Journal of Process Control 23 (2013) 664681

Contents lists available at SciVerse ScienceDirect

Journal of Process Control

journal homepage: www.elsevier.com/locate/jprocont

Modeling and advanced control method of PVC polymerization

process
Shu Zhi Gao a , Jie Sheng Wang b, , Xian Wen Gao c
a

School of Information and Engineering, Shenyang University of Chemical Technology, Liaoning, Shenyang 110142, China
School of Electronic and Information Engineering, University of Science & Technology Liaoning, Liaoning, Anshan 114044, China
c
School of Information Science and Engineering, Northeastern University, Liaoning, Shenyang 110819, China
b

a r t i c l e

i n f o

Article history:
Received 27 July 2012
Received in revised form
21 December 2012
Accepted 23 February 2013
Available online 9 April 2013
Keywords:
PVC polymerization process
TS fuzzy neural network
Principal component analysis
Soft sensor
Harmony search
Segmental afne model
Generalized predictive control

a b s t r a c t
Based on data driven modeling theory, PVC polymerization process modeling and intelligent optimization
control algorithm is studied. Firstly, a multi-TS fuzzy neural networks soft-sensing model combining
the principal component analysis (PCA) and fuzzy c-means (FCM) clustering algorithm is proposed to
predict the convention rate and velocity of Vinyle Chloride Monomer (VCM). The proposed hybrid learning
algorithm utilizing the harmony search (HS) and least square method is used to adjust the model premise
parameters and consequent parameters. Secondly, the generalized predictive control (GPC) algorithm
of polymerizer temperature based on segmental afne is proposed. According to dynamic equation of
polymerizer temperature deduced by heat balance mechanism, the segmental afne model is built by
temperature and convention rate of the polymerizer. Then linear matrix inequality (LMI) method is
used to design the controller. Finally, simulation results and industrial application show the validity and
feasibility of the proposed control strategy.
2013 Elsevier Ltd. All rights reserved.

1. Introduction
Polyvinylchloride (PVC) is one of the ve largest thermoplastic synthetic resins, and its production is second only to the polyethylene (PE)
and polypropylene (PP). PVC is a kind of general colophony, which is good in quality and is widely used. It has good mechanical properties,
anti-chemical properties and it is corrosion-resistant and difcult to burn. With vinyl chloride monomer (VCM) as a raw material, the
suspension method to produce polyvinyl chloride (PVC) resin is a kind of typical batch chemical production process. PVC polymerization
process is a complex control system with multi-variable, uncertain, nonlinear and strong coupling.
Domestic and foreign scholars have made many achievements on modeling, controlling and optimization of PVC polymerization process
[18]. In 2001, Piao and Chen designed a smith-fuzzy controller to conquer the great inertia and time-delay of polymerization kettle [1].
In 2003, Yu and Dong added the double adjustment factors in the fuzzy controller of the polymerization kettle temperature, which can
on-line adjust the fuzzy rules dynamically [2]. Asua in Australia applied the fuzzy logic technique to the temperature control of polymerizing kettle and achieved good control performance [3]. In 2003, Huzmezan and Dumont proposed an indirect self-adaptive predictive
control strategy based on the conventional PID controller by using Laguerre function identication and predictive control, which can
shorten the production period of polymerizing kettle, improve the production ability and successfully applied in twenty-ve polymerizing
production process [4]. In 2005, Wu and Zhang proposed a multi-model predictive control strategy on the PVC polymerizing kettle temperature control to achieve the satised application effect [5]. In 2006, Fu and Dai designed the traditional cascade structure controller by
utilizing the hybrid anti-windup PID control, forward feedback control and smith predictive control, which settled out the strong inertia
and big time-delay of the system [6]. In 2007, Yang and Zhang proposed the fuzzy controller connected with cascading PID algorithm
applied to the PVC production [7]. Marc-Andr Beyer and Wolfgang Grote proposed a self-adaptive controller composed of the nonlinear
differential geometry controller and the extended Kalman lter to effectively improve the controller performance in the case of model
mismatch [8].

