(12) Ulllted States Patent (10) Patent N0.: US 7,536,232 B2
US007536232B2
(12) Ulllted States Patent
(10) Patent N0.:
Boyden et al. (54)
US 7,536,232 B2
(45) Date of Patent:
MODEL PREDICTIVE CONTROL OF AIR POLLUTION CONTROL PROCESSES
May 19, 2009
5,605,552 A 5,635,149 A
2/1997 ShiIIliZu 6t 31 6/1997 Klingspor et 31.
5,729,661 A
3/1998 Keeler et a1.
(75) Inventors: Scott A. Boyden, Knoxville, TN (US); Stephen Piche, Austin, TX (US)
_
(Continued) FOREIGN PATENT DOCUMENTS
(73) Assignee: ALSTOM Technology Ltd, Baden (CH) EP
(*)
Notice:
0296500
12/1988
Subject to any disclaimer, the term of this patent is extended or adjusted under 35
U.S.C. 154(b) by 952 days.
(Continued)
(21) Appl. N0.: 10/927,243
OTHER PUBLICATIONS Tran, et 211., “Dynamic Matrix Control on Benzene and Toluene
(22)
Filed:
Aug. 27, 2004
(65)
Prior Publication Data Us 2006/0045801 A1
(51)
Towers”, Oct. 1989.
(Continued)
Mar. 2, 2006
Primary ExamineriN- Bhat
_
(74) Attorney, Agent, or FirmiAntonelli, Terry, Stout & Kfaus, LLP
Int. Cl. G05B 13/02 G05D 7/00
(2006.01) (2006.01)
(57)
ABSTRACT
(52)
US. Cl. ....................... .. 700/52; 700/266; 700/274;
(58)
Field of Classi?cation Search ................. .. 700/ 52,
system performing a process to control emissions of a pollut
700/266, 274; 422/171, 172; 95/108 See application ?le for complete search history.
ant has multiple process parameters (MPPs). One or more of the MPPs is a controllable process parameter (CTPP) and one
422/1 1 1; 422/171; 422/172
_
(56)
A controller for directing operation of an air pollution control
of the MPPs is an amount of the pollutant (AOP) emitted by
References Clted
the system. A de?ned AOP Value (AOPV) represents an
US. PATENT DOCUMENTS
objective or limit on an actual Value (AV) of the emitted AOP. The controller includes either a neural netWork process model or a non-neural netWork process model representing a rela
4,423,018 A 4,487,784 A 5,167,009 A
12/1983 Lester et a1. 12/1984 Kuroda et a1. 11/1992 Skeirik
5,171,552 A *
12/1992
Miura et a1.
5,212,765 5,282,261 5,386,373 5,479,573 5,548,528
5/1993 1/1994 1/1995 12/1995 8/1996
Skeirik Skeirik Keeler et a1. Keeler et a1. Keeler et a1.
A A A A A
tionship betWeen each CTPP and the emitted AOP. A control processor has the logic to predict, based on the model, hoW ........... .. 423/2391
changes to the current Value of each CTPP Will affect a future AV of emitted AOP, to select one of the changes in one CTPP based on the predicted affect of that change and on the AOPV, and to direct control of the one CTPP in accordance With the
selected change for that CTPP.
24 Claims, 25 Drawing Sheets
Operator/Engineer Emission history for 1 roillng~average period into the past, Operational/outage plans ‘for one roiling-average period into the future 1 225
PFOGess
_
Historian!
Opél'é'l'lOl'lEl
Database
Outage plans
1210
Tier 2 Controiier
1
Processing Unit 1100
Current
Sheri-term Rolling
Emissio
WFGD Process
520
Average Target 1235
‘
Tier 1 Controller > Processing Unit
Process Values &
Setpoints
705A
7058
US 7,536,232 B2 Page 2 U.S. PATENT DOCUMENTS 5,756,052 A *
7,323,036 B2 *
5/1998 SuZumura et al. ......... .. 422/171
5,770,161 A *
6/1998
5,770,166 A 5,781,432 A
6/ 1998 ShimiZu et a1. 7/1998 Keeler et a1.
Ochi et al. ...... ..
