Coupled Reactor Output Control Using Simulated Efficiency Models
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Solution Overview
Problem
Operating and controlling coupled chemical reactors to maximize the output of chemical products is complex and often ineffective due to differences in catalytic activities and other operational parameters that are not easily measurable.
Innovation Solution
An apparatus and method that utilize simulated efficiency models for each reactor to optimize the overall substance output by determining optimized coupled operation parameters, which are then used to control the reactors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If coupled chemical reactors are operated with the same operation parameters, then the system is simple to operate, but the overall production efficiency is reduced due to individual reactor differences
Solution Approach 1:
The patent applies parameter changes by determining individual efficiency parameters for each reactor based on their actual performance data, and then using these parameters to optimize operation parameters specifically tailored to each reactor's characteristics, resolving the contradiction between simplified operation and improved efficiency
Solution Approach 2:
The system implements feedback by continuously monitoring the actual efficiency of each reactor and using this information to adjust and optimize the operation parameters, creating a closed-loop control system that improves productivity while maintaining operational simplicity through automated adjustment
2Productivity
If operator experience is relied upon to control coupled reactors, then manual control flexibility is maintained, but controlling effectiveness is insufficient due to the complexity of the task
Solution Approach 1:
The patent introduces an intermediary optimization system that acts as a mediator between the complex reactor system and the operator. This system processes efficiency data and determines optimized operation parameters, effectively bridging the gap and improving controlling effectiveness without requiring the operator to directly manage the complexity
Solution Approach 2:
The system applies self-service by enabling the reactor control system to automatically determine and adjust its own operation parameters based on efficiency measurements, reducing the burden on operators and significantly improving controlling effectiveness through autonomous optimization
3Productivity
If individual reactor efficiency differences are not considered, then operational simplicity is maintained, but the potential for maximizing overall output is lost
Solution Approach 1:
The patent replaces complex physical efficiency measurements with a computational approach, using measured input and output data combined with efficiency models to calculate individual reactor efficiencies. This substitution of mechanical measurement systems with computational methods enables accurate efficiency detection while maintaining operational simplicity
Data Source
AI summary
The invention refers to an apparatus 110 for controlling a process for producing a substance by coupled chemical reactors 131, 132 being coupled with respect to an operation parameter. An efficiency model providing unit 111 provides a model for each reactor providing a simulated efficiency of each reactor based on the operation parameter. An optimization model providing unit 112 provides a model providing an optimizable function of a substance output of the reactors depending on the operation parameter and the efficiency of the reactors. An optimization unit 113 optimizes the substance output by utilizing the simulated efficiency models and the respective simulated efficiencies in the optimization model for determining an optimized operation parameter that optimizes the substance output of the reactors, and a control signal providing unit 114 provides a signal indicative of the optimized operation parameter to control the operation of the reactors.