On-line optimization of the Tennessee Eastman challenge process

A real-time optimization (RTO) strategy that eliminates the steady-state-wait requirement of conventional RTO is described. To ensure its success, four critical components-dynamic modeling, online parameter and state estimation, a plant-wide control system, and an optimization algorithm-must be well coordinated. It is especially effective when conventional RTO cannot be used, and sustained disturbances occur on a time scale that is close to the plant response time. This strategy was applied to the Tennessee Eastman challenge process, a process involving separation and compression (Downs and Vogel, “A plant-wide industrial process control problem,” Computers and Chemical Engineering, vol.17, no.3, p.245-55, 1993). RTO saved up to 6% of the operating cost relative to the cases without RTO