form. The gap is present indeed, but contrary to the views of many, it is the theoretician who must close it. Previous work on plantwide control: Page Buckley (1964) - Chapter on “Overall process control” (still industrial practice) Greg Shinskey (1967) – process control systems Alan Foss (1973) - control system structure Bill Luyben et al. (1975- ) – case studies ; “snowball effect” George Stephanopoulos and Manfred Morari (1980) – synthesis of control structures for chemical processes Ruel Shinnar (1981- ) - “dominant variables” Jim Downs (1991) - Tennessee Eastman challenge problem Larsson and Skogestad (2000): Review of plantwide control

13 Optimal operation of systems Example of systems we want to operate optimally Process plant (minimize J=cost) Runner (minimize J=time) World Economy –Maximize welfare (with given environmental impact) –Maximize happiness (with given environmental impact) –Minimize J=environmental impact (with given minimum welfare) General multiobjective: –Min J (scalar cost, $) –Subject to satisfying constraints (environment, resources)

14 Theory: Optimal operation ALLMIGHTY GOD? IDEAL COMMUNISM? PROCESS CONTROL? Objectives Present state Model of system Theory: Model of overall system Estimate present state Optimize all degrees of freedom Problems: Model not available Optimization complex Not robust (difficult to handle uncertainty) Slow response time Process control: Excellent candidate for centralized control (Physical) Degrees of freedom CENTRALIZED OPTIMIZER

15 Practice: Engineering systems Most (all?) large-scale engineering systems are controlled using hierarchies of quite simple controllers –Large-scale chemical plant (refinery) –Commercial aircraft 100’s of loops Simple components: on-off + PI-control + nonlinear fixes + some feedforward Same in biological systems

16 Practice: Process control Practice: Hierarchical structure

17 Process control: Hierarchical structure Director Process engineer Operator Logic / selectors / operator PID control u = valves

18 c s = y 1s MPC PID y 2s RTO Follow path (+ look after other variables) Stabilize + avoid drift Min J (economics) u (valves) OBJECTIVE Dealing with complexity Plantwide control: Objectives The controlled variables (CVs) interconnect the layers

19 Translate optimal operation into simple control objectives: What should we control? y 1 = c ? (economics) y 2 = ? (stabilization)

20 y 1 = distance to curb (1 m) y 2 = bike tilt (stabilization) u = muscles Example: Bicycle riding

21 Control structure design procedure I Top Down Step 1: Define operational objectives (optimal operation) –Cost function J (to be minimized) –Operational constraints Step 2: Identify degrees of freedom (MVs) and optimize for expected disturbances Step 3: Select primary controlled variables c=y 1 (CVs) Step 4: Where set the production rate? (Inventory control) II Bottom Up Step 5: Regulatory / stabilizing control (PID layer) –What more to control (y 2 ; local CVs)? –Pairing of inputs and outputs Step 6: Supervisory control (MPC layer) Step 7: Real-time optimization (Do we need it?) y1y1 y2y2 Process MVs

22 Step 1. Define optimal operation (economics) What are we going to use our degrees of freedom u (MVs) for? Define scalar cost function J(u,x,d) –u: degrees of freedom (usually steady-state) –d: disturbances –x: states (internal variables) Typical cost function: Optimize operation with respect to u for given d (usually steady-state): min u J(u,x,d) subject to: Model equations: f(u,x,d) = 0 Operational constraints: g(u,x,d) < 0 J = cost feed + cost energy – value products

23 Step 2. Optimize Identify degrees of freedom (u) Optimize for expected disturbances (d) –Identify regions of active constraints Need model of system Time consuming, but it is offline

24 Step 3: Implementation of optimal operation Optimal operation for given d * : min u J(u,x,d) subject to: Model equations: f(u,x,d) = 0 Operational constraints: g(u,x,d) < 0 → u opt (d * ) Problem: Usally cannot keep u opt constant because disturbances d change How should we adjust the degrees of freedom (u)?

25 Implementation (in practice): Local feedback control! “Self-optimizing control:” Constant setpoints for c gives acceptable loss y FeedforwardOptimizing controlLocal feedback: Control c (CV) d Main issue: What should we control?

