Advanced PID Control Optimisation and System Identification for Multivariable Glass Furnace Processes by Genetic Algorithms

This thesis focuses on the development and analysis of general methods for the design of optimal discrete PID control strategies for multivariable glass furnace processes, where standard genetic algorithms (SGAs) are applied to optimise specially formulated objective functions. Furthermore, a strong emphasis is given on the realistic model parameters identi cation method, which is illustrated to be applicable to a wide range of higher order model parameters identi cation problems. A complete, realistic and continuous excess oxygen model with nonlinearity effect was developed and the model parameters were identified. The developed excess oxygen model consisted of three sub-models to characterise the real plant response. The developed excess oxygen model was evaluated and compared with real plant dynamic response data, which illustrated the high degree of accuracy of the developed model. A new technique named predetermined time constant approximation was proposed to make an assumption on the initial value of a predetermined time constant, whose motive is to facilitate the SGAs to explore and exploit an optimal value for higher order of continuous model's parameters identi cation. Also, the proposed predetermined time constant approximation technique demonstrated that the population diversity is well sustained while exploring the feasible search region and exploiting to an optimal value. In general, the proposed method improves the SGAs convergence rate towards the global optimum and illustrated the effectiveness. An automatic tuning of decentralised discrete PID controllers for multivariable processes, based on SGAs, was proposed. The main improvement of the proposed technique is the ability to enhance the control robustness and to optimise discrete PID parameters by compensating the loop interaction of a multivariable process. This is attained by adding the individually optimised objective function of glass temperature and excess oxygen processes as one objective function, to include the total effect of the loop interaction by applying step inputs on both set points, temperature and excess oxygen, at two different time periods in one simulation. The effectiveness of the proposed tuning technique was supported by a number of simulation results using two other SGAs conventional tuning techniques with 1st and 2nd order control oriented models. It was illustrated that, in all cases, the resulting discrete PID control parameters completely satisfied all performance specifications. A new technique to minimise the fuel consumption for glass furnace processes while sustaining the glass temperature is proposed. This proposed technique is achieved by reducing the excess oxygen within the optimum thermal efficiency region within 1.7% to 3.2%, which is approximately equal to about 10% to 20% of excess air. Therefore, by reducing the excess oxygen set point within the optimum region, 2.45% to 2%, the fuel consumption is minimised from 0:002942kg/sec to 0:002868kg/sec while the thermal efficiency of the glass temperature is sustained at the desired set point (1550K). In addition, a reduction in excess oxygen within methane combustion guidelines will assure that undesirable emissions are in control throughout the combustion process. The efficiencies of the proposed technique were supported by a number of simulation results applying the three SGAs controller tuning techniques. It was illustrated that, in all cases, the fraction of excess oxygen reduction results in a great minimisation of fuel consumption over long plant operating periods.