Corresponding author. Tel.: +86 4125929699.

E-mail address: wang jiesheng@126.com (J.S. Wang).
0959-1524/$ see front matter 2013 Elsevier Ltd. All rights reserved.
http://dx.doi.org/10.1016/j.jprocont.2013.02.008

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665

Fig. 1. Flowchart of PVC polymerizer process.

The PVC polymerization process is an industrial process with mass transfer, heat transfer and complex chemical reaction. From the
control point of view, it has characters of nonlinear, stronger coupling, slow time-varying and large time-delay, which is a typically
complex industrial controlled object. A great deal of uncertainty information and diverse datum make it difcult to control effectively
with traditional control methods, while the advanced control methods provide effective way for this kind of the complex control problem.
The paper proposed a data-driven integrated modeling and intelligent control of PVC polymerization process. Simulation results show the
effectiveness of the proposed control strategy.
The paper is organized as follows. In Section 2, the PVC polymerizing process and the proposed advanced control strategy are introduced.
The soft-sensor model based on multi TS FNN optimized by HS algorithm is presented in Section 3. In Section 4, the GPC of PVC polymerizer
temperature based on piecewise afne is summarized. In Section 5, the application results of advanced control strategy in PVC polymerizing
process is introduced in details. Finally, the conclusion illustrates the last part.
2. Advanced control strategy of PVC polymerization process
2.1. PVC polymerization process
A owchart of the typical PVC polymerization kettle production process is shown in Fig. 1 [9].
In polyvinyl chloride (PVC) polymerizing process, all kinds of raw materials and auxiliary agents are placed into the reaction kettle. They
are fully and evenly dispersed under the function of stirring. Then, we begin to ventilate the cooling water to the clipset of the reaction
kettle and bafe plate constantly in order to remove homopolymer. When the conversion rate of VCM reaches a certain value, there is a
proper pressure drop. Then, the reactions are terminated and the nished product is created.
The discussed polymerizing reaction selects SG-5 as the example. 26 ton VCM is fed into the polymerization kettle. The conversion
rate is about 85%, the reaction temperature is 55.4 C and the heat released from PVC polymerizing reaction is 1600 kJ/kg. The important
parameters of polymerizing reaction process is shown in Table 1.

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Table 1
Polymerization parameters table.
Symbol

Physical meaning

Symbol

Physical meaning

HR
m0
mv
mp
Rc
Cw
Cp
Cv
Qj
Tj0
Tj
uj
Qb
Tb0
Tb
ub

Reaction exothermic coefcient

Initial quality of VCM
Residual mass of VCM
PVC quality after conversion
PVC conversion rate
Specic heat of water
Specic heat of PVC
Specic heat of VCM
Heat removed from jacket water
Inlet temperature of jacket water
Outlet temperature of jacket water
Jacket water ow
Heat removed from bafe water
Inlet temperature of bafe water
Outlet temperature of bafe water
Bafe water ow

Qi
Ti0
ui
Qs
Ts0
us
Qf
Tw0
V
w
p
v
Aj
Kj
Ab
Kb

Heat removed from injected water

Inlet temperature of injected water
Injected water ow
Heat removed from sealing water
Inlet temperature of sealing water
Sealing water ow
Heat-changing value of reactor material
Inlet temperature of cooling water
Volume difference
Density of water
Density of PVC
Density of VCM
Jacket size
Heat-transferring coefcient of jacket
Bafe size
Heat-transferring coefcient of bafe

2.2. Relationship between polymerizing temperature and conversing rate

The factors inuencing conversion velocity are initiator concentration, reaction temperature and polymerize degree. Polymerization
velocity is given by the following equation.
Rc = Kp [M]

 R 1/2
i
2Kt

(1)

where Ri is initiator velocity, Kp is a constant of chain increasing velocity, Rc is chain increasing ratio (polymerization velocity), Kt is the
termination velocity constant, and [M] is the monomer concentration. That is to say the polymerization reaction ratio is proportional to
the square of initiator velocity.
Kp = AeE/RT

(2)

where Kp is the polymerization velocity constant, E is the activation energy, R is the air constant, and T is the absolute temperature.
It can be seen from Eq. (1) that the reaction velocity has relationship with initiator concentration and reaction temperature of constant
kind. From Eq. (2), when T increases, K becomes larger so that the polymerization velocity becomes larger too. Substitute (2) into (1) to
get:

 R 1/2
i

Rc = AeE/RT [M]

2Kt

(3)

where Rc is chain growth rate (polymerizing rate).