5,902,555 A *
5/1999 Tatani et al. .............. .. 422/168
6,007,783 A *
l2/l999 O-chi et al. ................ .. 422/171
4/2000 P1che et a1. 1/2001 Etter
6,187,278 B1 *
2/2001 Brown et al. ......... .. 423/24306
Keeler et al. Piche et al. Martin et al. Chen et al. Crosswhite Martin et a1, Takashina et al. Stark et a1‘ Storm et a1‘ Hiram et a1‘ -
’
.
9/1998
1382905 03/065135
1/ 2004 8/2003
OTHER PUBLICATIONS
Two Hydrocracker Distillation Columns in Series”, Oct. 1991.
Brown, et al., “Adaptive, Predictive Controller for Optimal Process Control”, Los Almost National Laboratory, Los Alamos, NM, 1993. Boyden, et al., “The Development of DMCiX: The AXM-based (DMC)TM Controller Interface”, Honeywell OpenUSE Technical Exchange Seminar, Mar. 1995. Boyden, “Controlled Variable Predictions with DMI: Temperature to Analyzer Predictors”, Jun 1995 Bequette, Model Predictive ControliReferences (Aug. 2000). B. Hacking, “Advanced Control of Selective Catalytic Reduction (SCR) Literature and Patent Review”, Pegasus Technologies Tech nical Report, Mar. 2003.
B. Hacking, “Advanced Control of Wet Flue Gas DesulfuriZation
'
6,985,779 B2
1/2006 Hs1ung et al.
7,113,835 B2 *
9/2006
7,117,046 B2 *
0866395
O’Conner, et al., “Application of a Single Multivariable Controller to
sign: :5 31' ’
EP
EP W0
6,047,221 A 6,168,709 B1
6/ 2001 8/2001 12/2002 4/ 2003 8/2003 9/2003 12/2003 12/2003 6/2004 200%
Magumbe et al. ......... .. 423/210 Fallon et 31‘
FOREIGN PATENT DOCUMENTS
8/1999 Martin et al. 12/1999 Keeler et al.
B1 B1 B1 B2 B1 B2 B2 B1 B2 B2
1/2008 Boyden et al. .............. .. 95/108 5/2008 12/2005
422/111
5,933,345 A 6,002,839 A
6,243,696 6,278,899 6,493,596 6,542,852 6,611,726 6,625,501 6,656,440 6,662,185 6,746,237 6,856,855
7,371,357 B2 * 2005/0265417 A1
Boyden et al.
Literature and Patent Review”, Pegasus Technologies Technical
Repon Apr 2003
.............. .. 700/52
10/2006 Boyden et al. .............. .. 700/52
’
'
'
* cited by examiner
US. Patent
May 19, 2009
Sheet 1 0f 25
US 7,536,232 B2
35%0m? hm? 9G:53 0 mnw
L
G
S
16D
Waste Stream
:1 59
2LE5.358a0$
3: m
mFimE. 526cm
US. Patent
May 19, 2009
Sheet 2 0f 25
US 7,536,232 B2
US. Patent
May 19, 2009
Sheet 3 0f 25
US 7,536,232 B2
FIUG G85 116
ME Wash
209
3w
File 62$ with 302 4
Figure 3
Prior Art
Absorber Tuwer
US. Patent
May 19, 2009
Sheet 4 0f 25
US 7,536,232 B2
Mumpsndkg 91% 90% ~ 89% - 88% - 87%
~ 86%
‘~ 85% 84%
Slurry pH
Figure 4
US. Patent
May 19, 2009
6
sum HJrit yp Limit y
520
Sheet 5 0f 25
US 7,536,232 B2
Area of
Feasible Operation
H
525
$02Permit Emission
{)i;
=60
505
Maximum Valve Limit 515
Dissoived 02 510
Figure 5A Optimum
555
G
Pu ' t
ypsémn n y
Area af Feasibie Operation 525
so2Permit Emission
QC;
‘=06 Maximum Valve Limit 515
Figure 5B
US. Patent
May 19, 2009
Sheet 6 0f 25
US 7,536,232 B2
Reference 640
——————> Controller MVs(pH,air,etc)615‘ Wet FGD V
|__>
610
m Estimator ‘ 635
620 Observed PVs(DVS,MV$ and CVS) 625 MVs = llfanipulated Variables DVs = Disturbance Variables CV s = Controlled Variables
Figure 6
US. Patent
May 19, 2009
Sheet 7 0f 25
US 7,536,232 B2
Figure 7 Display 730
Processlng Umt
Disk Storage Unit
705
710
722
:
727
:
i
Keyboard 120 Mouse 725
i MPCC 700 ;
US. Patent
May 19, 2009
Sheet 9 0f 25
US 7,536,232 B2
930 Observed
'
MVs and DVS
960
.
