EP2477734A1 - Régulation à deux degrés de liberté avec commutation explicite pour la régulation de processus techniques - Google Patents

Régulation à deux degrés de liberté avec commutation explicite pour la régulation de processus techniques

Info

Publication number
EP2477734A1
EP2477734A1 EP10752353A EP10752353A EP2477734A1 EP 2477734 A1 EP2477734 A1 EP 2477734A1 EP 10752353 A EP10752353 A EP 10752353A EP 10752353 A EP10752353 A EP 10752353A EP 2477734 A1 EP2477734 A1 EP 2477734A1
Authority
EP
European Patent Office
Prior art keywords
variables
control
controller
manipulated
manipulated variables
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP10752353A
Other languages
German (de)
English (en)
Inventor
Matthias Zipplies
Ortwin Keil
Veit Hagenmeyer
Marcus Nohr
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
BASF SE
Original Assignee
BASF SE
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Filing date
Publication date
Application filed by BASF SE filed Critical BASF SE
Priority to EP10752353A priority Critical patent/EP2477734A1/fr
Publication of EP2477734A1 publication Critical patent/EP2477734A1/fr
Withdrawn legal-status Critical Current

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Classifications

    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B13/00—Adaptive control systems, i.e. systems automatically adjusting themselves to have a performance which is optimum according to some preassigned criterion
    • G05B13/02—Adaptive control systems, i.e. systems automatically adjusting themselves to have a performance which is optimum according to some preassigned criterion electric
    • G05B13/04—Adaptive control systems, i.e. systems automatically adjusting themselves to have a performance which is optimum according to some preassigned criterion electric involving the use of models or simulators
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J19/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
    • B01J19/0006—Controlling or regulating processes
    • B01J19/0033—Optimalisation processes, i.e. processes with adaptive control systems
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B13/00—Adaptive control systems, i.e. systems automatically adjusting themselves to have a performance which is optimum according to some preassigned criterion
    • G05B13/02—Adaptive control systems, i.e. systems automatically adjusting themselves to have a performance which is optimum according to some preassigned criterion electric
    • G05B13/0205—Adaptive control systems, i.e. systems automatically adjusting themselves to have a performance which is optimum according to some preassigned criterion electric not using a model or a simulator of the controlled system
    • G05B13/021—Adaptive control systems, i.e. systems automatically adjusting themselves to have a performance which is optimum according to some preassigned criterion electric not using a model or a simulator of the controlled system in which a variable is automatically adjusted to optimise the performance
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J2219/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
    • B01J2219/00049—Controlling or regulating processes
    • B01J2219/00051—Controlling the temperature
    • B01J2219/00074—Controlling the temperature by indirect heating or cooling employing heat exchange fluids
    • B01J2219/00087—Controlling the temperature by indirect heating or cooling employing heat exchange fluids with heat exchange elements outside the reactor
    • B01J2219/00094—Jackets
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J2219/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
    • B01J2219/00049—Controlling or regulating processes
    • B01J2219/00162—Controlling or regulating processes controlling the pressure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J2219/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
    • B01J2219/00049—Controlling or regulating processes
    • B01J2219/00164—Controlling or regulating processes controlling the flow
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J2219/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
    • B01J2219/00049—Controlling or regulating processes
    • B01J2219/00191—Control algorithm
    • B01J2219/00193—Sensing a parameter
    • B01J2219/00195—Sensing a parameter of the reaction system
    • B01J2219/00198—Sensing a parameter of the reaction system at the reactor inlet
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J2219/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
    • B01J2219/00049—Controlling or regulating processes
    • B01J2219/00191—Control algorithm
    • B01J2219/00193—Sensing a parameter
    • B01J2219/00195—Sensing a parameter of the reaction system
    • B01J2219/002—Sensing a parameter of the reaction system inside the reactor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J2219/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
    • B01J2219/00049—Controlling or regulating processes
    • B01J2219/00191—Control algorithm
    • B01J2219/00193—Sensing a parameter
    • B01J2219/00195—Sensing a parameter of the reaction system
    • B01J2219/00202—Sensing a parameter of the reaction system at the reactor outlet
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J2219/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
    • B01J2219/00049—Controlling or regulating processes