26 –Cost to be minimized, J=T –One degree of freedom (u=power) –What should we control? Optimal operation - Runner Example: Optimal operation of runner

27 Sprinter (100m) 1. Optimal operation of Sprinter, J=T –Active constraint control: Maximum speed (”no thinking required”) Optimal operation - Runner

28 2. Optimal operation of Marathon runner, J=T –Unconstrained optimum! –Any ”self-optimizing” variable c (to control at constant setpoint)? c 1 = distance to leader of race c 2 = speed c 3 = heart rate c 4 = level of lactate in muscles Optimal operation - Runner Marathon (40 km)

29 Conclusion Marathon runner c = heart rate select one measurement Simple and robust implementation Disturbances are indirectly handled by keeping a constant heart rate May have infrequent adjustment of setpoint (heart rate) Optimal operation - Runner

30 Further examples Central bank. J = welfare. c=inflation rate (2.5%) Cake baking. J = nice taste, c = Temperature (200C) Business, J = profit. c = ”Key performance indicator (KPI), e.g. –Response time to order –Energy consumption pr. kg or unit –Number of employees –Research spending Optimal values obtained by ”benchmarking” Investment (portofolio management). J = profit. c = Fraction of investment in shares (50%) Biological systems: –”Self-optimizing” controlled variables c have been found by natural selection –Need to do ”reverse engineering” : Find the controlled variables used in nature From this identify what overall objective J the biological system has been attempting to optimize

31 Step 3. What should we control (c)? (primary controlled variables y 1 =c) Selection of controlled variables c 1.Control active constraints! 2.Unconstrained variables: Control self-optimizing variables!

32 Operation of Distillation columns in series With given F (disturbance): 4 steady-state DOFs (e.g., L and V in each column) DOF = Degree Of Freedom Ref.: M.G. Jacobsen and S. Skogestad (2011) Energy price: p V =0-0.2 $/mol (varies) Cost (J) = - Profit = p F F + p V (V 1 +V 2 ) – p D1 D 1 – p D2 D 2 – p B2 B 2 > 95% B p D2 =2 $/mol F ~ 1.2mol/s p F =1 $/mol < 4 mol/s < 2.4 mol/s > 95% C p B2 =1 $/mol N=41 α AB =1.33 N=41 α BC =1. 5 > 95% A p D1 =1 $/mol QUIZ: What are the expected active constraints? 1. Always. 2. For low energy prices. Example /QUIZ 1 = ==

33 Control of Distillation columns in series Given LC PC QUIZ. Assume low energy prices (pV=0.01 $/mol). How should we control the columns? HINT: CONTROL ACTIVE CONSTRAINTS Red: Basic regulatory loops QUIZ 2

34 Control of Distillation columns in series Given LC PC Red: Basic regulatory loops CC xBxB x BS =95% MAX V1 MAX V2 SOLUTION QUIZ 2 UNCONSTRAINED CV=?

35 Active constraint regions for two distillation columns in series [mol/s] [$/mol] CV = Controlled Variable Energy price SOLUTION QUIZ 1 (more details) BOTTLENECK Higher F infeasible because all 5 constraints reached

36 Control “self-optimizing” variables Old idea (Morari et al., 1980): “We want to find a function c of the process variables which when held constant, leads automatically to the optimal adjustments of the manipulated variables, and with it, the optimal operating conditions.” The ideal self-optimizing variable c is the gradient (c =  J/  u = J u ) –Keep gradient at zero for all disturbances (c = J u =0) –Problem: no measurement of gradient Unconstrained degrees of freedom u cost J J u =0 JuJu

37 H Ideal: c = J u In practise: c = H y. Task: Determine H!

38 Systematic approach: What to control? Define optimal operation: Minimize cost function J Each candidate c = Hy: ”Brute force approach”: With constant setpoints c s compute loss L for expected disturbances d and implementation errors n Select variable c with smallest loss Acceptable loss  self-optimizing control

39 Control of Distillation columns in series Given LC PC Red: Basic regulatory loops CC xBxB x BS =95% MAX V1 MAX V2 CC xBxB x AS =2.1% Cost (J) = - Profit = p F F + p V (V 1 +V 2 ) – p D1 D 1 – p D2 D 2 – p B2 B 2

40 Example recycle plant. 3 steady-state degrees of freedom (u) Minimize J=V (energy) Active constraint M r = M rmax Active constraint x B = x Bmin L/F constant: Easier than “two-point” control Self-optimizing

41 Optimal operation Cost J Controlled variable c c opt J opt Unconstrained optimum

42 Optimal operation Cost J Controlled variable c c opt J opt Two problems: 1. Optimum moves because of disturbances d: c opt (d) 2. Implementation error, c = c opt + n d n Unconstrained optimum

