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Towards the synthesis of modular process intensification systems with safety and operability considerations - application to heat exchanger network
In this paper, we present a systematic framework for the synthesis of safely operable process intensification systems. Herein, intensified designs are automatically generated by using phenomena-based Generalized Modular Representation Framework, while their safety and operability performances are guaranteed by incorporating: (i) flexibility analysis and multiperiod design, (ii) inherent safety analysis utilizing quantitative risk assessment, and (iii) multi-parametric model predictive control strategies developed via the PAROC framework. As an example from a broader set of intensified systems, the proposed framework is applied to heat exchanger network synthesis for thermal intensification, demonstrating its capability on enhancing safety and operability at early design stage.
Optimal pumping schedule with high-viscosity gel for uniform distribution of proppant in unconventional reservoirs
Hydrocarbon recovery from a hydraulic-fractured unconventional reservoir can be enhanced by replacing slickwater with non-Newtonian high-viscosity gel as a fracturing fluid. However, in the literature, the role of gel rheology on hydrocarbon production from a fractured reservoir is not very well understood. This lack of understanding makes it difficult for the industry to choose appropriate viscosity parameters of fracturing gels. Motivated by these limitations, first, we have developed a high-fidelity model of non-Newtonian fluid flow to simulate fracture propagation, fluid leak-off, and gel flowback processes to predict the oil production from a hydraulic fractured reservoir. Simulation results of the high-fidelity model show how fracture geometry, formation damage, and gel cleanup process varies with the fracturing fluid rheology. Therefore, the developed model is used to understand the effect of gel rheology on hydrocarbon production via a sensitivity analysis, which provides a set of rheological parameters that maximize the cumulative amount of oil production. Finally, utilizing this optimal high-viscosity gel, a model predictive controller is designed to obtain an optimal pumping schedule necessary for producing a target fracture geometry and proppant concentration. The closed-loop simulation results demonstrate that the obtained pumping schedule successfully achieved the desired fracture geometry and proppant concentration at the end of pumping, leading to the maximum oil production from an unconventional reservoir.
Frequency Analysis of Solar PV Power to Enable Optimal Building Load Control
In this paper, we present a flexibility estimation mechanism for buildings’ thermostatically controlled loads (TCLs) to enable the distribution level consumption of the majority of solar photovoltaic (PV) generation by local building TCLs. The local consumption of PV generation provides several advantages to the grid operation as well as the consumers, such as reducing the stress on the distribution network, minimizing voltage fluctuations and two-way power flows in the distribution network, and reducing the required battery storage capacity for PV integration. This would result in increasing the solar PV generation penetration levels. The aims of this study are twofold. First, spectral (frequency) analyses of solar PV power generation together with the power consumption of multiple building TCLs (such as heating, ventilation, and air conditioning (HVAC) systems, water heaters, and refrigerators) are performed. These analyses define the bandwidth over which these TCLs can operate and also describe the PV generation frequency bandwidth. Such spectral analyses, in frequency domain, can help identify the flexible components of PV generation that can be consumed by the various TCLs through optimal building load utilization. Second, a quadratic optimization problem based on model predictive control is formulated to allow consuming most of the low and medium frequency content of the PV power locally by building TCLs, while maintaining occupants’ comfort and TCLs’ physical constraints. The solution to the proposed optimization problem is achieved using optimal control strategies. Numerical results show that most of the low and medium frequency content of the PV generation can be consumed locally by building TCLs. The remaining high-frequency content of the PV generation can then be stored/offset using energy storage systems.