    • B01J2219/00191—Control algorithm
    • B01J2219/00211—Control algorithm comparing a sensed parameter with a pre-set value
    • B01J2219/00216—Parameter value calculated by equations
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J2219/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
    • B01J2219/00049—Controlling or regulating processes
    • B01J2219/00191—Control algorithm
    • B01J2219/00211—Control algorithm comparing a sensed parameter with a pre-set value
    • B01J2219/0022—Control algorithm comparing a sensed parameter with a pre-set value calculating difference
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J2219/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
    • B01J2219/00049—Controlling or regulating processes
    • B01J2219/00191—Control algorithm
    • B01J2219/00222—Control algorithm taking actions
    • B01J2219/00227—Control algorithm taking actions modifying the operating conditions
    • B01J2219/00229—Control algorithm taking actions modifying the operating conditions of the reaction system
    • B01J2219/00231—Control algorithm taking actions modifying the operating conditions of the reaction system at the reactor inlet
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J2219/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
    • B01J2219/00049—Controlling or regulating processes
    • B01J2219/00243—Mathematical modelling

Definitions

  • the present invention relates to a method for controlling process engineering processes in which setpoint trajectories for control variables are provided, control variables and further state variables of the process are detected, control deviations are calculated, and control manipulated variables are calculated therefrom by means of a control algorithm, and precontrol manipulated variables are determined Controller manipulated variables and feedforward control variables resulting manipulated variables are calculated and set in the process. Furthermore, the invention relates to a control device and a computer program for carrying out the method.
  • process engineering processes on an industrial scale an increasing trend toward automation has been observed in recent years, which is due not least to the desire for reproducibility and safety of the plants.
  • continuous processes In addition to continuous processes, often discontinuous processes for the production, purification or conditioning of products are used which often place increased demands on the process management.
  • reactors that are operated in batch or semi-batch mode and in which the product quality depends crucially on the course of the process conditions such as pressure and temperature over the batch duration are widespread.
  • reactions that are associated with a strong increase or decrease in temperature or are highly exothermic or endothermic often arise demanding control tasks that can not be solved or only unsatisfactory with classical control methods.
  • these control tasks were further complicated by the trend towards ever larger reactors, since in this case the ratio of reaction volume to heat-transferring surface is unfavorable.
  • 6,144,897 discloses a model-type controller for chemical reaction processes. Both the model on which the prediction is based and the controller itself can be adapted to the respective system state. Compared with other model-predictive control methods, this method is characterized by a mathematical model that is easy to solve and thus allows a fast prediction of components in the reaction mixture.
  • EP 1 267 229 B1 discloses a control method for starting and stopping process engineering processes, e.g. in power plants, which uses model-based pilot controls to specify manipulated variables for the process to be controlled. To this end, simulation calculations are carried out offline in advance in order to obtain optimum set point trajectories, which are stored and read out during the process sequence and used to influence the manipulated variables. The model can also track the current process status and optimization calculations based on it can be performed repeatedly.
  • Process engineering processes to which the control method according to the invention can be applied can generally be characterized by state variables. Statements about the state of the process can be made at any time with the aid of these state variables. Some of the state variables can usually be measured directly in or on the process, for example volume or mass flows, pressure, temperature, density, viscosity or also concentrations of individual components of a substance mixture or a class of substances. Other state variables can only be measured with great effort or not at all. For example, the complete composition of a substance mixture, particle size distributions, chain length distributions, melt flow index or cooling capacities.
  • non-measurable state variables can be determined from other measurable or non-measurable state variables using mathematical models.
  • a simple example of this is a substance system consisting of two substances whose concentrations can be clearly calculated using phase equilibrium relationships from measured values for pressure and temperature.
  • the determination of non-measurable state variables can be based both on current measured values and on information about the history of certain variables.