43 Good candidate controlled variables c (for self-optimizing control) 1.The optimal value of c should be insensitive to disturbances Small F c = dc opt /dd 2.c should be easy to measure and control 3.Want “flat” optimum -> The value of c should be sensitive to changes in the degrees of freedom (“large gain”) Large G = dc/du = HG y BADGood

44 Optimizer Controller that adjusts u to keep c m = c s Plant cscs c m = c + n u y nyny d u c J c s =c opt u opt n  Want c sensitive to u (”large gain”) “Flat optimum is same as large gain” H

45 Optimal measurement combinations “Optimal policy independent of disturbances” Need model or data for optimal response to disturbances –Marathon runner case –c = h 1 hr + h 2 v Extension to polynomial systems –Preheat train for energy recovery (Jäschke) –Patent pending

46 Optimal measurement combination H Candidate measurements (y): Include also inputs u

47 Optimal measurement combination: Nullspace method Want optimal value of c independent of disturbances  Δc opt = 0 ∙Δ d Find optimal solution as a function of d: u opt (d), y opt (d) Linearize this relationship: Δy opt = F ∙Δd F – optimal sensitivity matrix Want: To achieve this for all values of Δd (Nullspace method): Always possible if Comment: Nullspace method is equivalent to J u =0

48 Example. Nullspace Method for Marathon runner u = power, d = slope [degrees] y 1 = hr [beat/min], y 2 = v [m/s] F = dy opt /dd = [ ]’ H = [h 1 h 2 ]] HF = 0 -> h 1 f 1 + h 2 f 2 = 0.25 h 1 – 0.2 h 2 = 0 Choose h 1 = 1 -> h 2 = 0.25/0.2 = 1.25 Conclusion: c = hr v Control c = constant -> hr increases when v decreases (OK uphill!)

49 c s = constant K H y c u “Minimize” in Maximum gain rule ( maximize S 1 G J uu -1/2, G=HG y ) “Scaling” S 1 “=0” in nullspace method (no noise) Optimal measurement combination, c = Hy With measurement noise

50 Example: CO2 refrigeration cycle J = W s (work supplied) DOF = u (valve opening, z) Main disturbances: d 1 = T H d 2 = T Cs (setpoint) d 3 = UA loss What should we control? pHpH

51 CO2 refrigeration cycle Step 1. One (remaining) degree of freedom (u=z) Step 2. Objective function. J = W s (compressor work) Step 3. Optimize operation for disturbances (d 1 =T C, d 2 =T H, d 3 =UA) Optimum always unconstrained Step 4. Implementation of optimal operation No good single measurements (all give large losses): –p h, T h, z, … Nullspace method: Need to combine n u +n d =1+3=4 measurements to have zero disturbance loss Simpler: Try combining two measurements. Exact local method: –c = h 1 p h + h 2 T h = p h + k T h ; k = bar/K Nonlinear evaluation of loss: OK!

52 CO2 cycle: Maximum gain rule

53 Refrigeration cycle: Proposed control structure Control c= “temperature-corrected high pressure”. k = -8.5 bar/K

54 Control structure design using self-optimizing control for economically optimal CO 2 recovery * Step S1. Objective function= J = energy cost + cost (tax) of released CO 2 to air Step S3 (Identify CVs). 1. Control the 4 equality constraints 2. Identify 2 self-optimizing CVs. Use Exact Local method and select CV set with minimum loss. 4 equality and 2 inequality constraints: 1.stripper top pressure 2.condenser temperature 3.pump pressure of recycle amine 4.cooler temperature 5.CO 2 recovery ≥ 80% 6.Reboiler duty < 1393 kW (nominal +20%) 4 levels without steady state effect: absorber 1,stripper 2,make up tank 1 *M. Panahi and S. Skogestad, ``Economically efficient operation of CO2 capturing process, part I: Self-optimizing procedure for selecting the best controlled variables'', Chemical Engineering and Processing, 50, (2011).``Economically efficient operation of CO2 capturing process, part I: Self-optimizing procedure for selecting the best controlled variables'', Step S2. (a) 10 degrees of freedom: 8 valves + 2 pumps Disturbances: flue gas flowrate, CO 2 composition in flue gas + active constraints (b) Optimization using Unisim steady-state simulator. Region I (nominal feedrate): No inequality constraints active 2 unconstrained degrees of freedom = Case study

