Applications of the existing steady-state plant-wide optimization and the single-scale fast-rate dynamic optimization strategies to an integrated plant with material recycle have been impeded by several factors. While the steady-state optimization formulation is very simple, the very long transient dynamics of an integrated plant have limited the optimizers execution rate to be extremely low, yielding a suboptimal performance. In contrast, performing dynamic plant-wide optimization at the same rate as local controllers requires exorbitant on-line computational load and may increase the sensitivity to high-frequency dynamics that are irrelevant to the plant-level interactions, which are slow-scale in nature. This thesis proposes a novel multi-scale dynamic optimization and control strategy suitable for an integrated plant. The dynamic plant-wide optimizer in this framework executes at a slow rate to track the slow-scale plant-wide interactions and economics, while leaving the local controllers to handle fast changes related to the local units. Moreover, this slow execution rate demands less computational and modeling requirement than the fast-rate optimizer. An important issue of this method is obtaining a suitable dynamic model when first-principles are unavailable. The difficulties in the system identification process are designing proper input signal to excite this ill-conditioned system and handling the lack of slow-scale dynamic data when the plant experiment cannot be conducted for a long time compared to the settling time. This work presents a grey-box modeling method to incorporate steady-state information to improve the model prediction accuracy. A case study of an integrated plant example is presented to address limitations of the nonlinear model predictive control (NMPC) in terms of the on-line computation and its inability to handle stochastic uncertainties. Then, the approximate dynamic programming (ADP) framework is investigated. This method computes an optimal operating policy under uncertainties off-line. Then, the on-line multi-stage optimization can be transformed into a single-stage problem, thus reducing the real-time computational effort drastically. However, the existing ADP framework is not suitable for an integrated plant with high dimensional state and action space. In this study, we combine several techniques with ADP to apply nonlinear optimal control to the integrated plant example and show its efficacy over NMPC.

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