Eog‘amtilc ——>
3 ma on
Validation V
910
Model 880
‘ Estimation V
920
A Estg‘lzted V
940
Observed CVs 950
Figure 9
US. Patent
May 19, 2009
Sheet 10 0f 25
l l | i l l l | l
Memory 820A
Interfac 830A
US 7,536,232 B2
Control Generator
| l
Logic 860A
l
I l l I
I
850A
| l l l l
Processor 81 0A
l
Estimation Logic 840A Prediction Logic
l l
Dynamic Control
Dynamic Estimation
I I l l l l l l l i l l l l
Model 880A Data 885A
1
s02 Emissions
I
1
History Database
ll
:
8 90A
'
l
Memory
8408
8205
Prediction Logic 8508
Control Generator
Logic 8608
Dynamic Control Model 8708
Dynamic Estimation Model 8805
Data I
| |
I
1
i
Processor 81 08
l l l i l l l |
Model 870A
Estimation Logic
Interfac 8305
l l I I
885B
:
|
S02 Emissions
:
1
History Database
l
: '
| 1
890B
Figure 10
US. Patent
May 19, 2009
Sheet 11 0125
US 7,536,232 B2
nq Average Management
Ploiecled WFGD 'Fiun Facial
_ Add Pil‘lanned Outage;
?esczfPtpn ‘i
95;;
1
‘ M?dify/Fieview Planned Outages
filiawwilr
End Date
Fiuure 11B
_
-
qo
US. Patent
May 19, 2009
Sheet 12 0f 25
US 7,536,232 B2
m#c:wm3uoi m ?“
23:2".
lk
and? P
wmoEn. E2 :
mEsw:oEm
wmuoi omw
US. Patent
Reference
May 19, 2009
Sheet 13 0f 25
US 7,536,232 B2
| | |
______l_>
C E 0s mwmP1
m?a?
m mr
P m
an}?Swa\|)5
m m.
>
D1C3S2
m Fw 0
t&
0
MPCC 1300
Figure 13
US. Patent
May 19, 2009
US 7,536,232 B2
Sheet 14 0f 25
We! FGD Advanced Controller
Unit-1
UnltZ
[:1 comaoum none
On
U CONTROLLER MODE
On
wATcu?os
soon
WATCHDOG
soon
vensscrsn smrus
soul:
PERFEGTER srnus
soon
MAHIPULATED VARIABLES D ENABLEALL MODE
U P"
SP
MANIPULATED'VARIABLES D WALL
MINLMT mxuwr
w
“on;
@E@ [El CE
[I P"
CONTROLLED VARIABLES us
ss‘nwu-e
WW“ @ 6mm
coMiRoLLEovARmaLEs _ PV , LAB ,sgmm:
um
11']
@MW
"@E
7 ‘
2
L ‘
mo
,
mu
’
mu
1m
own
one
_ mu‘ ~
@EQELII "LEE
6%
120a
,‘ '
_ .. 12m
_
whmasezkimaamuuummv
v121.1_o_
mtmunrunyumunmn
1m{2m
PV
sozasuovux
, @@@1
W'soznmmsimi'mum
mg
Mnum mun
E1 mm QUE
[3 mm 111%, PV
SP
@ETLJIEI LE [E1
-
1am
mm,
mnmqypunfwigymwunzgw‘
um‘ > 1200
1200-
_
1am
2",‘
._
1
Figure 14A
PERITY
M5515; E
Figure 143
US. Patent
May 19, 2009
Sheet 17 0f 25
US 7,536,232 B2
US. Patent
May 19, 2009
Sheet 18 0f 25
US 7,536,232 B2
MPCC 150D
(12) Ulllted States Patent
(10) Patent N0.:
Boyden et al. (54)
US 7,536,232 B2
(45) Date of Patent:
MODEL PREDICTIVE CONTROL OF AIR POLLUTION CONTROL PROCESSES
May 19, 2009
5,605,552 A 5,635,149 A
2/1997 ShiIIliZu 6t 31 6/1997 Klingspor et 31.