It is known from Eq. (3) that the polymerizing rate of VCM (conversion rate) is the function of temperature. The polymerization
degree decreases with an increase in temperature. Therefore, polymerization degree only has a relationship with temperature for the VCM
polymerization reaction. Ultimately, the accuracy of the conversion velocity soft-sensor model has a direct inuence on the product quality
and type of PVC.
2.3. Structure of advanced control strategy in PVC polymerizing process
The structure diagram of data-driven integrated modeling and advanced control strategy of the PVC polymerizing process is shown in
Fig. 2. Firstly, a multi TS fuzzy neural networks soft-sensing model is proposed to predict the conversion velocity and conversion rate
based on principal component analysis (PCA) method and fuzzy c-means (FCM) clustering algorithm. Then the generalized predictive
control algorithm based on the piecewise afne strategy is used to control the polymerization kettle temperature in order to reduce the
production costs and improve PVC product quality.
3. Soft-sensor modeling of polymerizing process based on multi TS FNN optimized by HS algorithm
The polymerization cycle and conversion ratio are important quality indices in PVC production process. Therefore it is critical to shorten
the production cycle of every polymerizer, increase the conversion ratio to a certain degree and ensure the control accuracy in order
to strengthen the ability of the instruments and improve product quality. The traditional polymerization monomer conversion ratio is
controlled to lower than 85%. However with the development of bigger polymerizer, the increase in conversion ratio of every polymerizer
has an important signicance for enhancing the production capability of the polymerizer device and reducing the production costs.
Currently, the nonlinear soft-sensor modeling methods based on sample datum mostly adopt a single model structure. Based on the
guiding ideology of divide and conquer on the sum task decomposition, many manifold model structures have been put forward, such as
multiple neural networks (MNN), stacked NN (SNN) and distributed NN (DNN) [10,11]. So according to the principle that multiple models
can enhance the overall accuracy and robustness of a predicative model, a multi TS fuzzy neural network soft-sensing model combining
with fuzzy c-means (FCM) clustering algorithm is proposed to predict the conversion rate and velocity of VCM in the PVC polymerizing
production process.

S.Z. Gao et al. / Journal of Process Control 23 (2013) 664681

667

Soft-sensor modelling
Harmony search Optimization
algorithm

Multi T-S fuzzy neural

networks

Temperature
mechanism
model

Convention
rate model

Temperature advanced
control strategy
Segmental affine model of
temperature and convention
rate

Generalized predictive control

VCM

PVC polymerizing process

Polymerization kettle
temperature

Sealing water
flow

Tempeture of
cooling water

Principal component analysis

PVC

Fig. 2. Advanced control structure of PVC polymerize process.

