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In the chemical or biochemical industry most processes are modeled by nonlinear equations. It is of a great significance to design high-performance nonlinear controllers for efficient control of these nonlinear processes to achieve closed-loop system's stability and high performance. However, there are many difficulties which hinder the design of such controllers due mainly to the process nonlinearity. In this work, comprehensive design procedures based on robust control have been proposed to efficiently deal with the design of gain-scheduled controllers for nonlinear systems. Since all the design procedures proposed in this work rely strongly on the process model, the first difficulty addressed in this thesis is the identification of a relatively simple model of the nonlinear processes under study. The nonlinearity of the processes makes it often difficult to obtain a first-principles model which can be used for analysis and design of the controller. As a result, relatively simple empirical models, Volterra series model and state-affine model, are chosen in this work to represent the nonlinear process for the design of controllers. The second major difficulty is that although the nonlinear models used in this thesis are easy to identify, the analysis of stability and performance for such models using nonlinear control theory is not straightforward. Instead, it is proposed in this study to investigate the stability and performance using a robust control approach. In this approach, the nonlinear model is approximated by a nominal linear model combined with a mathematical description of model error to be referred to, in this work, as model uncertainty. In the current work it was assumed that the main source of uncertainty with respect to the nominal linear model is due to the system nonlinearity. Then, in this study, robust control theoretical tools have been especially developed and applied for the design of gain-scheduled Proportional-Integral (PI) control and gain-scheduled Model Predictive Control (MPC). Gain-scheduled controllers are chosen because for nonlinear processes operated over a wide range of operation, gain-scheduling has proven to be a successful control design technique (Bequette, 1997) for nonlinear processes. To guarantee the closed-loop system's robust stability and performance with the designed controllers, a systematic approach has been proposed for the design of robust gain-scheduled controllers for nonlinear processes. The design procedure is based on robust stability and performance conditions proposed in this work. For time-varying uncertain parameters, robust stability and performance conditions using fixed Lyapunov functions and parameter-dependent Lyapunov functions, were used. Then, comprehensive procedures for the design and optimization of robust gain-scheduled PI and MPC controllers tuning parameters based on the robust stability and performance tests are then proposed. Since the closed-loop system represented by the combination of a state-affine process model and the gain-scheduled controller is found to have an affine dependence on the uncertain parameters, robust stability and performance conditions can be tested by a finite number of Linear Matrix Inequalities (LMIs). Thus, the final problems are numerically solvable. One of the inherent problems with robust control is that the design is conservative. Two approaches have been proposed in this work to reduce the conservatism. The first one is based on parameter-dependent Lyapunov functions, and it is applied when the rate of change of the time-varying uncertainty parameters is <i>a priori</i> available. The second one is based on the relaxation of an input-saturation factor defined in the thesis to deal with the issue of actuator saturation. Finally, to illustrate the techniques discussed in the thesis, robust gain-scheduled PI and MPC controllers are designed for a continuous stirred tank reactor (CSTR) process. A simple MIMO example with two inputs and two outputs controlled by a multivariable gain-scheduled MPC controller is also discussed to illustrate the applicability of the methods to multivariable situations. All the designed controllers are simulated and the simulations show that the proposed design procedures are efficient in designing and comparing robust gain-scheduled controllers for nonlinear processes.

In the chemical or biochemical industry most processes are modeled by nonlinear equations. It is of a great significance to design high-performance nonlinear controllers for efficient control of these nonlinear processes to achieve closed-loop system's stability and high performance. However, there are many difficulties which hinder the design of such controllers due mainly to the process nonlinearity. In this work, comprehensive design procedures based on robust control have been proposed to efficiently deal with the design of gain-scheduled controllers for nonlinear systems. Since all the design procedures proposed in this work rely strongly on the process model, the first difficulty addressed in this thesis is the identification of a relatively simple model of the nonlinear processes under study. The nonlinearity of the processes makes it often difficult to obtain a first-principles model which can be used for analysis and design of the controller. As a result, relatively simple empirical models, Volterra series model and state-affine model, are chosen in this work to represent the nonlinear process for the design of controllers. The second major difficulty is that although the nonlinear models used in this thesis are easy to identify, the analysis of stability and performance for such models using nonlinear control theory is not straightforward. Instead, it is proposed in this study to investigate the stability and performance using a robust control approach. In this approach, the nonlinear model is approximated by a nominal linear model combined with a mathematical description of model error to be referred to, in this work, as model uncertainty. In the current work it was assumed that the main source of uncertainty with respect to the nominal linear model is due to the system nonlinearity. Then, in this study, robust control theoretical tools have been especially developed and applied for the design of gain-scheduled Proportional-Integral (PI) control and gain-scheduled Model Predictive Control (MPC). Gain-scheduled controllers are chosen because for nonlinear processes operated over a wide range of operation, gain-scheduling has proven to be a successful control design technique (Bequette, 1997) for nonlinear processes. To guarantee the closed-loop system's robust stability and performance with the designed controllers, a systematic approach has been proposed for the design of robust gain-scheduled controllers for nonlinear processes. The design procedure is based on robust stability and performance conditions proposed in this work. For time-varying uncertain parameters, robust stability and performance conditions using fixed Lyapunov functions and parameter-dependent Lyapunov functions, were used. Then, comprehensive procedures for the design and optimization of robust gain-scheduled PI and MPC controllers tuning parameters based on the robust stability and performance tests are then proposed. Since the closed-loop system represented by the combination of a state-affine process model and the gain-scheduled controller is found to have an affine dependence on the uncertain parameters, robust stability and performance conditions can be tested by a finite number of Linear Matrix Inequalities (LMIs). Thus, the final problems are numerically solvable. One of the inherent problems with robust control is that the design is conservative. Two approaches have been proposed in this work to reduce the conservatism. The first one is based on parameter-dependent Lyapunov functions, and it is applied when the rate of change of the time-varying uncertainty parameters is <i>a priori</i> available. The second one is based on the relaxation of an input-saturation factor defined in the thesis to deal with the issue of actuator saturation. Finally, to illustrate the techniques discussed in the thesis, robust gain-scheduled PI and MPC controllers are designed for a continuous stirred tank reactor (CSTR) process. A simple MIMO example with two inputs and two outputs controlled by a multivariable gain-scheduled MPC controller is also discussed to illustrate the applicability of the methods to multivariable situations. All the designed controllers are simulated and the simulations show that the proposed design procedures are efficient in designing and comparing robust gain-scheduled controllers for nonlinear processes.