Optimal Power Management for Large-Scale Battery Energy Storage Systems via Bayesian Inference
Large-scale battery energy storage systems (BESS) have found ever-increasing use across industry and society to accelerate clean energy transition and improve energy supply reliability and resilience. However, their optimal power management poses significant challenges: the underlying high-dimensional nonlinear nonconvex optimization lacks computational tractability in real-world implementation, and the uncertainty of the exogenous power demand makes exact optimization difficult. This paper presents a new solution framework to address these bottlenecks. The solution pivots on introducing power-sharing ratios to specify each cell’s power quota from the output power demand. To find the optimal power-sharing ratios, we formulate a nonlinear model predictive control (NMPC) problem to achieve power-loss-minimizing BESS operation while complying with safety, cell balancing, and power supply-demand constraints. We then propose a parameterized control policy for the power-sharing ratios, which utilizes only three parameters, to reduce the computational demand in solving the NMPC problem. This policy parameterization allows us to translate the NMPC problem into a Bayesian inference problem for the sake of 1) computational tractability, and 2) overcoming the nonconvexity of the optimization problem. We leverage the ensemble Kalman inversion technique to solve the parameter estimation problem. Concurrently, a low-level control loop is developed to seamlessly integrate our proposed approach with the BESS to ensure practical implementation. This low-level controller receives the optimal power-sharing ratios, generates output power references for the cells, and maintains a balance between power supply and demand despite uncertainty in output power. We conduct extensive simulations and experiments on a 20-cell prototype to validate the proposed approach.
A modeling framework for optimal energy management of a residential building
Residential buildings are currently equipped with energy production facilities, e.g., solar rooftops and batteries, which in conjunction with smart meters, can function as smart energy hubs coordinating the loads and the resources in an optimal manner. This paper presents a mathematical model for the optimal energy management of a residential building and proposes a centralized energy management system (CEMS) framework for off-grid operation. The model of each component of the hub is integrated within the CEMS. The optimal decisions are determined in real-time by considering these models with realistic parameter settings and customer preferences. Model predictive control (MPC) is used to adapt the optimal decisions on a receding horizon to account for the deviations in the system inputs. Simulation results are presented to demonstrate the feasibility and effectiveness of the proposed CEMS framework. Results show that the proposed CEMS can reduce the energy cost and energy consumption of the customers by approximately 17% and 8%, respectively, over a day. In conclusion, using the proposed CEMS, the total charging cycles of the ESS were reduced by more than 50% in a day.
Economy analysis of second-life battery in wind power systems considering battery degradation in dynamic processes: Real case scenarios
Energy storage system plays an important role in modern power systems for mitigating the variation and intermittency of renewable energy sources. The Lithium-ion battery is currently the most widely used solution for energy storage system. However, its high cost is considered as one of the major barriers hampering the integration of renewable energy and the adoption of electric vehicles. Reusing electric vehicle batteries seems a promising solution to the aforementioned problem. Based on a dynamic degradation model of Lithium-ion batteries, this paper first compares the profits that second-life and fresh batteries can bring to the wind farm. Model predictive control is adopted to solve an hourly optimal wind scheduling problem and maximize the profit of wind farm owner. Here, the optimal size of battery is determined and then the comparison of second-life and fresh batteries is conducted taking the battery degradation, the profit of the wind farm owner, and various remaining capacities of battery into account. Two case studies in USA and Denmark are conducted and the analysis shows that given the current prices of wind energy and Lithium-ion batteries, reusing batteries is not worthwhile for the studied wind farms, but it may outperform fresh batteries in the future if the wind energy price decreases much faster than the battery price.
Data-driven predictive probability density function control of fiber length stochastic distribution shaping in refining process
Pulp is the most important raw material in paper in paper industries, whose Fiber Length Stochastic Distribution (FLSD) shaping directly determines the energy consumption and paper quality of the subsequent papermaking processes. However, the mean and variance are insufficient to describe the output FLSD shaping, which display non-Gaussian distribution properties. Therefore, the traditional control, method based on the mean and variance of fiber length is difficult to control the FLSD shaping effectively. In this paper, a novel data-driven predictive probability density function (PDF) control method is proposed for output FLSD shaping in refining process. Primarily, in order to improve the approximation accuracy of the PDF employing RBF neural network, the parameters (center value and width) of each RBF basis functions are tuned via utilizing iterative learning control (ILC) law, and the corresponding estimations of weights law can be obtained. Secondly, considering that the conventional linear model of weights vector has drawbacks of low accuracy and weak generalization ability, random vector functional link networks (RVFLNs) based data driven nonlinear modelling method is employed to characterize the prediction model between the input variables and weights vector. Finally, in order to reduce the randomness of the output FLSD, a minimum entropy control method under mean constraint is employed to design the predictive PDF controller for the output FLSD shaping with the help of the established nonlinear stochastic distribution model. Both simulations and experiments are given to illustrate the effectiveness and practicability of the proposed method.