  • control variables are those state variables of a process engineering process whose values are to be influenced in a targeted manner by the method according to the invention.
  • these are state variables that have a major impact on the goals to be achieved, such as a concentration of a component in a product draw of a distillation column or the temperature in a reactor whose value is critical to product quality.
  • state variables are selected as controlled variables, for which the specified limits must not be exceeded or fallen below, such as a maximum pressure or level in a container.
  • Controlled variables can be measurable or non-measurable state variables. Of course, if a plurality of controlled variables are present, one controlled variable can also be measured directly, while another controlled variable is determined indirectly from other state variables.
  • control method according to the invention can use control variables in addition to other state variables, for example for the calculation of control variables that can not be measured directly. These quantities are referred to below as “further state variables.” These quantities can also be measured in or on the process or determined on the basis of other further state variables.
  • setpoints are made for controlled variables.
  • these can be values that remain constant over the time span of the process, but on the other hand also values that can vary over the time span.
  • Setpoint specifications over a certain period of time are referred to as setpoint trajectories. These may be, for example, time intervals, constant values, ramps, polygons or other continuous, continuous or discontinuous courses of the nominal values.
  • setpoint trajectory The special case of a constant setpoint value over the entire time span of the course of the process is therefore also encompassed by the term setpoint trajectory.
  • controlled variables or other state variables can be done in different ways. Depending on the size to be recorded and the concrete procedural process, such quantities can be determined, for example, with the aid of known the physical measuring principles are determined. Examples include classic flowmeters, pressure transducers or temperature sensors. Concentrations of a number of substances can be determined, for example, by means of gas chromatography or spectroscopic methods, such as NMR (nuclear magnetic resonance) or NIR (near-infrared spectroscopy).
  • control variables or other state variables can often be done by means of very simple to complex mathematical relationships. For example, it is very simple to calculate the mass flow of an individual component in a mixture, which itself can not be measured directly, from a measured total quantity flow and the measured concentration of the relevant component.
  • state estimation methods can advantageously be used to determine the variables of interest.
  • state estimation methods are Luenberger observers, Kalman filters or extended Kalman filters, as described, for example, in the above-cited articles by Graichen / Hagenmeyer / Zeitz and Hagenmeyer / Nohr, respectively.
  • the methods as such as well as the possibilities of adapting to the respective process to be controlled are known.
  • an extended Kalman filter is used as a state estimation method based on process variables (y * ) directly measurable in the process to detect controlled variables (y) and / or further state variables (y). By comparing controlled variables with their current, respective setpoints, control deviations are calculated.
  • control manipulated variables are determined by means of a control algorithm.
  • manipulated variables variables are usually selected whose change in the process has the greatest possible influence on the controlled variables in order to counteract the control deviations.
  • the feed or discharge quantities are available as manipulated variables.
  • manipulated variables of the control method according to the invention can themselves be set values of subordinate controls.
  • the inflow amount could be a setpoint for a subordinate control, which in turn has, for example, the valve position of a valve in the inlet to the container as the manipulated variable.
  • resulting manipulated variable is used for values of the manipulated variables that are set in the process
  • a resulting manipulated variable can be identical to a controller manipulated variable determined by the control algorithm.
  • precontrol is understood to mean that precontrol manipulated variables are determined on the basis of desired values, controlled variables or other state variables by means of an algorithm. Process know-how is used to relieve and improve the regulation of the process.
  • a feedforward control according to the invention can comprise state-dependent calculation rules which define a relationship between desired values, controlled variables, further state variables or regulator manipulated variables on the one hand and resulting precontrol manipulated variables on the other hand, for example in the form of a mathematical model.
  • state-dependent calculation rules are used which take into account the behavior of the procedural process to be controlled.
  • pilot controls are used which invert stationary or dynamic behavior.
  • the feedforward control variables are calculated in such a way that the process engineering process follows exactly one setpoint trajectory when the feedforward control variables are applied and the process is not subject to any disturbances.
  • system inversion is easily possible for so-called differentially flat systems and known from the specialist literature.
