A heat-exchanger/reactor (HEX reactor) is a kind of plug-flow chemical reactor which combines high heat transfer ability and chemical performance. It is a compact reactor designed under the popular trend of process intensification in chemical engineering. Previous studies have investigated its characteristics experimentally. This paper aimed to develop a general numerical model of the HEX reactor for further control and diagnostic use. To achieve this, physical structure and hydrodynamic and thermal performance were studied. A typical exothermic reaction, which was used in experiments, is modeled in detail. Some of the experimental data without reaction were used for estimating the heat transfer coefficient by genetic algorithm. Finally, a non-linear numerical model of 255 calculating modules was developed on the Matlab/Simulink platform. Simulations of this model were done under conditions with and without chemical reactions. Results were compared with reserved experimental data to show its validity and accuracy. Thus, further research such as fault diagnosis and fault-tolerant control of this HEX reactor could be carried out based on this model. The modeling methodology specified in this paper is not restricted, and could also be used for other reactions and other sizes of HEX reactors.

In the process of fault diagnosis and the health and safety operation evaluation of modern industrial processes, it is crucial to measure important state variables, which cannot be directly detected due to limitations of economy, technology, environment and space. Therefore, this paper proposes a data-driven soft sensor approach based on an echo state network (ESN) optimized by an improved genetic algorithm (IGA). Firstly, with an ESN, a data-driven model (DDM) between secondary variables and dominant variables is established. Secondly, in order to improve the prediction performance, the IGA is utilized to optimize the parameters of the ESN. Then, the immigration strategy is introduced and the crossover and mutation operators are changed adaptively to improve the convergence speed of the algorithm and address the problem that the algorithm falls into the local optimum. Finally, a soft sensor model of an ESN optimized by an IGA is established (IGA-ESN), and the advantages and performance of the proposed method are verified by estimating the alumina concentration in an aluminum reduction cell. The experimental results illustrated that the proposed method is efficient, and the error was significantly reduced compared with the traditional algorithm.

The heat-exchanger/reactor (HEX reactor) is a kind of plug-flow chemical reactor which combines high heat transfer ability with good chemical performances. It was designed under the popular trend of process intensification in chemical engineering. Previous studies have investigated its characteristics and developed its nominal model. This paper is concerned with its fault tolerant control (FTC) applications. To avoid the difficulties and nonlinearities of this HEX reactor under chemical reactions, a two-layer, multiple-model structure is proposed for designing the FTC scheme. The first layer focuses on representing the nonlinear system with a bank of local linear models while the second layer uses model banks for approaching faulty situations. Model banks are achieved by system identification, and the corresponding controller banks are designed using model predictive control (MPC). The unscented Kalman filter (UKF) is introduced to estimate the states and form the fault detection and isolation (FDI) section. Finally, the FTC simulation and validation results are presented. The idea of a two-layer, multiple-model structure presents a general framework for FTC design of complex and highly nonlinear systems, such as the HEX reactor, whose mathematical model has been created. It implements the design process in an unusual way and is also worth trying on other cases.

The problem of local fault (unknown input) reconstruction for interconnected systems is addressed in this paper. This contribution consists of a geometric method which solves the fault reconstruction (FR) problem via observer based and a differential algebraic concept. The fault diagnosis (FD) problem is tackled using the concept of the differential transcendence degree of a differential field extension and the algebraic observability. The goal is to examine whether the fault occurring in the low-level subsystem can be reconstructed correctly by the output at the high-level subsystem under given initial states. By introducing the fault as an additional state of the low subsystem, an observer based approached is proposed to estimate this new state. Particularly, the output of the lower subsystem is assumed unknown, and is considered as auxiliary outputs. Then, the auxiliary outputs are estimated by a sliding mode observer which is generated by using global outputs and inverse techniques. After this, the estimated auxiliary outputs are employed as virtual sensors of the system to generate a reduced-order observer, which is caplable of estimating the fault variable asymptotically. Thus, the purpose of multi-level fault reconstruction is achieved. Numerical simulations on an intensified heat exchanger are presented to illustrate the effectiveness of the proposed approach.

Modular multilevel converters (MMCs) play an important role in the power electronics industry due to their many advantages such as modularity and reliability. However, one of the challenges is to suppress fluctuations of circulating current and capacitor voltage and to ensure the quality of the output current. In this paper, the upper and lower arm voltages are employed as control inputs to control the output current and circulating current which are fed back to track the desired value. Based on linear matrix inequality (LMI), the control law of the MMC with multi-input system is designed to optimize the control value. The optimum arm voltage is divided by the SM nominal capacitor voltage to determine the number of SMs inserted into the upper/lower arm. The Voltage Sorting Algorithm (VSA) is then used to suppress the capacitor voltage fluctuation. The proposed tracking control strategy is implemented in MATLAB/Simulink. The results show that even under a small number of SMs (4 per arm), the output current can track the desired values and have better harmonic performance (current THD: 5.42%,voltage THD: 5.67%), and the fluctuations of the circulating current can be suppressed. Furthermore, it has better robustness and three-phase variable load fault tolerance.