5,729,661 A
3/1998 Keeler et a1.
(75) Inventors: Scott A. Boyden, Knoxville, TN (US); Stephen Piche, Austin, TX (US)
_
(Continued) FOREIGN PATENT DOCUMENTS
(73) Assignee: ALSTOM Technology Ltd, Baden (CH) EP
(*)
Notice:
0296500
12/1988
Subject to any disclaimer, the term of this patent is extended or adjusted under 35
U.S.C. 154(b) by 952 days.
(Continued)
(21) Appl. N0.: 10/927,243
OTHER PUBLICATIONS Tran, et 211., “Dynamic Matrix Control on Benzene and Toluene
(22)
Filed:
Aug. 27, 2004
(65)
Prior Publication Data Us 2006/0045801 A1
(51)
Towers”, Oct. 1989.
(Continued)
Mar. 2, 2006
Primary ExamineriN- Bhat
_
(74) Attorney, Agent, or FirmiAntonelli, Terry, Stout & Kfaus, LLP
Int. Cl. G05B 13/02 G05D 7/00
(2006.01) (2006.01)
(57)
ABSTRACT
(52)
US. Cl. ....................... .. 700/52; 700/266; 700/274;
(58)
Field of Classi?cation Search ................. .. 700/ 52,
system performing a process to control emissions of a pollut
700/266, 274; 422/171, 172; 95/108 See application ?le for complete search history.
ant has multiple process parameters (MPPs). One or more of the MPPs is a controllable process parameter (CTPP) and one
422/1 1 1; 422/171; 422/172
_
(56)
A controller for directing operation of an air pollution control
of the MPPs is an amount of the pollutant (AOP) emitted by
References Clted
the system. A de?ned AOP Value (AOPV) represents an
US. PATENT DOCUMENTS
objective or limit on an actual Value (AV) of the emitted AOP. The controller includes either a neural netWork process model or a non-neural netWork process model representing a rela
4,423,018 A 4,487,784 A 5,167,009 A
12/1983 Lester et a1. 12/1984 Kuroda et a1. 11/1992 Skeirik
5,171,552 A *
12/1992
Miura et a1.
5,212,765 5,282,261 5,386,373 5,479,573 5,548,528
5/1993 1/1994 1/1995 12/1995 8/1996
Skeirik Skeirik Keeler et a1. Keeler et a1. Keeler et a1.
A A A A A
tionship betWeen each CTPP and the emitted AOP. A control processor has the logic to predict, based on the model, hoW ........... .. 423/2391
changes to the current Value of each CTPP Will affect a future AV of emitted AOP, to select one of the changes in one CTPP based on the predicted affect of that change and on the AOPV, and to direct control of the one CTPP in accordance With the
selected change for that CTPP.
24 Claims, 25 Drawing Sheets
Operator/Engineer Emission history for 1 roillng~average period into the past, Operational/outage plans ‘for one roiling-average period into the future 1 225
PFOGess
_
Historian!
Opél'é'l'lOl'lEl
Database
Outage plans
1210
Tier 2 Controiier
1
Processing Unit 1100
Current
Sheri-term Rolling
Emissio
WFGD Process
520
Average Target 1235
‘
Tier 1 Controller > Processing Unit
Process Values &
Setpoints
705A
7058
US 7,536,232 B2 Page 2 U.S. PATENT DOCUMENTS 5,756,052 A *
7,323,036 B2 *
5/1998 SuZumura et al. ......... .. 422/171
5,770,161 A *
6/1998
5,770,166 A 5,781,432 A
6/ 1998 ShimiZu et a1. 7/1998 Keeler et a1.
Ochi et al. ...... ..