Equation-based languages – A new paradigm for building energy modeling, simulation and optimization
Most of the state-of-the-art building simulation programs implement models in imperative programming languages. This complicates modeling and excludes the use of certain efficient methods for simulation and optimization. In contrast, equation-based modeling languages declare relations among variables, thereby allowing the use of computer algebra to enable much simpler schematic modeling and to generate efficient code for simulation and optimization. We contrast the two approaches in this paper. We explain how such manipulations support new use cases. In the first of two examples, we couple models of the electrical grid, multiple buildings, HVAC systems and controllers to test a controller that adjusts building room temperatures and PV inverter reactive power to maintain power quality. In the second example, we contrast the computing time for solving an optimal control problem for a room-level model predictive controller with and without symbolic manipulations. As a result, exploiting the equation-based language led to 2, 200 times faster solution
A general infrastructure for data-driven control design and implementation in tokamaks
A general infrastructure for tokamak controllers based on data-driven neural net models is presented. The paradigm allows for more flexible choices of both the underlying model and the desired controlled variables and targets. The system is implemented and tested on the DIII-D tokamak, enacting simultaneous pressure and temperature control via a finite-set model-predictive controller. Traditional control methods such as proportional–integral–derivative (PID) have proven effective for decoupled control tasks, but scale poorly when trying to achieve more complicated goals such as full state control. This is exactly where model-based controllers succeed.
Current-Source Solid-State DC Transformer Integrating LVDC Microgrid, Energy Storage, and Renewable Energy Into MVDC Grid
Solid-state DC transformer to integrate low-voltage DC (LVDC) microgrid, wind turbine (WT) generator, photovoltaic (PV), and energy storage (ES) into medium-voltage (MV) direct-current (MVDC) distribution grids is attractive. This paper proposes current-source DC solid-state transformer (SST) for MVDC collection system in WT, PV, and ES farms or as an interface between the MVDC grid and the LVDC microgrid. Compared to conventional current-source converter (CSC) based SSTs, a switch reduction scheme on reverse-blocking device bridges is proposed to reduce device count and the number of devices on the DC-link current path. Importantly, the proposed switch reduction scheme is generic and can be applied to the DC ports of DC-AC, AC-DC, or DC-DC hard-switching or soft-switching CSC-based SSTs. Based on this scheme, the proposed current-source DC SSTs are derived, which have reduced electrolytic-capacitor-less DC-link. The proposed DC SSTs also achieve single-stage isolated DC-DC or DC-AC conversion, full-range zero-voltage switching (ZVS) for main switches, zero-current switching (ZCS) for resonant switches, and controlled dv/dt. The proposed DC SSTs, operating principles, predictive control method, the ZVS, and the controlled dv/dt under voltage buck-boost ranges are verified with MV simulations and an experimental prototype based on SiC MOSFETs, diodes, and a nanocrystalline transformer.
