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Heating-up control with delay-free output prediction for industrial jacketed reactors based on step response

Tao Liu1, Hongyu Tian1, Shili Rong1

  • 1Institute of Advanced Control Technology, Dalian University of Technology, Dalian, 116024, PR China.

ISA Transactions
|September 22, 2018
PubMed
Summary

A new predictor-based two-degree-of-freedom (2DOF) control strategy improves heating control in industrial reactors. This method uses a identified process model to enhance temperature regulation performance, even with long delays.

Keywords:
Integrating type process modelJacketed reactorsOutput predictionStep response identificationTemperature controlTime delay

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Area of Science:

  • Chemical Engineering
  • Process Control
  • Automation

Background:

  • Industrial jacketed reactors often exhibit long input delays, complicating precise temperature control during heating-up phases.
  • Existing control methods struggle to maintain optimal performance under these challenging dynamic conditions.

Purpose of the Study:

  • To propose a novel predictor-based two-degree-of-freedom (2DOF) control scheme for enhancing heating-up control performance in industrial jacketed reactors.
  • To develop a robust model identification method for accurately characterizing the reactor's thermal dynamics, including time delays.

Main Methods:

  • A simple step response test was conducted to identify a transfer function model, representing an integrating process with time delay.
  • A predictor-based 2DOF control structure was designed, utilizing two filters for delay-free output prediction.
  • Controllers were analytically derived for set-point tracking and load disturbance rejection, featuring a single tunable parameter for performance optimization.

Main Results:

  • The proposed identification method successfully established an accurate process model for the heating-up dynamics.
  • The predictor-based 2DOF control scheme demonstrated effective temperature regulation and disturbance rejection capabilities.
  • Validation through illustrative examples and a practical application on a 4-liter jacketed reactor confirmed the method's effectiveness.

Conclusions:

  • The predictor-based 2DOF control strategy offers a significant improvement over existing methods for heating-up control in industrial reactors with long delays.
  • The developed model identification and control design provide a tunable and effective solution for pharmaceutical crystallization and similar processes.