  • calculation instructions may be predefined, time-dependent and / or state-dependent trajectories, for example, progressions, ramps or other predefined forms of the trajectories piece-wise over time with state-dependent parameters. It is also possible to provide trajectories as calculation rules that have been optimized offline in advance.
  • the structure of a precontrol is determined by various factors, for example the basic type of a calculation rule for precontrol manipulated variables or the combination of variables used for the calculation.
  • a calculation rule is characterized by one or more parameters by means of which feedforward control variables are determined. Which parameters are used depends on the respective structure of the calculation rules. If, for example, the calculation rule is a section-wise constant function, then the points in time that define the sections and the values of the function in the respective sections can be regarded as parameters of the precontrol. Other types of calculation rules result in correspondingly different parameters, for example coefficients in the value range or time range.
  • control algorithms come different approaches in question, as they are known from the literature. Examples are PI or PID algorithms, or switching sliders (Sliding Mode). They may be both regulators, which have a gear and an output, so-called SISO controllers, as well as controllers with multiple inputs and outputs, so-called MIMO controller.
  • SISO controllers which have a gear and an output
  • MIMO controller controllers with multiple inputs and outputs
  • the structure of a control algorithm is characterized by different features such as the basic structure of the algorithm or the assignment of controlled variables and manipulated variables.
  • PI or PID controllers for example, a further structural feature is to be considered as to whether the gain of the control algorithm, that is to say the P component, is designed to be fixed or variable, for example in the form of gain scheduling.
  • the control algorithms Similar to the precontrol, the control algorithms have various parameters that affect the determination of the controller manipulated variables. An example of this is the gain, the lead time and the lag time in a PID algorithm.
  • the control method according to the invention can also be cascaded.
  • the process engineering process is divided into two or more sub-processes for information and control purposes, each of which is assigned at least one controller based on control algorithms as described above.
  • Cascaded means that at least one of the sub-process controllers receives one or more setpoints from a higher-level controller. The one or more setpoint values can be superimposed on a feedforward control variable.
  • Superordinate controllers are also referred to as master controllers (master controllers), subordinate controllers as slave controllers (slave controllers).
  • 4 shows a schematic representation of a cascaded method according to the invention.
  • One master controller can have several slave controllers assigned to it.
  • a follower may itself be a leader for him subordinate follower. Such a configuration is referred to as multiple cascading.
  • at least one resulting manipulated variable is calculated in at least one sub-process from a controller manipulated variable and a precontrol manipulated variable.
  • the process engineering process is subdivided into two or more subprocesses and resulting manipulated variables of at least one master controller and at least one subordinate controller subordinate to it are calculated from the respective controller manipulated variables and their pre-control manipulated variables assigned to them.
  • other superordinate or subordinate controllers can be present, with or without feedforward control.
  • the method according to the invention for controlling process-related processes furthermore comprises a switching logic which can process different information, for example information about desired values and their trajectories, measured or otherwise detected state variables of the process, but also structures and parameters of the control algorithm or the precontrol. External specifications, for example in the form of setpoints, limits or their chronological progression, can also be processed by the switching logic. On the basis of this information as well as given relations between this information, the switching logic determines whether the structures of the control algorithm or the feedforward control are to be changed. It is also possible to make changes to the associated parameters.
  • control algorithm and "precontrol” refer to the entire method according to the invention and are not to be understood strictly in the singular. In a cascaded method, for example, this is understood to mean the control algorithms and pilot controls of all controllers, regardless of how or where they are implemented in terms of information technology.
  • the control method according to the invention is cascaded, resulting manipulated variables of at least one master controller and at least one subordinate controller subordinate to it are calculated from the respective controller manipulated variables and their precontrol manipulated variables, and the structure of the control algorithm and / or the precontrol of the at least one Follow-up controllers are changed by the switching logic.
  • a set of structures and parameters of the control algorithm and the precontrol is referred to below as "switching mode.” If it results from the evaluation of the information in the switching logic that a change is made, there is a changeover from one switching mode to another switching mode Structural changes can be either only in the control algorithm or only in the precontrol, or in both of them, and corresponding parameters can also be changed.
