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Robust state estimation of feeding–blending systems in continuous pharmaceutical manufacturing

Chemical Engineering Research and Design

Liu, Jianfeng; Su, Qinglin; Moreno, Mariana; Laird, Carl D.; Nagy, Zoltan; Reklaitis, Gintaras

State estimation is a fundamental part of monitoring, control, and real-time optimization in continuous pharmaceutical manufacturing. For nonlinear dynamic systems with hard constraints, moving horizon estimation (MHE) can estimate the current state by solving a well-defined optimization problem where process complexities are explicitly considered as constraints. Traditional MHE techniques assume random measurement noise governed by some normal distributions. However, state estimates can be unreliable if noise is not normally distributed or measurements are contaminated with gross or systematic errors. To improve the accuracy and robustness of state estimation, we incorporate robust estimators within the standard MHE skeleton, leading to an extended MHE framework. The proposed MHE approach is implemented on two pharmaceutical continuous feeding–blending system (FBS) configurations which include loss-in-weight (LIW) feeders and continuous blenders. Numerical results show that our MHE approach is robust to gross errors and can provide reliable state estimates when measurements are contaminated with outliers and drifts. Moreover, the efficient solution of the MHE realized in this work, suggests feasible application of on-line state estimation on more complex continuous pharmaceutical processes.

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TYPE Journal Article YEAR 2018
ScopusOSTIDOI

Strengthened SOCP Relaxations for ACOPF with McCormick Envelopes and Bounds Tightening

Computer Aided Chemical Engineering

Bynum, Michael L.; Castillo, Anya; Watson, Jean-Paul W.; Laird, Carl D.

The solution of the Optimal Power Flow (OPF) and Unit Commitment (UC) problems (i.e., determining generator schedules and set points that satisfy demands) is critical for efficient and reliable operation of the electricity grid. For computational efficiency, the alternating current OPF (ACOPF) problem is usually formulated with a linearized transmission model, often referred to as the DCOPF problem. However, these linear approximations do not guarantee global optimality or even feasibility for the true nonlinear alternating current (AC) system. Nonlinear AC power flow models can and should be used to improve model fidelity, but successful global solution of problems with these models requires the availability of strong relaxations of the AC optimal power flow constraints. In this paper, we use McCormick envelopes to strengthen the well-known second-order cone (SOC) relaxation of the ACOPF problem. With this improved relaxation, we can further include tight bounds on the voltages at the reference bus, and this paper demonstrates the effectiveness of this for improved bounds tightening. We present results on the optimality gap of both the base SOC relaxation and our Strengthened SOC (SSOC) relaxation for the National Information and Communications Technology Australia (NICTA) Energy System Test Case Archive (NESTA). For the cases where the SOC relaxation yields an optimality gap more than 0.1 %, the SSOC relaxation with bounds tightening further reduces the optimality gap by an average of 67 % and ultimately reduces the optimality gap to less than 0.1 % for 58 % of all the NESTA cases considered. Stronger relaxations enable more efficient global solution of the ACOPF problem and can improve computational efficiency of MINLP problems with AC power flow constraints, e.g., unit commitment.

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TYPE Conference Poster YEAR 2018
ScopusOSTIDOI

A global stochastic programming approach for the optimal placement of gas detectors with nonuniform unavailabilities

Journal of Loss Prevention in the Process Industries

Liu, Jianfeng; Laird, Carl D.

Optimal design of a gas detection systems is challenging because of the numerous sources of uncertainty, including weather and environmental conditions, leak location and characteristics, and process conditions. Rigorous CFD simulations of dispersion scenarios combined with stochastic programming techniques have been successfully applied to the problem of optimal gas detector placement; however, rigorous treatment of sensor failure and nonuniform unavailability has received less attention. To improve reliability of the design, this paper proposes a problem formulation that explicitly considers nonuniform unavailabilities and all backup detection levels. The resulting sensor placement problem is a large-scale mixed-integer nonlinear programming (MINLP) problem that requires a tailored solution approach for efficient solution. We have developed a multitree method which depends on iteratively solving a sequence of upper-bounding master problems and lower-bounding subproblems. The tailored global solution strategy is tested on a real data problem and the encouraging numerical results indicate that our solution framework is promising in solving sensor placement problems. This paper was selected for the special issue in JLPPI from the 2016 International Symposium of the MKO Process Safety Center.

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TYPE Journal Article YEAR 2018
ScopusOSTIDOI

Sensor Placement Optimization using Chama

Klise, Katherine A.; Laird, Carl D.; Nicholson, Bethany L.

Continuous or regularly scheduled monitoring has the potential to quickly identify changes in the environment. However, even with low - cost sensors, only a limited number of sensors can be deployed. The physical placement of these sensors, along with the sensor technology and operating conditions, can have a large impact on the performance of a monitoring strategy. Chama is an open source Python package which includes mixed - integer, stochastic programming formulations to determine sensor locations and technology that maximize monitoring effectiveness. The methods in Chama are general and can be applied to a wide range of applications. Chama is currently being used to design sensor networks to monitor airborne pollutants and to monitor water quality in water distribution systems. The following documentation includes installation instructions and examples, description of software features, and software license. The software is intended to be used by regulatory agencies, industry, and the research community. It is assumed that the reader is familiar with the Python Programming Language. References are included for addit ional background on software components. Online documentation, hosted at http://chama.readthedocs.io/, will be updated as new features are added. The online version includes API documentation .

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TYPE SAND Report YEAR 2017
OSTIDOI
Results 51–75 of 90
Results 51–75 of 90