3.1. Multi TS fuzzy neural network soft-sensor model

According to the characteristics of a polymerization process, 10 process variables related with the conventional rate and velocity of VCM
are identied as the secondary variables of the soft-sensor model, which respectively are kettle inside temperature (TIC-P101), kettle inside
pressure (PIC-P102) and bafe ow (FIC-P101), clip set of water ow (FIC-P102), infuse water ow (FIC-P104), seal water ow (FIC-P105),
cooling water inlet temperature, clip set of water outlet temperature (TI-P109), damper water outlet temperature (TI-P110) and injecting
water and seal water inlet temperature (cold cistern exit temperature, TIC-WA01).
3.1.1. Structure of multi TS fuzzy neural network soft-sensor model
Considering a multiple-input multiple-output (MIMO) system, its training samples can be expressed as [12]: D = {Y, Xi |i = 1, 2, . . . , m},
where Y = {yj |j = 1, 2, . . . , n} is the output matrix (n denotes the sample size of a training set and m shows the number of input variables)
and Xi = [x1i , x2i , . . . , xni ] (i = 1, 2, . . . , m) indicates the i-th input variable. The FCM algorithm partitions a collection of n data points
(X = {x1 , x2 , . . . , xn }) into c fuzzy clusters (2 c n). V = {v1 , v2 , . . . , vc } is a set of corresponding cluster centers in the data set X. uij (0
uij 1) is the membership degree of data xj belonging to the cluster center vi . The object function of the FCM algorithm is to nd U = [uij ]cn
and V = (v1 , v2 , . . . , vc ) to make the formula (4) smallest.
Jm (U, V ) =

n
c



(uij )m ||xj vi ||2

(4)

i=1 j=1

Assume D is partitioned into C clusters {D1 , D2 , . . . , Dc } by the FCM algorithm. The c sub-models {M1 , M2 , . . . , Mc } are established based
on the TS fuzzy neural network by adopting the subset {Di |i = 1, 2, . . . , c}. Multi TS FNN conguration based on the FCM algorithm [13]
is shown in Fig. 3.
3.1.2. Model dimensionality reduction based on principal component analysis
If the input vector dimension of the TS model is too long, the network topology will be complex and training will become very
complex. Therefore, the principal component analysis (PCA) method [10] is adopted to reduce the model dimension of the TS model. The

Fig. 3. Multi TS FNN conguration based on FCM algorithm.

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Table 2
Accumulated contributed ratio of different principal.
PCs

Eigenvalues

Percentage of eigenvalues (%)

Cumulated percentage (%)

1
2
3
4
5
6
7
8
9
10

1.1620
0.3278
0.1575
0.1185
0.0958
0.0366
0.0249
0.0185
0.0111
0

59.51
16.79
6.07
7.34
4.91
1.87
1.27
0.95
0.57
0

59.51
76.30
84.36
90.43
95.34
97.21
98.48
99.43
100.00
100.00

PCA approach uses all of the original variables to obtain a smaller set of new variables (principal components PCs) that can be used to
approximate the original variables. PCs are uncorrelated and are ordered so that the rst few retain most of the variation present in the
original set.
The principal component analysis method is adopted to tackle the historical datum composed of the input variables of the soft-sensor
model. The analysis results are shown in Table 2. The variance contribution ratio of the former 4 principal components reaches 90.43%, so
the corresponding principal variables are selected as input variables of the soft-sensor model.
3.2. TS fuzzy neural networks based on harmony search algorithm
3.2.1. Structure of TS fuzzy neural networks soft-sensor model
The TakagiSugeno (TS) fuzzy model has the ability to construct inputoutput mapping based on human knowledge (in the form of
fuzzy if-then rules) and stipulate inputoutput data pairs [12]. The architecture of the TS fuzzy model under study is shown in Fig. 4.
The model inputs are Xr (r = 1, . . . , 4). The fuzzy linguistic variable of each xi is represented as:
i}
T (xi ) = {A1i , A2i , . . . , Am
i

(5)

where Ai (j = 1, 2, 3, . . . , mi ) is the jth language variable value of xi , a fuzzy set dened in the domain Ux , whose corresponding membership
functions is dened as follows.
 j (xi ) (i = 1, 2, . . . , r; j = 1, 2, 3, . . . , mi )

(6)

The VCM conversion and conversion velocity are model outputs (fh , h = 1, 2). So the form of the jth fuzzy rule in the TS model may be
represented as:
j

Then yj = p0 + p1 x1 +, . . . , pr xr

If x1 is A1 , x2 is A2 , . . . , xr is Ar

(j = 1, 2, . . . , m; m =

m


mi )

