The oil production in wells using electric submersible pumps (ESPs) demands precise control of parameters within safety and efficiency constraints to minimise failures, extend equipment lifespan, and reduce costs. This study proposes a non-linear model predictive control (NMPC) system designed for ESP-lifted wells, leveraging pump frequency and choke valve adjustments to maximise production while adhering to operational limits. Tested on a simulated pilot plant using a first-principles model to predict key variables like flow and liquid column height, the NMPC demonstrated offset-free performance, effective disturbance rejection, and ensured stable, safe, and optimised operations, addressing challenges in nonlinear, constraint-intensive environments.

Wastewater treatment and resources recovery from large wastewater flowrates of the municipalities and circular bio-based economy ask for efficient control solutions. The paper presents solutions for operating the wastewater treatment plant, based on advanced process control methods aimed to merge the benefits of the cooperation between the lower-level regulatory control loops and the upper-level model predictive control strategy. The lower-level is designed to regulate the nitrification in the aerated bioreactors by controlling the Dissolved Oxygen or the ammonia concentration and to control the denitrification in the anoxic reactor by controlling the nitrates concentration. The model predictive controller either sets the setpoints of the regulatory layer or directly manipulates the air and nitrate recycle flow rates. The plant performance results obtained using the regulatory Proportional and Integral control are compared to the direct or the supervisory model predictive control outco... [more]

Intensified schemes, such as reactive distillation, have been proposed to produce silane (SiH4). Several studies have been carried out around this intensified scheme focusing directly on its improvement in energy or economic criteria. However, these mentioned criteria do not ensure that the scheme is also optimal from the control point of view. There is a direct compromise between the economic criterion and the control criterion. Thus, the best controllable scheme is not necessarily the most economical and vice versa. Analyses have been proposed to evaluate the controllability of steady-state processes using open-loop with Singular Value Decomposition (SVD) under quantitative a criterion such as A? + ?sm with simplified first-order transfer functions. This work considers four feasible designs with multiple reactive zones and evaluates their controllability from their open-loop dynamic responses obtained from Aspen Dynamics® by calculating the condition number for different frequency ra... [more]

Maintaining operational efficiency while ensuring safety is a longstanding challenge in industrial process control, particularly in high-risk environments. This paper presents a novel Dynamic Risk-Informed Explicit Model Predictive Control (R-eMPC) framework that integrates safety and operational objectives using probabilistic constraints and real-time risk assessments. Unlike traditional approaches, this framework dynamically adjusts safety thresholds based on Bayesian updates, ensuring a balanced trade-off between reliability and efficiency. The validation of this approach is illustrated through a case study on tank level control, a safety-critical process where maintaining the liquid level within predefined safety limits is paramount. The results demonstrate the framework’s capability to optimize performance while maintaining robust safety margins. By emphasizing adaptability and computational efficiency, this research provides a scalable solution for integrating safety into real-ti... [more]

Process optimisation and quality control are crucial in process industries for minimising product waste and improving plant economics. Identifying robust operational regions that ensure both product quality and performance is particularly valued in industries. However, this task is complicated by operational uncertainties, which can lead to violations of product quality constraints and significant batch discards. We propose a novel robust optimisation strategy that integrates advanced machine learning and process systems engineering to systematically identify optimal operational regions under uncertainty. Our approach begins by using a process model to screen a broad operational space across various uncertainty scenarios, pinpointing promising control trajectories to satisfy process constraints and product quality. Machine learning is then employed to cluster these trajectories into sub-regions. Finally, a two-layer dynamic optimisation framework is employed to determine the optimal co... [more]

Recent advancements in machine learning and time series analysis have opened new avenues for improving predictive control in complex systems such as mineral flotation. Techniques leveraging multivariate predictive control in mineral flotation have seen significant progress in recent years. However, challenges in developing an accurate dynamic model that encapsulates both the pulp and froth phases have hindered further advancements. Now, with a readily available model containing equations that describe the physics of flotation froths, an opportunity for novel control strategies presents itself. In this study, a Gaussian Process (GP) Model Predictive Control (MPC) strategy is proposed to integrate uncertainty quantification directly into the control framework. By leveraging the probabilistic nature of GP models, this approach captures process variability and adapts dynamically to new data, ensuring continuous refinement of the GP model within the MPC strategy. Unlike previous implementat... [more]

