Hybrid MPC Plant Model Using Dynamic Unit Sub-Models
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Solution Overview
Problem
Commercially available Model Predictive Control (MPC) products do not directly integrate a flowsheet model, requiring user-generated dynamic models for whole-plant optimization, which becomes unwieldy with complex processes and necessitates reconfiguration when piping networks change, limiting flexibility and efficiency.
Innovation Solution
A hybrid MPC simulation model that embeds dynamic sub-models for process units within a flowsheet representation of the piping network, allowing for separate control of individual units and global optimization without needing a single global dynamic model, enabling flexibility in adding or redesigning process units and piping networks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a user-generated holistic dynamic model is used to relate the impact of operational changes on end-product production and quality, then whole plant optimization can be achieved, but the model becomes unwieldy with complex processes and requires reconfiguration when piping networks change
Solution Approach 1:
The patent divides the holistic plant model into separate dynamic models for each process unit. Each unit has its own dynamic model that can be independently developed and maintained. These unit models are then integrated through the flowsheet structure to achieve whole-plant optimization without requiring a single complex user-generated model.
Solution Approach 2:
The patent creates a universal framework where the flowsheet structure serves multiple functions: it defines the process configuration, establishes material balances, and provides the integration architecture for multiple dynamic unit models. This universal structure eliminates the need to reconfigure models when piping networks change.
2Reliability
If a single global dynamic model is used for whole plant optimization, then global optimization can be achieved, but flexibility in adding or redesigning process units and piping networks is limited
Solution Approach 1:
The patent segments the plant into independent process units, each with its own dynamic model. This segmentation allows individual units to be added, removed, or modified without affecting the entire model. The flowsheet structure provides the flexible connectivity framework that adapts to changing process configurations.
Solution Approach 2:
The patent implements a dynamic architecture where the flowsheet structure can be easily modified to reflect changes in piping networks or process units. The system dynamically adapts to reconfigurations by updating the flowsheet representation while maintaining the integrity of individual unit models and their integration.
3Reliability
If commercially available MPC products rely on user-generated holistic dynamic models, then whole plant optimization is possible, but reconfiguration is necessary when piping networks change
Solution Approach 1:
The patent creates a universal flowsheet-based framework that automatically adapts to piping network changes. The flowsheet structure serves as the single source of truth for process configuration, eliminating the need to manually reconfigure dynamic models when piping networks change. This universal approach significantly reduces reconfiguration time.
Solution Approach 2:
The system automatically updates the integration between unit models when the flowsheet is modified. The flowsheet structure self-updates to reflect piping network changes, and the integration framework automatically reconfigures the connections between dynamic unit models without requiring manual intervention, thereby minimizing reconfiguration time.
Data Source
AI summary
A method of generating a hybrid model predictive control (MPC) simulation model for a plant configured to run a process that processes at least one raw material to generate at least one tangible product. A predictive dynamic MPC sub-model is provided for each of plurality of process units in the plant, the plant including at least one process controller coupled to field devices coupled to the plurality of process units, where the process units comprise equipment for converting the raw material or an intermediate material formed from the raw material into to another material. A piping network diagram is obtained that provides a representation of a piping network for routing of the raw material and the intermediate material during the process. The dynamic MPC sub-models are coupled together using the piping network to generate the hybrid MPC simulation model which models the plant as a whole.