  • Preferred structural changes in the control algorithm relate to a change in the assignment of controlled variables and controller manipulated variables. Another advantageous structural change is the selection of another control algorithm.
  • Structural changes of the precontrol are preferably changes between different state-dependent calculation rules.
  • a structural change can also be that other variables are used for the calculation.
  • a further preferred structural change of the precontrol consists in the selection of one or more further or other pilot control manipulated variables.
  • Also associated with a shift mode are one or more set point trajectories.
  • one or more desired value trajectories are recalculated during the transition from a shift mode to a new shift mode.
  • the switching logic can also cause the recalculation of setpoint trajectories during a switching mode, for example when control variables or other state variables approach limit values, when a threshold value of the control deviation is exceeded or undershot, or because of external specifications.
  • a change in the parameters of the control algorithm or the precontrol can take place.
  • different, temporally successive switching modes arise. The changes from one switching mode to the next can concern the precontrol, the control algorithm, the recalculation of a desired value trajectory or combinations thereof.
  • control method according to the invention is used for monitoring and maintaining limits for one or more state variables.
  • the corresponding limit values are used in the switching logic to determine the conditions for a transition to a new switching mode or to cause the recalculation of setpoint trajectories.
  • control method according to the invention is used to specifically approach limits of one or more state variables. Such a process has the advantage that the process can be run more economically, e.g. in terms of quality requirements or the space-time yield.
  • a control device which has at least one signal generator for the provision of setpoint trajectories for controlled variables, a device for detecting controlled variables and further state variables of the process, a controller which, on the basis of control deviations, is controlled by means of a control algorithm.
  • Manipulated variables determined a feedforward control for the determination of feedforward control variables, a means for calculating resulting manipulated variables from controller manipulated variables and feedforward control variables and means for adjusting the resulting control variables in the process
  • the control device further comprises at least one switching logic which is suitable for changing the structure of the control algorithm and / or the pilot control as a function of controlled variables, further state variables and / or desired value trajectories.
  • Devices for detecting controlled variables and other state variables as well as means for calculating and setting the manipulated variables in the process are known to the person skilled in the art, as well as signal generators, controllers, controller algorithms, pilot controls, as well as options for their hardware and software implementation.
  • precontrol, control algorithms and the calculation rules of the switching logic are implemented in a computer program with program code means, for example in a program created in a programming language or with commercially available software that is suitable for use in a regulation of process engineering processes.
  • the computer program is set up executable on a computer and provided with interfaces for communication with the process engineering process.
  • the communication can be be carried out with a process control system, by means of which many procedural processes are controlled today. In processes that do not have a process control system, communication can be via interfaces that allow data to be exchanged with meters and controllers in the process. Such interfaces and their hardware and software technical implementations are known to the person skilled in the art.
  • the computer can be located in the vicinity of the process engineering process, for example in a control room, but it can also be remote and communicate with the process via standard network connections.
  • feedforward control, control algorithms and the calculation instructions of the switching logic are implemented at least partially as software components in a process control system.
  • pilot control, control algorithms and the calculation rules of the switching logic are completely implemented or integrated in a process control system.
  • the method according to the invention for controlling process engineering processes results in improved process control.
  • the processes can be operated closer to the limits, which usually increases the space-time yield.
  • the method according to the invention can be advantageously applied to a large number of process engineering processes. Particularly advantageous effects are evident in batch processes such as batch or semi-batch processes. This can often be achieved a batch time reduction and the reproducibility of a batch can be improved.
