Data-Driven Modeling and Optimization of Semibatch Reactors Using Artificial Neural Networks

Novel Formulation of Adaptive MPC as EKF Using ANN Model: Multiproduct Semibatch Polymerization Reactor Case Study

In this paper, a novel formulation for nonlinear model predictive control (MPC) has been proposed incorporating the extended Kalman filter (EKF) control concept using a purely data-driven artificial neural network (ANN) model based on measurements for supervisory control. The proposed scheme consists of two modules focusing on online parameter estimation based on past measurements and control estimation over control horizon based on minimizing the deviation of model output predictions from set points along the prediction horizon. An industrial case study for temperature control of a multiproduct semibatch polymerization reactor posed as a challenge problem has been considered as a test bed to apply the proposed ANN-EKFMPC strategy at supervisory level as a cascade control configuration along with proportional integral controller [ANN-EKFMPC with PI (ANN-EKFMPC-PI)]. The proposed approach is formulated incorporating all aspects of MPC including move suppression factor for control effort minimization and constraint-handling capability including terminal constraints. The nominal stability analysis and offset-free tracking capabilities of the proposed controller are proved. Its performance is evaluated by comparison with a standard MPC-based cascade control approach using the same adaptive ANN model. The ANN-EKFMPC-PI control configuration has shown better controller performance in terms of temperature tracking, smoother input profiles, as well as constraint-handling ability compared with the ANN-MPC with PI approach for two products in summer and winter. The proposed scheme is found to be versatile although it is based on a purely data-driven model with online parameter estimation.

Parameterized data-driven fuzzy model based optimal control of a semi-batch reactor

A parameterized data-driven fuzzy (PDDF) model structure is proposed for semi-batch processes, and its application for optimal control is illustrated. The orthonormally parameterized input trajectories, initial states and process parameters are the inputs to the model, which predicts the output trajectories in terms of Fourier coefficients. Fuzzy rules are formulated based on the signs of a linear data-driven model, while the defuzzification step incorporates a linear regression model to shift the domain from input to output domain. The fuzzy model is employed to formulate an optimal control problem for single rate as well as multi-rate systems. Simulation study on a multivariable semi-batch reactor system reveals that the proposed PDDF modeling approach is capable of capturing the nonlinear and time-varying behavior inherent in the semi-batch system fairly accurately, and the results of operating trajectory optimization using the proposed model are found to be comparable to the results obtained using the exact first principles model, and are also found to be comparable to or better than parameterized data-driven artificial neural network model based optimization results.

Modeling of batch processes using explicitly time-dependent artificial neural networks

A neural network architecture incorporating time dependency explicitly, proposed recently, for modeling nonlinear nonstationary dynamic systems is further developed in this paper, and three alternate configurations are proposed to represent the dynamics of batch chemical processes. The first configuration consists of L subnets, each having M inputs representing the past samples of process inputs and output; each subnet has a hidden layer with polynomial activation function; the outputs of the hidden layer are combined and acted upon by an explicitly time-dependent modulation function. The outputs of all the subnets are summed to obtain the output prediction. In the second configuration, additional weights are incorporated to obtain a more generalized model. In the third configuration, the subnets are eliminated by incorporating an additional hidden layer consisting of L nodes. Backpropagation learning algorithm is formulated for each of the proposed neural network configuration to determine the weights, the polynomial coefficients, and the modulation function parameters. The modeling capability of the proposed neural network configuration is evaluated by employing it to represent the dynamics of a batch reactor in which a consecutive reaction takes place. The results show that all the three time-varying neural networks configurations are able to represent the batch reactor dynamics accurately, and it is found that the third configuration is exhibiting comparable or better performance over the other two configurations while requiring much smaller number of parameters. The modeling ability of the third configuration is further validated by applying to modeling a semibatch polymerization reactor challenge problem. This paper illustrates that the proposed approach can be applied to represent dynamics of any batch/semibatch process.