Experimental Performance of a Nonlinear Control Strategy to Regulate Temperature of a High-Temperature Solar Reactor
Abstract Despite the significant potential of solar thermochemical process technology for storing solar energy as solid-state solar fuel, several challenges have made its industrial application difficult. It is important to note that solar energy has a transient nature that causes instability and reduces process efficiency. Therefore, it is crucial to implement a robust control system to regulate the process temperature and tackle the shortage of incoming solar energy during cloudy weather. In our previous works, different model-based control strategies were developed namely a proportional integral derivative controller (PID) with gain scheduling and adaptive model predictive control (MPC). These methods were tested numerically to regulate the temperature inside a high-temperature tubular solar reactor. In this work, the proposed control strategies were experimentally tested under various operation conditions. The controllers were challenged to track different setpoints (500 °C, 1000 °C, and 1450 °C) with different amounts of gas/particle flowrates. Additionally, the flow controller was tested to regulate the reactor temperature under a cloudy weather scenario. The ultimate goal was to produce 5 kg of reduced solar fuel magnesium manganese oxide (MgMn2O4) successfully, and the controllers were able to track the required process temperature and reject disturbances despite the system's strong nonlinearity. The experimental results showed a maximum error in the temperature setpoint of less than 0.5% (6 °C), and the MPC controller demonstrated superior performance in reducing the control effort and rejecting disturbances.
OpenFacadeControl: enabling integration of automated facades with other building systems
Automated facades are, for the most part, still considered as separate from other building systems throughout the design, installation, commissioning, operation, and maintenance cycle. This takes place despite the fact that their energy and comfort performance are deeply interlinked with the operation of lighting and HVAC systems. Over the last two decades, research has shown that there are significant advantages from operating facades as an integrated system with the rest of the building. Nevertheless, significant barriers prevent this type of integration becoming more common. One of them is the lack of a platform that is inexpensive to implement and that easily allows the practical implementation of integrated control algorithms across fenestration and other building systems, using a variety of communications protocols. This is particularly challenging when automated facades are installed in existing buildings, where interaction with legacy building systems that were installed over the past lifetime of the building can require a high degree of interoperability. OpenFacadeControl (OFC) is an open-source controls framework aimed at unified control of facades and other building systems, including the sharing of third-party sensor information. Through leveraging the Volttron controls platform, it allows the integration of systems and sensors that are manufactured by different companies and that use different communications protocols into an ensemble that functions as a single system. OFC is designed to enable integrated control algorithms of varying degrees of complexity, ranging from simple, heuristic controls to more sophisticated approaches like model-predictive control. Use of a research version to test advanced lighting and shading strategies in a full-scale experimental testbed has demonstrated the ease of deploying advanced control solutions using OpenFacadeControl. This paper presents the structure of OpenFacadeControl and a demonstration case showing the use of OFC in laboratory tests of advanced lighting and fenestration controls that coordinated motorized shades communicating via the BACnet building communications standard and lights communicating via internet-protocol-based application programming interface (API), based on the readings of a shared light level sensor communicating via a different API.
Optimal control system design of an acid gas removal unit for an IGCC power plants with CO2 capture
Future IGCC plants with CO{sub 2} capture should be operated optimally in the face of disturbances without violating operational and environmental constraints. To achieve this goal, a systematic approach is taken in this work to design the control system of a selective, dual-stage Selexol-based acid gas removal (AGR) unit for a commercial-scale integrated gasification combined cycle (IGCC) power plant with pre-combustion CO{sub 2} capture. The control system design is performed in two stages with the objective of minimizing the auxiliary power while satisfying operational and environmental constraints in the presence of measured and unmeasured disturbances. In the first stage of the control system design, a top-down analysis is used to analyze degrees of freedom, define an operational objective, identify important disturbances and operational/environmental constraints, and select the control variables. With the degrees of freedom, the process is optimized with relation to the operational objective at nominal operation as well as under the disturbances identified. Operational and environmental constraints active at all operations are chosen as control variables. From the results of the optimization studies, self-optimizing control variables are identified for further examination. Several methods are explored in this work for the selection of these self-optimizing control variables. Modifications made to the existing methods will be discussed in this presentation. Due to the very large number of candidate sets available for control variables and due to the complexity of the underlying optimization problem, solution of this problem is computationally expensive. For reducing the computation time, parallel computing is performed using the Distributed Computing Server (DCS®) and the Parallel Computing® toolbox from Mathworks®. The second stage is a bottom-up design of the control layers used for the operation of the process. First, the regulatory control layer is designed followed by the supervisory control layer. Finally, an optimization layer is designed. In this paper, the proposed two-stage control system design approach is applied to the AGR unit for an IGCC power plant with CO{sub 2} capture. Aspen Plus Dynamics® is used to develop the dynamic AGR process model while MATLAB is used to perform the control system design and for implementation of model predictive control (MPC).