Successful implementation of optimization-driven control techniques, such as model predictive control (MPC), is highly dependent on an accurate and detailed model of the process. As complexity in the system increases, linear approximation used in MPC may result in poor performance since a critical operating point is valid in only a small neighborhood of operation. To address this problem, this paper proposes a collaborative approach that combines linear and data-based models to predict state variables individually. The outputs of these models, along with constraints, are then incorporated into the MPC algorithm. For data-based process model, a multi-layered feed-forward network is used. Additionally, the offset-free technique is applied to eliminate steady-state errors resulting from model-process mismatch. To demonstrate the results, a binary distillation column process which is multivariable and inherently nonlinear is chosen as testbed. We compare the performance of the proposed met... [more]

One market scope of bioindustries is the production of recombinant proteins for its application in serotherapy. However, its process's monitoring and optimization present limitations. There are different approaches to optimize bioprocess performance; one is using model-based control strategies such as Model Predictive Control (MPC). Another strategy is learning-based control, such as Reinforcement Learning (RL). In this work, an RL approach was applied to maximize the production of recombinant proteins in E. coli at the induction phase using as a control variable the substrate feed flow rate (Fin). The RL model was trained using the actor-critic Twin-Delayed Deep Deterministic (TD3) Policy Gradient agent. The reward corresponded to the maximum value of protein productivity. The environment was represented with a dynamic hybrid model. The optimization was evaluated by stages of two hours to check the protein productivity performance. Afterwards, the results were compared with an MPC app... [more]

Model-based control and optimisation strategies can play a key role in improving energy efficiency and reducing emissions into produced water re-injection facilities. However, building a model that adequately describes the plant is challenging and can also be used in online decision-making procedures. This work proposes a simple model based on a real water re-injection facility operating on the Norwegian continental shelf. The results demonstrate the model's flexibility, which could be fitted to different plant operating points while being fast to solve when embedded in optimisation problems. The developed model is expected to aid the implementation of strategies like self-optimising control and real-time optimisation on produced water re-injection facilities.

The motivation of this work is an application of a production scheduling based on Real-Time Optimization and Zone Control Nonlinear Model Predictive Controller on a liquid recovery unit of an LPG production plant. In this unit, the scheduling-relevant disturbances occur on a time scale relevant to the system dynamics; thus, we propose a novel combination of a well-known control strategies leading to a hierarchical two-layered strategy, where the lower layer employs a zone control nonlinear model predictive controller (NMPC) to define inventory setpoints while the upper layer uses real-time optimization (RTO) to determine optimal plant-wide flow rates from an economic perspective. Unlike a traditional RTO, the proposed upper-layer problem is parameterized by product demands, with a distinct optimization problem formulated for each demand scenario. Our novel approach allows for proactive mitigation of potential inventory issues by dynamically recalculating the distribution of plant produ... [more]

This work presents an approach to implement and assess fractional controllers in an extractive distillation system. The experimental dynamic data for an extractive distillation column is used as a case study. A strategy is developed to fit the operation data to fractional-order transfer functions. Then, the fractional controllers are designed in the Simulink environment in Matlab, tuning the controllers through a hybrid optimization approach. First, the approach uses a genetic algorithm to find an initial point, and then the solution is improved through the fmincon algorithm. According to the results of the design of fractional controllers, the sum of the square of errors is below 2.9x10-6 for perturbations in heat duty, and 1.2x10-5 for perturbations in the reflux ratio. Moreover, after controller tuning, a minimal value for ISE of 1,278.12 is obtained, which is approximately 8% lower than the value obtained for an integer-order controller.

This study presents the design and evaluation of a plantwide control (PWC) system for Formic acid (FA) production under unsteady green Hydrogen supply. Starting from a steady-state foundation in Aspen Plus V12, the system was prepared to handle variable inputs and was subsequently transitioned into Aspen Dynamics for real-time responsiveness. The two-level design methodology to build a PWC scheme, which is comprised of equipment-specific and plantwide controllers, effectively managed fluctuations in feed rates ranging up to ±20%, maintaining FA purity and production rate targets. Gradual SRAMP (sinusoidal ramp) adjustments of 1% per hour provided optimal stability. These results confirm the PWC system's effectiveness in maintaining production goals under the variability of throughput.

