Model Predictive Control of CMSMPR Crystalliser

Abstract

One of the most critical components of the chemical industry in terms of crystallisation is the pharmaceutical sector. Most medicine components are expensive and require complex processes for their production, so producing waste is highly inefficient. Another concern is the high-quality standards for most pharmaceutical products. Therefore, optimising the crystallisation process is critical from a quality perspective, with the main concerns being the product's crystal structure and particle diameter distribution. Regardless efficient control in batch processes such as crystallisation is a difficult task due to the inherently nonlinear behaviour of the system. Using a priori model of the system as the basis for nonlinear model predictive control could provide a useful tool for handling the crystallisation process, mitigating the effects of disturbance and noise and ensuring appropriate product quality. In this work, we wish to showcase the possibility of controlling a crystallisation process using model predictive control to enable the production of crystal products with desired particle diameter distribution and crystalline product average size. The method is shown using citric acid as a model substance in a case study of a continuous crystallisation procedure in a stirred tank reactor. The crystalliser model includes an energy balance, so the system's behaviour depends on the cooling rate and residence time. Accordingly, the control problem can be formulated as multiple inputs and multiple outputs (MIMO) system. Moreover, the two controlled (average particle size and crystal size dispersion) variables are not easily detached from each other. So, the traditional controlling strategies, for example, the decoupling controller, is challenging to apply. The MPC (model predictive control) as an advanced control algorithm can be a solution to this.