System and method for operator control of heterogeneous unmanned system teams
A control architecture and associated control methods are under development to allow a single user to control a team of multiple heterogeneous UMS as they conduct multi-faceted (i.e. multi-objective) missions in real time is disclosed. The control architecture is hierarchical, modular and layered and enables operator interaction at each layer, ensuring the human operator is in close control of the unmanned team at all times. The architecture and key data structures are introduced. Two approaches to distributed collaborative control of heterogeneous unmanned systems are described, including an extension of homogeneous swarm control and a novel application of distributed model predictive control. Initial results are presented, demonstrating heterogeneous UMS teams conducting collaborative missions.
Laboratory Evaluation of Federated, Hierarchical Controls for Distribution Power System Management: Preprint
The connection of more loads and distributed energy resources (DERs) to the distribution power system brings both challenges and opportunities to system operators. There are opportunities to aggregate flexible loads and DERs to provide transmission grid services, but the coordinated actions of DERs being managed by independent, third-party DER aggregators to support transmission system operations can present challenges. We developed a federated DER management architecture and control framework that aims to manage heterogeneous DERs to deliver reliable transmission grid services while respecting distribution system constraints. The controls include stochastic day-ahead optimization, model predictive control, and a simple real-time management scheme. We present simulation results obtained from a realistic laboratory test bed of federated controls managing DERs within a substation service area to make the substation net power follow the optimal net power determined by the day-ahead optimization based on cost and limiting reverse power flow.
Intelligent Process Visualization through Nuclear Operation Process Modeling, Reasoning, and Object Detection from Field Videos (Final Report)
This report is a deliverable for the “Final Report” task of DOE NEET Project 19-16790, "Context-Aware Safety Information Display for Nuclear Field Workers." This project's overall goal is to test the hypothesis that integrating computer vision and process reasoning methods will enable proactive visualization of the safe operation and maintenance processes of Nuclear Power Plants (NPP) for field workers. Augmented Reality (AR) glasses adopting such proactive safety information visualization techniques can significantly increase personnel safety and reduce the NPP’s operating costs. The current practice of monitoring NPPs requires workers to switch between digital models, data, and physical workspaces in identifying relevant but potentially occluded objects and in assessing the risks of operation and maintenance processes. On the other hand, frequently changed field conditions require field workers to report to supervisors for real-time guidance. Such guidance is essential to ensure that changing conditions will not invalidate or endanger the work order and other ongoing processes that may jeopardize NPP operations. Additionally, incorrect recognition of equipment objects can result in communication errors and safety problems. AR techniques can assist engineers in viewing the physical workspaces with objects labeled with detailed operation procedures and safety reminders during field operations. The project team developed an “Intelligent Context-Aware Safety Information Display” (ICAD) for supporting Nuclear Power Plant (NPP) field workers in achieving safe and efficient execution of a series of operational tasks in uncertain and changing workspaces of an NPP. Before designing the ICAD-AR prototype, the project team synthesized NPP operational knowledge models through literature review studies, surveys, interviews with domain experts, and knowledge modeling. The project team conducted an extensive study of the operational procedures of various NPPs, and digital technologies that can support the safe and efficient execution of those procedures in different NPP operational contexts. This literature review helped the project team conduct surveys and interviews with nuclear engineers and field workers to identify three categories of information. The NPP knowledge modeling efforts reveal that the three categories of information identified have different levels of importance in a typical procedure of carrying out a series of tasks to achieve a specific NPP operation goal (e.g., shutdown, mode changes). These three categories of information include 1) Workspace dynamics – the changing spatial arrangements of workspaces, tools, protection equipment, and supporting materials, 2) Workflow prognostics – the dynamic dependencies between different parts of an NPP that functionally support and influence each other in terms