(7)

i=1

The TS model in Fig. 4 is consisted of the antecedent network and the consequent network. The antecedent network is used to match
the antecedent component of fuzzy rules and the consequent network is used to generate the consequent component of fuzzy rules.
3.2.1.1. Antecedent network. There are four layers in the antecedent network. The rst layer is input layer to transfer input values to the
next layer, in which the number of nodes N1 = r. Each node in the second layer represents a language variable to compute the membership
function gij of every input component. Each node of the third layer represents a fuzzy rule to match the antecedent component of the fuzzy
rules and then calculate the tness of each rule. The number of the fourth layer is the same as the third layer, whose function is to realize
the normalization calculation represented as follows.
l =

l

m


k=1 k

r

exp[

m

k=1

i=1

(xi cij )2 /2ij2 ]

r

exp[

i=1

(xi cij )2 /2ij2 ]

(8)

3.2.1.2. Consequent network. The fth layer is called fuzzy decision layer fl = Wl l , in which Wl = wl0 + wl1 x1 + wlr xr (l = 1, 2, . . . , m).
The sixth layer is called defuzziation layer, whose node number is in correspond with the number of output variables.
The Hybrid algorithm combining HS algorithm and minimum least square method is used to the ne tuning the consequent and
antecedent parameters for each TS sub-model in this paper.
3.2.2. Harmony search optimization algorithm
Harmony search (HS) proposed by Geem et al. [14] is a derivative-free and meta-heuristic algorithm (also known as soft computing
algorithm or evolutionary algorithm) mimicking the improvisation process of musicians. In the process, each musician plays a note for
nding the best harmony. Likewise, each decision variable in the optimization process has a value for nding a best vector all together.
Since its inception, HS has found several applications in a wide variety of practical optimization problems such as pipe-network design,
structural optimization, vehicle routing problem, combined heat and power economic dispatch problem, and Dam Scheduling [1520].
The instruments i(i = 1, 2, . . . , pop) are analogized with the i-th design variable of optimization problems by the HS algorithm. The
harmony Hj (j = 1, 2, . . . , HMS) of every instrument tone is equivalent to the j-th solution vector of optimization problems and its estimate
is in analogy with objective function. First, the HS algorithm produces HMS initial solutions (harmony), which are put in harmony memory
storage HM. Then a new solution is searched in HM by probability phmcr and outside HM by probability 1 phmcr with a possible variable

S.Z. Gao et al. / Journal of Process Control 23 (2013) 664681

669

Fig. 4. Structure diagram of TS fuzzy neural network.

range of HM. Local disturbance is produced in this algorithm for a new solution by probability ppar . Then it is determined that the objective
function value of the new solution is any better than the worst solution. The worst solution will be replaced if a worse solution arises are
continuously produced until it reaches the predetermined iteration.

3.2.3. Algorithm procedure

The algorithm procedure of the proposed hybrid learning algorithm to adjust the parameters of TS fuzzy neural network is shown
below.

Step 1: Initialize the HS algorithm parameters. The parameters include the population size pop, searching space dimension D (the number
of premise parameters), harmonic memory storage HMS, memory storage selecting probability phmcr , tone adjustment probability ppar and
iterative number n. Set the iterative number n = 1. In the searching space, randomly initialize population individuals. The i-th individual
n (1 i pop, 1 d D).
vector is expressed as Xid
Step 2: Each individual vector of the population is taken in turn as premise parameters TS fuzzy neural network. Then the excitation
intensity and normalized excitation intensity of all rules are calculated. Therefore, conclusion parameters are distinguished by using least
square method. Finally, according to the Eq. (35), the root mean square error (RMSE) produced by the individuals TS fuzzy neural network
is calculated, which is set as the tness value RMSEni of the individual.


 N
 (yk y )2
k
RMSE =
N

k=1

(9)

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S.Z. Gao et al. / Journal of Process Control 23 (2013) 664681

Fig. 5. Predictive output of convert ratio of VCM.

Step 3: Initialize the harmony memory. The HM matrix is lled with as many randomly generated solution vectors as the HMS as shown
by Eq. (36).

x11

x21

1
xD1

1
xD

x2

2
2
x22

xD1
xD
1

..
..
..
..
HM =

..
.
.
.
.