55 Proposed control structure with given feed

56 Step 4. Where set production rate? Where locale the TPM (throughput manipulator)? –The ”gas pedal” of the process Very important! Determines structure of remaining inventory (level) control system Set production rate at (dynamic) bottleneck Link between Top-down and Bottom-up parts

57 Production rate set at inlet : Inventory control in direction of flow* * Required to get “local-consistent” inventory controlC TPM

58 Production rate set at outlet: Inventory control opposite flow TPM

59 Production rate set inside process TPM Radiating inventory control around TPM (Georgakis et al.)

60 “Sellers marked” = high product prices: Optimal operation = max. throughput (active constraint) Time Back-off = Lost production Rule for control of hard output constraints: “Squeeze and shift”! Reduce variance (“Squeeze”) and “shift” setpoint c s to reduce backoff Want tight bottleneck control to reduce backoff!

61 LOCATE TPM? Conventional choice: Feedrate Consider moving if there is an important active constraint that could otherwise not be well controlled Good choice: Locate at bottleneck

62 Step 5. Regulatory control layer Purpose: “Stabilize” the plant using a simple control configuration (usually: local SISO PID controllers + simple cascades) Enable manual operation (by operators) Main structural decisions: What more should we control? (secondary CV’s, y 2, use of extra measurements) Pairing with manipulated variables (MV’s u 2 ) y 1 = c y 2 = ?

63 “ Control CV2s that stabilizes the plant (stops drifting)” In practice, control: 1.Levels (inventory liquid) 2.Pressures (inventory gas/vapor) (note: some pressures may be left floating) 3.Inventories of components that may accumulate/deplete inside plant E.g., amount of amine/water (deplete) in recycle loop in CO2 capture plant E.g., amount of butanol (accumulates) in methanol-water distillation column E.g., amount of inert N2 (accumulates) in ammonia reactor recycle 4.Reactor temperature 5.Distillation column profile (one temperature inside column) Stripper/absorber profile does not generally need to be stabilized

64 Degrees of freedom for optimization (usually steady-state DOFs), MVopt = CV1s Degrees of freedom for supervisory control, MV1=CV2s + unused valves Physical degrees of freedom for stabilizing control, MV2 = valves (dynamic process inputs) Optimizer (RTO) PROCESS Supervisory controller (MPC) Regulatory controller (PID) H2H2 H CV 1 CV 2s y nyny d Stabilized process CV 1s CV 2 Physical inputs (valves) Optimally constant valves Always active constraints

65 Main objectives control system 1.Implementation of acceptable (near-optimal) operation 2.Stabilization ARE THESE OBJECTIVES CONFLICTING? Usually NOT –Different time scales Stabilization fast time scale –Stabilization doesn’t “use up” any degrees of freedom Reference value (setpoint) available for layer above But it “uses up” part of the time window (frequency range)

66 Example: Exothermic reactor (unstable) u = cooling flow (q) y 1 = composition (c) y 2 = temperature (T) u TC y 2 =T y 2s CC y 1 =c y 1s feed product cooling LC L s =max Active constraints (economics): Product composition c + level (max)

67 Step 5: Regulatory control layer Step 5. Choose structure of regulatory (stabilizing) layer (a) Identify “stabilizing” CV2s (levels, pressures, reactor temperature,one temperature in each column, etc.). In addition, active constraints (CV1) that require tight control (small backoff) may be assigned to the regulatory layer. (Comment: usually not necessary with tight control of unconstrained CVs because optimum is usually relatively flat) (b) Identify pairings (MVs to be used to control CV2), taking into account –Want “local consistency” for the inventory control –Want tight control of important active constraints –Avoid MVs that may saturate in the regulatory layer, because this would require either reassigning the regulatory loop (complication penalty), or requiring back-off for the MV variable (economic penalty) Preferably, the same regulatory layer should be used for all operating regions without the need for reassigning inputs or outputs.