Two application applications of Fuzzy Logic to improve the performance of two controllers are presented. The first application takes a Sliding Mode Controller designed for chemical process to reject disturbances. A fuzzy element is added to the sliding surface to improve the controller performance when set point change affects the control loop; especially for process showing highly nonlinear behavior. This fuzzy element, , is calculated by means of a set of fuzzy rules designed based on expert knowledge and experience. The addition of improved the controller response because accelerate or smooth the controller as the control loop requires. The Fuzzy Sliding Mode Controller (FSMCr) is a completely general controller. The FSMCr was tested with two models of nonlinear process: mixing tank and neutralization reactor. In both cases the FSMCr improves the performance shown for other control strategies, as the industrial PID, the conventional Sliding Mode Control and the Stan dard Fuzzy Logic Controller. The second part of this research presents a new way to implement the Dynamic Matrix Control Algorithm (DMC). A Parametric structure of DMC (PDMC) control algorithm is proposed, allowing to the controller to adapt to process nonlinearities. For a standard DMC a process model is used to calculate de controller response. This model is a matrix calculated from the dynamic response of the process at open loop. In this case the process parameters are imbibed into the matrix. The parametric structure isolates the process parameters allowing adjust the model as the nonlinear process changes its behavior. A Fuzzy supervisor was developed to detect changes in the process and send taht [sic]information to the PDMCr. The modeling error and other parameters related were used to estimate those changes. Some equations were developed to calculate the PDMCr tuning parameter,lambda, as a function of the process parameters. The performance of PDMCr was tested using to model of nonlinear process and compare with the standard DMC; in most the cases PDMCr presents less oscillations and tracks with less error the set point. Both control strategies presented in this research can be implemented into industrial applications easily.

The standardization of operational procedures in chemical plants through the use of automation have became a mandatory practice for the current companies that tries or have tried a place in the commodities competitive stock. Real gains in productivity and recovery are closely related to controller s performance used in chemical process of this companies. There are a several controllers strategies in which the predictive control is a powerful tool that shows attractive results. The use of predictive control is achieved by the implementation of the control strategy in a pilot plant of a MIMO (Multiple-Input Multiple-Output) non-linear process. The nonlinear process is a experimental system of a neutralization reactor with three input flows and one output flow, and the manipulated variable are the level of reactor and the pH of mixture. The input flows are one of acid, one of base and one of buffer solution and this are the controlled variables. The information used to controller project was obtained in a open loop procedure. In this procedure, it was made disturbances in input variable and watched the output variable behavior. The MPC ( Model Predictive Control) performance was tested in a simulation and after in the pilot plant. The results achieved in simulation and practice implementation shows the excellent performance of controller to the process. / A padronização dos procedimentos operacionais nas plantas químicas através do emprego de automação vem tornando-se uma prática obrigatória para as atuais empresas que ocupam ou tentam ocupar um lugar de destaque no competitivo mercado de commodities. Ganhos reais de produtividade e recuperação estão intimamente associados ao desempenho dos controladores utilizados nos processos químicos destas empresas. Dentre as diversas estratégias de controle existentes, o controle preditivo corresponde a uma poderosa ferramenta que apresenta resultados bastante atrativos. Este trabalho investiga a aplicação prática de controle preditivo em uma planta piloto representativa de processos não-lineares MIMO (Multiple-Input Multiple-Output). O processo não-linear é um sistema experimental composto por um reator de neutralização com três correntes de entrada e uma de saída, sendo que as variáveis manipuladas correspondem ao nível do tanque e ao pH da mistura. As correntes de entrada são uma de ácido, uma de base e uma de solução tampão e correspondem às variáveis controladas. Informações necessárias para o projeto do controlador foram coletadas através do procedimento de operação em malha aberta, no qual provocou-se pertubações nas variáveis de entrada e observou-se o comportamento das variáveis de saída. O desempenho do controlador MPC (Model Predictive Control) proposto foi inicialmente avaliado em simulação e posteriormente na planta piloto. Os resultados obtidos na simulação e na implementação prática comprovam o excelente desempenho do controlador para o processo em estudo. / Mestre em Engenharia Química