of safety and efficiency, and 3) Hazards – objects and spaces that contain hazardous materials or physical conditions that can pose risks to workers or mechanical systems. The project team has profiled the importance levels of these categories of information into a knowledge model. This knowledge model specifies what types of information are more critical for a given task in a given workspace so that computers can automatically identify critical objects and sensors in a scene for delivering context-ware safety information to field workers through AR devices. Significant research development of this project results in technical research outcomes and a prototyping system that illustrates the technical feasibility of establishing an ICAD-AR system supporting the proactive safety information display for nuclear field workers. This final report summarizes the project team’s technological achievements in the past three years. Overall, the project team completed the development and integration of five techniques into a prototype ICAD Augmented Reality (ICAD-AR) system and demonstrated the developed system’s real-time execution in a mechanical room. The project team completed the analysis of using this prototype in other types of workspaces based on 3D image data and digital design models collected from two additional workspaces (a water treatment plant and a flow loop training facility). The integrated techniques include 1) Natural Language Processing (NLP) algorithms supporting the generation and updates of nuclear fieldwork process models based on text analysis of work packages and operation manuals; 2) sensor log analysis for predicting control actions in given sensor reading contexts; 3) computer vision algorithms for automatic localization and navigation of workers; 4) object detection algorithms for identifying task-related objects and correlated sensors for safety checking; 5) AR technique as a platform for supporting the integration. The testing results of these five techniques have shown that 1) the sensor log analysis model can predict the next control action with an accuracy of 0.883; 2) the trained natural language processing model can extract more than 80% of the critical information from paper-based procedures (PBPs); 3) the navigation algorithm with the integration of Visual Inertial Odometry (VIO) and Non-Recursive Bayesian Filter methods make operator’s trajectory estimation resilient to drift error; 4) the computer vision algorithm can detect task-specific and safety-critical objects with an average accuracy of 95.3%. The project team used work procedures collected from a flow loop training facility and two datasets collected from two mechanical rooms simulating the workspaces of NPPs to demonstrate the technical capabilities of the developed ICAD-AR prototype. The demonstration validated the technical feasibility of establishing the ICAD-AR system for nuclear field workers and identified the challenges in 1) automatic text analysis of work packages; 2) use of limited samples of sensor logs for predicting the proper timings of control actions; 3) reliably tracking workers and their task progress in mechanical rooms with many similar objects.
An encoder–decoder LSTM-based EMPC framework applied to a building HVAC system
Numerous studies have demonstrated the benefit of economic model predictive control (EMPC) applied to building heating, ventilation, and air conditioning (HVAC) systems. However, the construction and training of predictive models for building HVAC systems are widely recognized as a key technological barrier preventing large-scale adoption of EMPC for buildings. In this work, an encoder–decoder long short-term memory-based EMPC framework is developed. The key advantage of the approach is that a model may be automatically generated from a list of inputs and outputs. From the definition of inputs and outputs, the constructed model may be trained and automatically embedded into the EMPC framework for real-time estimation and control. The overall end-to-end EMPC framework from model training to on-line estimation and control are described. To this end, the encoder–decoder model provides a natural framework for state estimation (encoder), which is required to provide an initial condition for the predictive model of EMPC (decoder). Closed-loop simulations using EnergyPlus are performed to demonstrate the approach. The simulated closed-loop system consists of a building zone from a multi-zone building, which is served by an air handling unit-variable air volume HVAC system. For the HVAC example considered, the trained encoder–decoder model can predict the indoor air temperature and HVAC sensible cooling rate of a building zone over a two-day horizon with high accuracy. Overall, we find that considering a time-of-use electric rate structure, the EMPC, which manipulates the zone temperature setpoint, can reduce the HVAC power consumption cost relative to keeping the zone temperature setpoint at its maximum value (i.e., minimum energy approach).