Economics-based coordination of advanced process control and real-time optimization
First Claim
1. A method for control and optimization of a process, comprising:
- receiving process data and economic data corresponding to the process to be controlled;
calculating an economic objective function based on the process data, the economic data and a nonlinear steady-state model of the process;
deriving a non-linear approximation of the economic objective function in terms of a set of process control variables associated with the process;
transmitting the non-linear approximation to an advanced process control module; and
controlling the process according to the non-linear approximation and within a constraint to drive the process toward a constrained economic optimum by the advanced process control module;
wherein the calculation of the economic objective function and the derivation of the non-linear approximation of the economic objective function are performed at a frequency lower than controlling the process according to the non-linear approximation by the advanced process control module.
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Abstract
A system and method for coordinating advanced process control and real-time optimization of a manufacturing process are provided. The system and method receive process data and economic data corresponding to the manufacturing process to be controlled and optimized. Based on the process data, the economic data and a nonlinear steady-state model of the process, an economic objective function is calculated by a real-time optimization module. A reduced-order non-linear approximation of the economic objective function is thereafter calculated by the real-time optimization module and transmitted to an advanced process control module. The advanced process control module utilizes the reduced-order non-linear approximation of the economic objective function to control the manufacturing process towards the constrained economic optimum.
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Citations
18 Claims
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1. A method for control and optimization of a process, comprising:
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receiving process data and economic data corresponding to the process to be controlled; calculating an economic objective function based on the process data, the economic data and a nonlinear steady-state model of the process; deriving a non-linear approximation of the economic objective function in terms of a set of process control variables associated with the process; transmitting the non-linear approximation to an advanced process control module; and controlling the process according to the non-linear approximation and within a constraint to drive the process toward a constrained economic optimum by the advanced process control module; wherein the calculation of the economic objective function and the derivation of the non-linear approximation of the economic objective function are performed at a frequency lower than controlling the process according to the non-linear approximation by the advanced process control module. - View Dependent Claims (2, 3, 4, 5, 6, 7)
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8. A method for control and optimization of a process, comprising:
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receiving process data and economic data corresponding to the process to be controlled; calculating an economic objective function based on the process data, the economic data and a nonlinear steady-state model of the process; deriving a non-linear approximation of the economic objective function in terms of a set of process control variables associated with the process; transmitting the non-linear approximation to an advanced process control module; and controlling the process according to the non-linear approximation and within a constraint to drive the process toward a constrained economic optimum by the advanced process control module; wherein the non-linear approximation is comprised of a Hessian matrix and a gradient vector which represent an economic surface in terms of the set of process control variables of the process.
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9. A method for control and optimization of a process, comprising:
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receiving process data and economic data corresponding to the process to be controlled; calculating an economic objective function based on the process data, the economic data and a nonlinear steady-state model of the process; deriving a non-linear approximation of the economic objective function in terms of a set of process control variables associated with the process; transmitting the non-linear approximation to an advanced process control module; and controlling the process according to the non-linear approximation and within a constraint to drive the process toward a constrained economic optimum by the advanced process control module; wherein the non-linear approximation of the economic objective function is a local quadratic approximation of the economic objective function.
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10. A system for coordinating advanced process control and real-time optimization of a process, comprising:
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a real-time optimization (RTO) module for calculating an economic objective function based on process data, economic data and a nonlinear steady-state model of the process and deriving a non-linear approximation of the economic objective function in terms of a set of process control variables of the process; and an advanced process control (APC) module for controlling the process according to the non-linear approximation and within a constraint to drive the process toward the economic objective; wherein the RTO module operates at a lower frequency than the APC module. - View Dependent Claims (11, 12, 13, 14)
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15. An article of manufacture comprising a machine readable medium having stored instructions that, when executed by a computer system:
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receive process data and economic data corresponding to the process to be controlled; calculate an economic objective function by a real-time optimization module based on the process data, the economic data and a nonlinear steady-state model of the process; derive a non-linear approximation of the economic objective function by the real-time optimization module in terms of a set of process control variables associated with the process; transmit the non-linear approximation to an advanced process control module; and control the process according to the non-linear approximation and within a constraint to drive the process toward the economic objective by the advanced process control module; wherein the non-linear approximation of the economic objective function is a local quadratic approximation of the economic objective function. - View Dependent Claims (16, 17, 18)
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Specification