Production Process Control Using Real-Time Simulator Initialization
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Solution Overview
Problem
Existing methods for controlling complex production processes, such as pulp and paper production, are hindered by time-consuming initial state estimation, which can result in outdated process control settings, leading to inefficiencies and potential disruptions.
Innovation Solution
An on-line simulator system is used to provide real-time initial condition data for optimization, allowing for immediate and continuous updates of process state variables, with set points being validated through an auxiliary simulation before implementation in the real production process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional state estimation methods are used to obtain initial conditions for optimization, then the optimization can be performed with a complete process model, but the initial state estimation takes several minutes which causes the control settings to become outdated
Solution Approach 1:
The on-line simulator system continuously simulates the production process in real-time to pre-calculate and maintain up-to-date initial condition data before optimization is needed. This preliminary action ensures that when optimization starts, the initial conditions are already available and current, eliminating the time-consuming state estimation step while maintaining accuracy.
2Productivity
If an on-line simulator system is used to provide real-time initial condition data, then the control settings remain current and optimization can proceed immediately, but the system complexity increases
Solution Approach 1:
The on-line simulator system serves multiple functions: it provides initial conditions for optimization, validates set points through auxiliary simulation, and continuously updates process state variables. By making the simulator multi-functional, the patent reduces the need for separate dedicated systems for each function, thereby managing complexity while achieving real-time control updates.
Solution Approach 2:
The on-line simulator acts as an intermediary between the actual production process and the optimization algorithm. It receives real-time process data, simulates the process behavior, and provides processed initial condition data to the optimizer. This intermediary role simplifies the overall system architecture by centralizing the simulation functionality rather than requiring direct complex interactions between sensors, optimizers, and actuators.
3Reliability
If set points are validated through auxiliary simulation before implementation, then control reliability is improved, but the control process time is increased
Solution Approach 1:
The on-line simulator continuously runs the auxiliary validation simulation in parallel with the main optimization process. Rather than performing validation as a separate sequential step that adds time, the validation occurs continuously in the background, ensuring that when set points need validation, the results are already available or can be immediately generated without interrupting the main control loop.
Data Source
AI summary
A method of controlling a real production process, wherein the method includes: a) receiving initial condition data from an on-line simulator system simulating the real production process, and b) performing an optimization based on the initial condition data and on an objective function to obtain set points for controlling the real production process.