Reactor Multi-Level Predictive Control for Stable Operation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current reactor control systems, such as those for C3 liquid-phase hydrogenation reactors, rely on manual adjustments and single-variable direct control methods, which are limited in adjustable parameters, lack intuition, and result in inaccurate adjustments, making real-time monitoring and expert-level operation difficult.
Innovation Solution
A control device and method implementing a multi-level control scheme using manipulation-level, regulation-level, and target-level parameters, with defined relationships through first- and second-level functions, and employing a dynamic matrix predictive control algorithm to adjust parameters automatically and accurately.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If manual regulation is used to control reactor parameters, then operational flexibility is maintained, but real-time monitoring and expert-level adjustment cannot be achieved
Solution Approach 1:
The control system is segmented into multiple hierarchical levels (manipulation-level, regulation-level, and target-level parameters) with distinct functions. Each level handles specific control tasks, allowing the system to achieve comprehensive automation while maintaining manageable complexity through modular organization of control responsibilities.
Solution Approach 2:
Regulation-level parameters serve as intermediaries between manipulation-level parameters and target-level parameters. This intermediary layer translates high-level control objectives into actionable manipulation commands, enabling automatic expert-level control without requiring direct complex mappings between all parameters.
2Manufacturing precision
If single-variable direct control method is used, then control simplicity is maintained, but adjustment accuracy and variety of adjustable parameters are limited
Solution Approach 1:
The control method transitions from single-variable direct control to multi-level hierarchical control, adding dimensional layers (manipulation-level, regulation-level, target-level) to the control structure. This enables simultaneous control of multiple parameters with high accuracy while maintaining clarity through the structured hierarchical approach.
Solution Approach 2:
The system changes the control parameters from single-variable to multi-level parameters with defined relationships. By establishing first-level and second-level functions between parameter levels, the system achieves precise control through coordinated parameter adjustments rather than isolated single-variable control.
3Productivity
If technicians manually adjust parameters, then human expertise is utilized, but limited human attention prevents real-time monitoring
Solution Approach 1:
The control system performs self-service by automatically monitoring all reactor parameters and executing control adjustments without requiring continuous human intervention. The hierarchical control structure enables the system to self-regulate by processing sensor data, comparing against target ranges, and automatically issuing control commands, thereby achieving real-time monitoring while maintaining operational simplicity.
Data Source
Figure 1~2
Figure 3~4
Figure 5~6A
AI summary
This application relates to the field of automatic control technology, specifically to a control device, method, machine-readable storage medium, and computer program product for a reactor. The automatic control method for the reactor includes: obtaining the multi-level relevant parameters of the reactor; controlling the values of the parameters of each level according to the transfer functions between the multi-level relevant parameters from level to level, so that the specified parameters are within the preset range. The automatic control method for the reactor of the present invention can achieve the dynamic process adjustment and optimization of the multi-level variables of the reactor and, at the same time, achieve the stable operation of the reactor.