5,902,555 A *
5/1999 Tatani et al. .............. .. 422/168
6,007,783 A *
l2/l999 O-chi et al. ................ .. 422/171
4/2000 P1che et a1. 1/2001 Etter
6,187,278 B1 *
2/2001 Brown et al. ......... .. 423/24306
Keeler et al. Piche et al. Martin et al. Chen et al. Crosswhite Martin et a1, Takashina et al. Stark et a1‘ Storm et a1‘ Hiram et a1‘ -
’
.
9/1998
1382905 03/065135
1/ 2004 8/2003
OTHER PUBLICATIONS
Two Hydrocracker Distillation Columns in Series”, Oct. 1991.
Brown, et al., “Adaptive, Predictive Controller for Optimal Process Control”, Los Almost National Laboratory, Los Alamos, NM, 1993. Boyden, et al., “The Development of DMCiX: The AXM-based (DMC)TM Controller Interface”, Honeywell OpenUSE Technical Exchange Seminar, Mar. 1995. Boyden, “Controlled Variable Predictions with DMI: Temperature to Analyzer Predictors”, Jun 1995 Bequette, Model Predictive ControliReferences (Aug. 2000). B. Hacking, “Advanced Control of Selective Catalytic Reduction (SCR) Literature and Patent Review”, Pegasus Technologies Tech nical Report, Mar. 2003.
B. Hacking, “Advanced Control of Wet Flue Gas DesulfuriZation
'
6,985,779 B2
1/2006 Hs1ung et al.
7,113,835 B2 *
9/2006
7,117,046 B2 *
0866395
O’Conner, et al., “Application of a Single Multivariable Controller to
sign: :5 31' ’
EP
EP W0
6,047,221 A 6,168,709 B1
6/ 2001 8/2001 12/2002 4/ 2003 8/2003 9/2003 12/2003 12/2003 6/2004 200%
Magumbe et al. ......... .. 423/210 Fallon et 31‘
FOREIGN PATENT DOCUMENTS
8/1999 Martin et al. 12/1999 Keeler et al.
B1 B1 B1 B2 B1 B2 B2 B1 B2 B2
1/2008 Boyden et al. .............. .. 95/108 5/2008 12/2005
422/111
5,933,345 A 6,002,839 A
6,243,696 6,278,899 6,493,596 6,542,852 6,611,726 6,625,501 6,656,440 6,662,185 6,746,237 6,856,855
7,371,357 B2 * 2005/0265417 A1
Boyden et al.
Literature and Patent Review”, Pegasus Technologies Technical
Repon Apr 2003
.............. .. 700/52
10/2006 Boyden et al. .............. .. 700/52
’
'
'
* cited by examiner
US. Patent
May 19, 2009
Sheet 1 0f 25
US 7,536,232 B2
35%0m? hm? 9G:53 0 mnw
L
G
S
16D
Waste Stream
:1 59
2LE5.358a0$
3: m
mFimE. 526cm
US. Patent
May 19, 2009
Sheet 2 0f 25
US 7,536,232 B2
US. Patent
May 19, 2009
Sheet 3 0f 25
US 7,536,232 B2
FIUG G85 116
ME Wash
209
3w
File 62$ with 302 4
Figure 3
Prior Art
Absorber Tuwer
US. Patent
May 19, 2009
Sheet 4 0f 25
US 7,536,232 B2
Mumpsndkg 91% 90% ~ 89% - 88% - 87%
~ 86%
‘~ 85% 84%
Slurry pH
Figure 4
US. Patent
May 19, 2009
6
sum HJrit yp Limit y
520
Sheet 5 0f 25
US 7,536,232 B2
Area of
Feasible Operation
H
525
$02Permit Emission
{)i;
=60
505
Maximum Valve Limit 515
Dissoived 02 510
Figure 5A Optimum
555
G
Pu ' t
ypsémn n y
Area af Feasibie Operation 525
so2Permit Emission
QC;
‘=06 Maximum Valve Limit 515
Figure 5B
US. Patent
May 19, 2009
Sheet 6 0f 25
US 7,536,232 B2
Reference 640
——————> Controller MVs(pH,air,etc)615‘ Wet FGD V
|__>
610
m Estimator ‘ 635
620 Observed PVs(DVS,MV$ and CVS) 625 MVs = llfanipulated Variables DVs = Disturbance Variables CV s = Controlled Variables
Figure 6
US. Patent
May 19, 2009
Sheet 7 0f 25
US 7,536,232 B2
Figure 7 Display 730
Processlng Umt
Disk Storage Unit
705
710
722
:
727
:
i
Keyboard 120 Mouse 725
i MPCC 700 ;
US. Patent
May 19, 2009
Sheet 9 0f 25
US 7,536,232 B2
930 Observed
'
MVs and DVS
960
.