Microfluidic chips represent a cutting-edge technology for manipulating fluids within micrometer-scale spaces and are gradually becoming a new favorite platform in life science research. Precise and fast zonal temperature control is essential for accelerating biological experiments. However, current multi-channel temperature controllers typically rely on multiple channel sets to achieve single set-point control, which results in discrepancies between the fluid temperature distribution and sensor temperature due to the distributed temperature field in the fluid channel. To estimate the actual temperature and implement gradient temperature control, this paper introduces an extension of the target tracking (TT) two degrees of freedom (2DOF) state feedback control (SFC) method, followed by a presentation of simulation and experimental results. Through comparisons with an enhanced PID system in both simulation and experimentation, the paper demonstrates an 8.96% reduction in the maximum tem... [more]

In response to the trajectory tracking control problem of manipulators under measurement disturbances, a novel multi-input multi-output discrete integral terminal sliding mode control scheme is proposed. Initially, this scheme establishes a dynamic model of a two-joint manipulator based on the Lagrangian dynamics analysis method. Subsequently, a discrete integral terminal sliding mode control law based on the dynamic model of the two joints is designed, incorporating delayed estimation of unknown disturbances and discretization errors in the manipulator system. To enhance the trajectory tracking accuracy of the control scheme and suppress the impact of sliding mode chattering on the manipulator system, an adaptive switching term is introduced into the discrete integral terminal sliding mode control law. The paper derives an adaptive discrete integral terminal sliding mode control scheme and provides stability proof for the proposed approach. Simulation experiments are conducted to comp... [more]

The motivation of this research was to assess the possibility of speed control for the selected pressure-compensated pump. Measured static characteristics of an axial piston pump with pressure compensation are presented in the paper. Based on these characteristics, the pump efficiencies are determined. The characteristics and efficiencies are determined for the different pump outlet pressures, pump speeds, relative displacements and for the different pressures set at the pressure compensator. In addition, the different methods of pump control were compared. These are displacement control, speed control and both controls. The efficiency of each control method was compared based on the determined mechanical input power at the pump drive shaft. By comparing these control methods, it was found that the combination of both control methods can achieve up to 93% savings of mechanical power in the controlled state (stand-by state). Also, the adverse effects resulting from each control method t... [more]

In this paper, an online energy-saving control allocation strategy based on self-updating loss estimation for multi-motor drive systems is proposed, where the impact of variations in motor parameters and distribution coefficients is considered. Firstly, a drive system model for multi-motor drive systems incorporating iron loss in permanent magnet synchronous motor (PMSM) is established. Then, a self-updating PMSM loss estimation method based on dynamic torque−current mapping is proposed. The torque−current mapping is initially identified based on the conv-fusion curve, and iteratively updated by optimal estimation. Subsequently, an online control allocation method based on line search is proposed, which mitigates the adverse effects caused by variations in distribution coefficients and reduces the total motor loss. Finally, the effectiveness of the proposed strategy is verified on the hardware-in-the-loop (HIL)-based platform. The results demonstrate that the strategy effectively enhan... [more]

To comprehensively understand the influence of mining speed on gas emissions in goaf during coal seam extraction, enhance gas extraction efficiency in goaf, manage gas emissions at the working face, and ensure safety in the mining production process. This study focuses on the No. 3 mining area of Wangjialing Mine, employing numerical simulations to analyze the evolution of mining-induced fractures and the characteristics of gas distribution in the overburden at varying mining speeds. Furthermore, by integrating actual gas emission and extraction data at the production face, this study examines the quantitative relationship between mining speed and gas emissions in the goaf, identifying optimal regions for high-position borehole layouts and conducting borehole optimization design and investigation. The results of this study indicate that the initial caving step distance of the goaf roof increases with the advancement speed of the working face. Conversely, the maximum height of through f... [more]

Tight sandstone gas has become an important field of natural gas development in China. The tight sandstone gas resources of Yan’an gas field in Ordos Basin have made great progress. However, due to the complex gas−water relationship, its exploration and development have been seriously restricted. The occurrence state of water molecules in tight reservoirs, the dynamic change characteristics of gas−water two-phase seepage and its main controlling factors are still unclear. In this paper, the water-occurrence state, gas−water two-phase fluid distribution and dynamic change characteristics of different types of tight reservoir rock samples in Yan’an gas field were studied by means of water vapor isothermal adsorption experiment and nuclear magnetic resonance methane flooding experiment, and the main controlling factors were discussed. The results show that water molecules in different types of tight reservoirs mainly occur in clay minerals and their main participation is in the formation... [more]