  • Fig. 1 control loop with pilot control and state estimator according to the prior art
  • Fig. 2 control loop in master-slave configuration with feedforward control and state estimator according to the prior art
  • Fig. 3 embodiment of the control method according to the invention with pilot control, state estimator and switching logic
  • Fig. 4 embodiment of the control method according to the invention with pilot control, state estimator and switching logic in master-slave configuration
  • FIG. 6 Schematic diagram of a semi-batch reactor with cooling jacket and inventive control device
  • FIG. 7 shows time profiles of characteristic quantities of the semi-batch process described in the example
  • FIG. 8 shows a schematic diagram of a further semi-batch reactor with cooling jacket and control device according to the invention
  • Fig. 1 illustrates a feedforward control loop 40 and conditioner 50 as known in the art.
  • a signal generator 10 provides setpoint values w, which are compared with their respective controlled variables y.
  • external setpoint values w ex t can be preset for the signal generator 10, for example by a higher-level system for process automation or as manual input by a system operator.
  • the differences between desired values w and their respective controlled variables y, the so-called control deviations are fed to a controller 20, which calculates controller manipulated variables UCM therefrom.
  • a pre-controller 40 determines from the setpoint values w and further state variables y pre-control manipulated variables UF.
  • the controller manipulated variables UCM From these and the controller manipulated variables UCM, the resulting manipulated variables u, which are set in the process 30, are calculated. This results in controlled variables y, which in turn are used to calculate the control deviations. If all other state variables y can not be measured directly in the process 30, a state estimator 50 is provided which determines the required quantities from measured state variables y * .
  • the control circuit illustrated in FIG. 2 forms an extension of the above-described control circuit from FIG. 1, in that two regulators are used in cascade in a so-called master-slave configuration.
  • the process to be controlled is subdivided into a first sub-process 31 and a second sub-process 32.
  • Controlled variables yi of the first partial process 31 are fed back to calculate the control deviations for the master controller 21 by means of the predetermined setpoint values w.
  • the controller manipulated variables UCM determined by the master controller 21 are offset with feedforward control variables UF and result in the resulting manipulated variables of the master controller UM. These manipulated variables act as setpoints for slave controller 22.
  • control variables V2 of the second sub-process 32 control deviations for the slave controller 22, which determines controller manipulated variables ucs. These controller manipulated variables ucs are set in the second sub-process 32.
  • a state estimator 50 can also be provided in this control loop, which determines further state variables y from measured state variables of the first partial process y-1 * and of the second partial process V2 *, which state variables can be used in the precontrol 40 in order to calculate feedforward control variables UF ZU.
  • FIG. 3 illustrates a control circuit according to the invention using the example of a simple control circuit analogous to FIG. 1.
  • Setpoint generator 10, controller 20, process 30, feedforward control 40 and the optional state estimator 50 fulfill the same functions as described with reference to FIG.
  • the control circuit furthermore has a switching logic 60 which can process different information as input signals, for example desired values w, controlled variables y, measured state variables y *, further state variables y, or signals from the controller sc or from the precontrol SF.
  • signals SLC and SLF can be generated in the switching logic 60 by means of state-dependent calculation rules, which signals can be sent to the controller 20 and to the precontrol 40.
  • the switching logic 60 may also affect the signal generator for set point trajectories 10.
  • FIG. 4 shows an example of a cascaded control loop according to the invention, which corresponds in its basic structure to that shown in FIG.
  • Setpoint generator 10 control controller 21, slave controller 22, partial processes 31 and 32, feedforward control 40 and optional state estimator 50 fulfill the same functions as described with reference to FIG.
  • a switching logic 60 is provided which can access various information from the process as a whole or the individual subprocesses, for example desired values w, controlled variables yi and y2, measured state variables yi * and y2 *, further state variables y and signals SCM and scs from the
  • signals SLCM, SLCS and SLF can be generated in the switching logic 60 by means of state-dependent calculation rules, which signals can be sent to the master controller 21, the slave controller 22 and to the feedforward controller 40. Furthermore, the switching logic 60 can also influence the signal generator for setpoint trajectories 10.
  • the signals of the switching logic 60 to the controllers 21, 22 and the feedforward control 40 can cause structures or parameters of the control algorithm or the precontrol 40 to be changed. Structures and parameters can only be changed in one controller, only in feedforward control, but also in several controllers and / or in feedforward control in combination. Preferably, changes in a controller and the associated pilot control are made simultaneously.