Eog‘amtilc ——>
3 ma on
Validation V
910
Model 880
‘ Estimation V
920
A Estg‘lzted V
940
Observed CVs 950
Figure 9
US. Patent
May 19, 2009
Sheet 10 0f 25
l l | i l l l | l
Memory 820A
Interfac 830A
US 7,536,232 B2
Control Generator
| l
Logic 860A
l
I l l I
I
850A
| l l l l
Processor 81 0A
l
Estimation Logic 840A Prediction Logic
l l
Dynamic Control
Dynamic Estimation
I I l l l l l l l i l l l l
Model 880A Data 885A
1
s02 Emissions
I
1
History Database
ll
:
8 90A
'
l
Memory
8408
8205
Prediction Logic 8508
Control Generator
Logic 8608
Dynamic Control Model 8708
Dynamic Estimation Model 8805
Data I
| |
I
1
i
Processor 81 08
l l l i l l l |
Model 870A
Estimation Logic
Interfac 8305
l l I I
885B
:
|
S02 Emissions
:
1
History Database
l
: '
| 1
890B
Figure 10
US. Patent
May 19, 2009
Sheet 11 0125
US 7,536,232 B2
nq Average Management
Ploiecled WFGD 'Fiun Facial
_ Add Pil‘lanned Outage;
?esczfPtpn ‘i
95;;
1
‘ M?dify/Fieview Planned Outages
filiawwilr
End Date
Fiuure 11B
_
-
qo
US. Patent
May 19, 2009
Sheet 12 0f 25
US 7,536,232 B2
m#c:wm3uoi m ?“
23:2".
lk
and? P
wmoEn. E2 :
mEsw:oEm
wmuoi omw
US. Patent
Reference
May 19, 2009
Sheet 13 0f 25
US 7,536,232 B2
| | |
______l_>
C E 0s mwmP1
m?a?
m mr
P m
an}?Swa\|)5
m m.
>
D1C3S2
m Fw 0
t&
0
MPCC 1300
Figure 13
US. Patent
May 19, 2009
US 7,536,232 B2
Sheet 14 0f 25
We! FGD Advanced Controller
Unit-1
UnltZ
[:1 comaoum none
On
U CONTROLLER MODE
On
wATcu?os
soon
WATCHDOG
soon
vensscrsn smrus
soul:
PERFEGTER srnus
soon
MAHIPULATED VARIABLES D ENABLEALL MODE
U P"
SP
MANIPULATED'VARIABLES D WALL
MINLMT mxuwr
w
“on;
@E@ [El CE
[I P"
CONTROLLED VARIABLES us
ss‘nwu-e
WW“ @ 6mm
coMiRoLLEovARmaLEs _ PV , LAB ,sgmm:
um
11']
@MW
"@E
7 ‘
2
L ‘
mo
,
mu
’
mu
1m
own
one
_ mu‘ ~
@EQELII "LEE
6%
120a
,‘ '
_ .. 12m
_
whmasezkimaamuuummv
v121.1_o_
mtmunrunyumunmn
1m{2m
PV
sozasuovux
, @@@1
W'soznmmsimi'mum
mg
Mnum mun
E1 mm QUE
[3 mm 111%, PV
SP
@ETLJIEI LE [E1
-
1am
mm,
mnmqypunfwigymwunzgw‘
um‘ > 1200
1200-
_
1am
2",‘
._
1
Figure 14A
PERITY
M5515; E
Figure 143
US. Patent
May 19, 2009
Sheet 17 0f 25
US 7,536,232 B2
US. Patent
May 19, 2009
Sheet 18 0f 25
US 7,536,232 B2
MPCC 150D