To tackle the issue of detecting early, subtle faults in rolling bearings in the presence of noise interference, the SCSSA-VMD-MCKD method is suggested. This method optimizes the Variational Mode Decomposition (VMD) and Maximum Correlated Kurtosis Deconvolution (MCKD) by integrating the sine-cosine and Cauchy Mutation Sparrow Search Algorithm (SCSSA). The approach aims to effectively diagnose faults in rolling bearings by leveraging the strengths of VMD and MCKD in noise reduction and highlighting fault frequencies. The method utilizes the SCSSA algorithm to autonomously search for parameters in both VMD and MCKD, using the EnvelopeCrest Factor Ec as a fitness function. Firstly, SCSSA is employed to optimize the decomposition mode number K and penalty factor α in the VMD algorithm. Secondly, the parameters in the MCKD algorithm are optimized, and MCKD is used for deconvolution to enhance the impulsive characteristics of the best modal component. Finally, the signal is further analyzed... [more]

Adaptive active suspension systems, integral to specialized vehicles, hold significance for their stability and safety. This study introduces a novel adaptive active suspension system featuring four independently controlled wheels employing wheel-hub motors, hydraulic cylinders, pump motor power, controllers, and sensors. A rapid and, within a certain range, leveling and height adjustment control strategy is proposed for this system, utilizing the Kalman filter algorithm. Additionally, the paper examines the front-wheel Ackermann steering model and four-wheel reverse Ackermann transition model to enhance the suspension’s stability. Subsequently, experiments on leveling and height adjustment are conducted, demonstrating the system’s capability to swiftly and accurately rectify the vehicle’s deviation angle within the specified threshold. Following adjustments made by the leveling and height control algorithm, the vehicle body promptly returns to the preset level state and designated hei... [more]

In addressing the issue of poor control over gas permeability during the CO2 flooding process in ultra-low permeability reservoirs, this study proposes the use of a low interfacial tension viscosity-increasing system as a substitute for water in CO2−water alternating flooding to enhance CO2 mobility control and increase oil recovery. The performance of the system was evaluated through tests of viscosity, interfacial tension, wettability, and emulsification properties, and the injection behavior and gas channeling prevention effect of the viscosity-increasing system with CO2 alternate flooding were investigated. The results indicate that the low interfacial tension viscosity-increasing fluid exhibits good thickening properties, interfacial activity, hydrophilic wettability, and oil−water emulsification performance, also demonstrating strong environmental adaptability. The CO2−low interfacial tension viscosity-increasing fluid alternate flooding shows good injectivity in ultra-low permea... [more]

The main objective of this research is to expand right coprime factorization based on operator theory in nonlinear systems. A novel method for right coprime factorization is proposed by introducing an operator that can deform the system’s response into an arbitrary shape. This enables the design of control systems that are highly effective against noise. As an application, we use a pneumatic stage. The effectiveness of this method is verified through simulations and real-world experiments.

Gob-side entry driving near an advancing working face can improve the recovery rate of coal resources and keep the balance between mining and development. However, the large displacement of the gob-side entry caused by the mining dynamics of abutment pressure challenges the safety and processes of coal mining. This article takes the 15102 tailentry of Xizhang Coal Mine in Changzhi City, Shanxi Province, as an example to study the stability of the coal pillar and the failure characteristics of the surrounding rock and proposes cooperative control strategies of surrounding rock stability. Field tests indicated that when the coal pillar width was 15 m, the displacements of the entry floor, roof, coal pillar side, and solid coal side were 1121 mm, 601 mm, 783 mm, and 237 mm, respectively. A meticulously validated numerical model, incorporating a double-yield model for the gob materials and calibrated parameters, was developed to investigate the stress changes and yield zone distribution ac... [more]

Fault data injection attacks may lead to a decrease in system performance and even a malfunction in system operation for an automatic feedback control system, which has motive to develop an effective method for rapidly detecting such attacks so that appropriate measures can be taken correspondingly. In this study, a secure descriptor estimation technique is proposed for continuous-time Lipschitz nonlinear cyber physical systems affected by actuator attacks, sensor attacks, and unknown process uncertainties. Specifically, by forming a new state vector composed of original system states and sensor faults, an equivalent descriptor dynamic system is built. A proportional and derivate sliding-mode observer is presented so that the system states, sensor attack, and actuator attack can be reconstructed successfully. The observer gains are obtained by using linear matrix inequality to secure robustly stable estimation error dynamics. Moreover, a robust descriptor fast adaptive observer estimat... [more]

In the article, the semi-global finite-time control strategy for stochastic nonlinear systems is studied. Firstly, the general stochastic nonlinear system is considered and the required conditions are provided. An important theorem that helps to construct the controller directly is subsequently obtained by adopting a dynamic gain and homogeneous domination method. The equilibrium of the whole system is semi-global finite-time stable in probability (SGFSP) under the designed controller. Finally, the presented method is successfully applied to a second-order system. Simulation results indicate the effectiveness of the method.