68 Example: Distillation Primary controlled variable: y 1 = c = x D, x B (compositions top, bottom) BUT: Delay in measurement of x + unreliable Regulatory control: For “stabilization” need control of (y 2 ): 1.Liquid level condenser (M D ) 2.Liquid level reboiler (M B ) 3.Pressure (p) 4.Holdup of light component in column (temperature profile) Unstable (Integrating) + No steady-state effect Variations in p disturb other loops Almost unstable (integrating) TC TsTs

69 ”Advanced control” STEP 6. SUPERVISORY LAYER Objectives of supervisory layer: 1. Switch control structures (CV1) depending on operating region Active constraints self-optimizing variables 2. Perform “advanced” economic/coordination control tasks. –Control primary variables CV1 at setpoint using as degrees of freedom (MV): Setpoints to the regulatory layer (CV2s) ”unused” degrees of freedom (valves) –Keep an eye on stabilizing layer Avoid saturation in stabilizing layer –Feedforward from disturbances If helpful –Make use of extra inputs –Make use of extra measurements Implementation: Alternative 1: Advanced control based on ”simple elements” Alternative 2: MPC

70 Why simplified configurations? Why control layers? Why not one “big” multivariable controller? Fundamental: Save on modelling effort Other: –easy to understand –easy to tune and retune –insensitive to model uncertainty –possible to design for failure tolerance –fewer links –reduced computation load

71 Summary. Systematic procedure for plantwide control Start “top-down” with economics: –Step 1: Define operational objectives and identify degrees of freeedom –Step 2: Optimize steady-state operation. –Step 3A: Identify active constraints = primary CVs c. –Step 3B: Remaining unconstrained DOFs: Self-optimizing CVs c. –Step 4: Where to set the throughput (usually: feed) Regulatory control I: Decide on how to move mass through the plant: Step 5A: Propose “local-consistent” inventory (level) control structure. Regulatory control II: “Bottom-up” stabilization of the plant Step 5B: Control variables to stop “drift” (sensitive temperatures, pressures,....) –Pair variables to avoid interaction and saturation Finally: make link between “top-down” and “bottom up”. Step 6: “Advanced/supervisory control” system (MPC): CVs: Active constraints and self-optimizing economic variables + look after variables in layer below (e.g., avoid saturation) MVs: Setpoints to regulatory control layer. Coordinates within units and possibly between units cscs

72 Summary and references The following paper summarizes the procedure: –S. Skogestad, ``Control structure design for complete chemical plants'', Computers and Chemical Engineering, 28 (1-2), (2004). There are many approaches to plantwide control as discussed in the following review paper: –T. Larsson and S. Skogestad, ``Plantwide control: A review and a new design procedure'' Modeling, Identification and Control, 21, (2000).`` The following paper updates the procedure: –S. Skogestad, ``Economic plantwide control’’, Book chapter in V. Kariwala and V.P. Rangaiah (Eds), Plant-Wide Control: Recent Developments and Applications”, Wiley (2012). More information:

73 S. Skogestad ``Plantwide control: the search for the self-optimizing control structure'', J. Proc. Control, 10, (2000).``Plantwide control: the search for the self-optimizing control structure'', S. Skogestad, ``Self-optimizing control: the missing link between steady-state optimization and control'', Comp.Chem.Engng., 24, (2000).``Self-optimizing control: the missing link between steady-state optimization and control'', I.J. Halvorsen, M. Serra and S. Skogestad, ``Evaluation of self-optimising control structures for an integrated Petlyuk distillation column'', Hung. J. of Ind.Chem., 28, (2000).``Evaluation of self-optimising control structures for an integrated Petlyuk distillation column'', T. Larsson, K. Hestetun, E. Hovland, and S. Skogestad, ``Self-Optimizing Control of a Large-Scale Plant: The Tennessee Eastman Process'', Ind. Eng. Chem. Res., 40 (22), (2001).``Self-Optimizing Control of a Large-Scale Plant: The Tennessee Eastman Process'', K.L. Wu, C.C. Yu, W.L. Luyben and S. Skogestad, ``Reactor/separator processes with recycles-2. Design for composition control'', Comp. Chem. Engng., 27 (3), (2003).``Reactor/separator processes with recycles-2. Design for composition control'', T. Larsson, M.S. Govatsmark, S. Skogestad, and C.C. Yu, ``Control structure selection for reactor, separator and recycle processes'', Ind. Eng. Chem. Res., 42 (6), (2003).``Control structure selection for reactor, separator and recycle processes'', A. Faanes and S. Skogestad, ``Buffer Tank Design for Acceptable Control Performance'', Ind. Eng. Chem. Res., 42 (10), (2003).``Buffer Tank Design for Acceptable Control Performance'', I.J. Halvorsen, S. Skogestad, J.C. Morud and V. Alstad, ``Optimal selection of controlled variables'', Ind. Eng. Chem. Res., 42 (14), (2003).``Optimal selection of controlled variables'', A. Faanes and S. Skogestad, ``pH-neutralization: integrated process and control design'', Computers and Chemical Engineering, 28 (8), (2004).``pH-neutralization: integrated process and control design'', S. Skogestad, ``Near-optimal operation by self-optimizing control: From process control to marathon running and business systems'', Computers and Chemical Engineering, 29 (1), (2004).``Near-optimal operation by self-optimizing control: From process control to marathon running and business systems'', E.S. Hori, S. Skogestad and V. Alstad, ``Perfect steady-state indirect control'', Ind.Eng.Chem.Res, 44 (4), (2005).``Perfect steady-state indirect control'', M.S. Govatsmark and S. Skogestad, ``Selection of controlled variables and robust setpoints'', Ind.Eng.Chem.Res, 44 (7), (2005).``Selection of controlled variables and robust setpoints'', V. Alstad and S. Skogestad, ``Null Space Method for Selecting Optimal Measurement Combinations as Controlled Variables'', Ind.Eng.Chem.Res, 46 (3), (2007).``Null Space Method for Selecting Optimal Measurement Combinations as Controlled Variables'', S. Skogestad, ``The dos and don'ts of distillation columns control'', Chemical Engineering Research and Design (Trans IChemE, Part A), 85 (A1), (2007).``The dos and don'ts of distillation columns control'', E.S. Hori and S. Skogestad, ``Selection of control structure and temperature location for two-product distillation columns'', Chemical Engineering Research and Design (Trans IChemE, Part A), 85 (A3), (2007).``Selection of control structure and temperature location for two-product distillation columns'', A.C.B. Araujo, M. Govatsmark and S. Skogestad, ``Application of plantwide control to the HDA process. I Steady-state and self- optimizing control'', Control Engineering Practice, 15, (2007).``Application of plantwide control to the HDA process. I Steady-state and self- optimizing control'', A.C.B. Araujo, E.S. Hori and S. Skogestad, ``Application of plantwide control to the HDA process. Part II Regulatory control'', Ind.Eng.Chem.Res, 46 (15), (2007).``Application of plantwide control to the HDA process. Part II Regulatory control'', V. Kariwala, S. Skogestad and J.F. Forbes, ``Reply to ``Further Theoretical results on Relative Gain Array for Norn-Bounded Uncertain systems'''' Ind.Eng.Chem.Res, 46 (24), 8290 (2007).``Reply to ``Further Theoretical results on Relative Gain Array for Norn-Bounded Uncertain systems'''' V. Lersbamrungsuk, T. Srinophakun, S. Narasimhan and S. Skogestad, ``Control structure design for optimal operation of heat exchanger networks'', AIChE J., 54 (1), (2008). DOI /aic.11366``Control structure design for optimal operation of heat exchanger networks'', T. Lid and S. Skogestad, ``Scaled steady state models for effective on-line applications'', Computers and Chemical Engineering, 32, (2008). T. Lid and S. Skogestad, ``Data reconciliation and optimal operation of a catalytic naphtha reformer'', Journal of Process Control, 18, (2008).``Scaled steady state models for effective on-line applications'', ``Data reconciliation and optimal operation of a catalytic naphtha reformer'', E.M.B. Aske, S. Strand and S. Skogestad, ``Coordinator MPC for maximizing plant throughput'', Computers and Chemical Engineering, 32, (2008).``Coordinator MPC for maximizing plant throughput'', A. Araujo and S. Skogestad, ``Control structure design for the ammonia synthesis process'', Computers and Chemical Engineering, 32 (12), (2008).``Control structure design for the ammonia synthesis process'', E.S. Hori and S. Skogestad, ``Selection of controlled variables: Maximum gain rule and combination of measurements'', Ind.Eng.Chem.Res, 47 (23), (2008).``Selection of controlled variables: Maximum gain rule and combination of measurements'', V. Alstad, S. Skogestad and E.S. Hori, ``Optimal measurement combinations as controlled variables'', Journal of Process Control, 19, (2009)``Optimal measurement combinations as controlled variables'', E.M.B. Aske and S. Skogestad, ``Consistent inventory control'', Ind.Eng.Chem.Res, 48 (44), (2009).``Consistent inventory control'',