  • FIG. 4 a cascaded control loop with a master controller 21 and a slave controller 22 is shown for the sake of clarity.
  • the control method according to the invention is not limited to this configuration, but can be used advantageously in any combination of master and slave controllers.
  • slave controller 22 may in turn be the master controller for further controllers.
  • the switching logic can be used both in control circuits with only one controlled variable and one manipulated variable, so-called SISO systems, as well as in MIMO systems with several control and manipulated variables. Both SISO and MIMO systems can be cascaded, combinations are also included according to the invention, for example in the case of a higher-level MIMO controller with a subordinate SISO controller.
  • Example A preferred embodiment of the method according to the invention was applied to an industrial semi-batch process. It was a strongly exothermic polyaddition reaction.
  • a first feedstock was placed in a stirred tank reactor, as shown schematically in FIG.
  • the addition of a second feed was carried out continuously via a line in the reactor.
  • the flow rate F, n of the second feedstock was detected by means of a flowmeter and adjusted via a control valve.
  • the lower part of the reactor was surrounded by a jacket, which was flowed through by cooling water as the heat transfer medium.
  • the flow rate of the incoming cooling water Fj could be influenced by another control valve. Cooling water inlet Fj and cooling water temperature in inlet Tjjn and in outlet Tj, ou t were recorded by measuring instruments.
  • the pressure in the reactor P and the temperature in the reaction mixture TR were measured. All measuring devices were connected to a control device CM according to the invention, so that the measured values were available to the control method according to the invention as measured state variables y
  • the reaction process should be conducted in such a way that the highest possible space-time yield is achieved.
  • the control method was firstly the reaction temperature TRS, which should be reached as quickly as possible in order to ensure a high reaction conversion.
  • a pressure Ps was set, which should not be exceeded in the reactor. The calculation of this limit was carried out in the connected process control system due to known procedural limits, essentially as a function of the degree of filling of the reactor and the reaction temperature
  • control method according to the invention was implemented in a commercial workstation with the aid of the MATLAB program package (The MathWorks Inc., Natick, MA, USA) and transmitted via the standard interface OPC (OLE for Process Control) coupled to the process control system.
  • OPC OPC for Process Control
  • the structure of the control method is shown schematically in Fig. 5 and corresponds to the control block "CM" in Fig. 6.
  • Fig. 7 shows the time courses of some selected quantities of the process in standardized values.
  • the upper graph shows the course of the reactor temperature.
  • the dotted line corresponds to the externally set reaction temperature TRS, which should be reached as quickly as possible.
  • the thin solid curve indicates the nominal value trajectory for the reactor temperature provided by the setpoint generator 10, while the bold solid curve represents the actually measured reactor temperature TR.
  • the middle graph shows the actual curves of the manipulated variables feed flow F, n as a solid curve and cooling water inlet Fj as a dash-dotted curve again.
  • the dotted curve indicates the externally set pressure Ps at each time point.
  • the thin solid curve indicates the calculated nominal value trajectory for the pressure, while the bold curve represents the actual measured pressure P.
  • a setpoint trajectory for the controlled variable reactor temperature TR was initially generated on the basis of the current process information.
  • the cooling water inflow Fj was selected as a manipulated variable in order to influence the reactor temperature TR ZU.
  • the feed Fi n feed was not used for control in this mode, but set along a pre-calculated trajectory in the process.
  • the pressure P was monitored so that it could not exceed the predetermined, state-dependent pressure Ps.
  • the setpoint trajectory for the pressure P was recalculated during the switching mode (II). This process was triggered by a rule in the switching logic 60, after the difference between the predetermined pressure Ps and actual pressure P had fallen below a minimum value. However, this recalculation neither changed the structure of the control algorithm nor that of the feedforward control, so that there was no transition to a new switching mode.
  • the accumulation of the starting materials was reduced so much that a corresponding calculation rule in the switching logic 60 triggered the transition to the new switching mode (III). In this switching mode, the reactor temperature was no longer regulated via the cooling water inlet Fj, but via the feed flow F, n as control variable.
