State estimation model based algorithm for on-line optimization and control of batch processes

Batch/semi-batch processes are highly nonlinear and involve complex reaction mechanisms. Model-plant mismatch always exists. The lack of rapid direct or indirect measurements of the properties to be controlled makes the control task difficult. It is the usual practice to follow the prespecified setpoint profiles for process variables for which measurements are available, in order to obtain the desired product properties. Modeling error can be the cause of bad performance when the optimal profiles computed for the model are implemented on the actual plant. In this paper, a state estimation model based algorithm is presented for online modification of the optimal profile and control with the goal of obtaining the desired properties at the minimum batch time. The effectiveness of the algorithm is demonstrated by its application to bulk polymerization of styrene.