  • the cooling water inflow Fj reached its maximum value.
  • the regulation of the reactor temperature TR via the cooling water was thus limited and the switching logic 60 initiated the transition to the switching mode (V), which corresponded in structure to the switching mode (III).
  • the trajectory for the cooling water inflow Fj consisted of a constant value, its maximum value. This mode was maintained for most of the batch runtime.
  • the setpoint trajectory for the pressure P was recalculated twice, because the actual pressure P was below the difference value to the externally set pressure Ps.
  • the switching logic 60 triggered the switching mode (VI).
  • Fig. 8 illustrates another reactor configuration to which the control method of the invention has been successfully used.
  • the difference to the example described above was that the influence of the cooling capacity in the jacket around the reactor was not made by the cooling water inlet, but by the adjustment of the cooling water inlet temperature Tj, in a split-range control.
  • control method according to the invention can be used advantageously.
  • one or more flow rates of supplied feedstocks, flow rates of supplied heat transfer medium, temperature of the supplied heat transfer medium, the power of a heater installed in or on the reactor, the pressure in the reactor or in one with connected to the reactor heat exchanger, and flow rates or temperature of a heat transfer medium to an external heat exchanger are particularly suitable for controlling the flow rates of supplied feedstocks.
  • the invention is not limited to processes in which heat released by a reaction has to be dissipated. Even in processes that have a heat requirement, the inventive method can be used advantageously.
  • the heat transfer medium may be water as described above, but also oil, another liquid or steam, such as water vapor.
  • the method according to the invention makes it possible to improve the process control not only in semi-batch and batch reactors, but also in processes in other process-engineering apparatuses and plants for material conversion or substance separation, e.g. in crystallizers, chromatography columns, distillation, rectification or absorption columns.

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Abstract

L'invention concerne un procédé de régulation de processus techniques consistant à fournir des trajectoires de valeurs de consigne pour des grandeurs de régulation; à détecter des grandeurs de régulation et d'autres grandeurs d'état du processus; à calculer des écarts de régulation et à calculer des grandeurs de commande de régulateur au moyen d'un algorithme de régulation à partir des écarts de régulation; à déterminer des grandeurs de commande de précommande; et à calculer des grandeurs de commande résultant des grandeurs de commande de régulateur et des grandeurs de commande de précommande et à les appliquer au processus, la structure de l'algorithme de régulation et/ou de la précommande étant modifiée en fonction de grandeurs de régulation, d'autres grandeurs d'état et/ou de trajectoires de valeurs de consigne. L'invention concerne également un dispositif de régulation et un produit-programme d'ordinateur pour la mise en oeuvre du procédé.
EP10752353A 2009-09-17 2010-09-13 Régulation à deux degrés de liberté avec commutation explicite pour la régulation de processus techniques Withdrawn EP2477734A1 (fr)

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EP09170546 2009-09-17
EP10752353A EP2477734A1 (fr) 2009-09-17 2010-09-13 Régulation à deux degrés de liberté avec commutation explicite pour la régulation de processus techniques
PCT/EP2010/063395 WO2011032918A1 (fr) 2009-09-17 2010-09-13 Régulation à deux degrés de liberté avec commutation explicite pour la régulation de processus techniques

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CN104898728B (zh) * 2015-05-20 2017-02-22 西安科技大学 一种基于双换热器的cstr温度容错控制方法
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DE102017002818A1 (de) * 2017-03-23 2018-09-27 Cosateq Gmbh Verfahren zum Betrieb einer Druckgusspresse mit Lagenregelung und Druckgusspresse zur Ausführung des Verfahrens
EP4323101A1 (fr) * 2021-04-15 2024-02-21 Basf Se Procédé de régulation en boucle fermée de la température dans un appareil d'ingénierie de processus
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WO2011032918A1 (fr) 2011-03-24
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CN102548650A (zh) 2012-07-04

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