HMS1 HMS1
HMS1
HMS1
x2
xD1
xD
x1

x1HMS

x2HMS

HMS
xD1

(10)

HMS
xD

Step 4: Improvise a new harmony. Firstly, make a new vector x . For each component xi with probability phmcr , pick the component from
rand()

memory, xi = xi
with probability 1 phmcr , pick a new random value in the allowed range. Then, for pitch adjustment, each component
xi : with probability ppar change xj by a small amount, xi = xi bw rand() with probability 1 ppar , do nothing.
Step 5: Update the harmony memory. If xm is better than the worst xi in the memory, then replace xi by xm .
Step 6: Check the stopping criterion. The HSA is terminated when the stopping criterion (e.g. maximum number of improvisations) has
been met. Otherwise, repeat from step 3.
The parameters in the proposed hybrid learning algorithm are set as follows: population number pop = 30, the iteration number n is 100,
harmonic memory storage (HMS) of HS algorithms is 10, the searching probability phmcr of HMS is 0.95, and tone adjustment probability
ppar changes from 0.3 linearly increasing to 0.99 with evolution iteration.
3.3. Simulation results
PVC generally has eight product grades: SG-1, SG-2, SG-3, SG-4, SG-5, SG-6, SG-7, and SG-8. The proposed soft-sensor model is established
based on the datum of the SG-5 production process. However, the proposed method can be used for the other grade productions by utilizing
new process datum. Aiming at the polymerization process in a 40,000 tons/year polyvinyl chloride (PVC) production line, 1500 uniform
and representative historical datum of ve kettles are chosen as the experiment data. After the data pretreatment, the former 4 kettles
are selected as the training data to be used to train the Multi TS FNN and single TS FNN. The last kettle datum is used to verify the
performance of the soft sensor model. The results of adopting the two methods for validating the data prediction output and predictive
error are shown in Figs. 58.
Usually average relative variance (ARV) is calculated to measure the error between the predicted value and real-time measured value,
which is dened as the following equation.

N

ARV =

Ni=1
i=1

[x(i) x (i)]

[x(i) x (i)]

(11)

where N is the numbers of comparative data, x(i) is the i-th real-time data, x is the average of measured datum, and x (i) is the predictive
value. Obviously, the fact that the value of AVR is smaller shows that the prediction effect is better. ARV = 0 shows that the predictive effect
is ideal. ARV = 1 shows that the predictive effect is equal to the mean. Table 3 shows the compared results of AVR under the two methods.
Table 3
Predictive AVR.

AVR (conversion ratio)

AVR (conversion velocity)

M TS FNN

TS FNN

0.104
0.132

0.139
0.214

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Fig. 6. Predictive output of rate of VCM conversion.

Fig. 7. Predictive error of convert ratio of VCM.

From Figs. 58 and Table 3, the multi TS FNN soft-sensor model based on the PCA method and FCM algorithm has higher precision of
prediction and generalization ability for the conversion and conversion rate of VCM proposed in the paper. The hybrid learning algorithm
combining the harmony search optimization algorithm and the least square method proposed in the paper can effectively adjust the
premise parameters and conclusion parameters of the TS model. Simulation results show that the prediction accuracy of the soft sensor
model proposed in this paper is higher. Optimization control of a PVC polymerization process based on the prediction model will surely
have a great signicance on increasing the conversion rate of polymerization kettles and reducing the production costs.

Fig. 8. Predictive error of rate of VCM conversion.

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4. GPC of PVC polymerizer temperature based on piecewise afne

The discussed polyethylene polymerization process is an intense exothermic reaction (1600 kJ/kg) process. Heat of reaction is needed to
be removed in time to keep the reaction in constant temperature, so the transformation will not happen. Therefore, in order to guarantee the
quality of PVC production, Polymerizer temperature has to be controlled in constant value required by the PVC polymerization technique. A
70 m3 polymerizer temperature of PVC production process is used as the controlled object. The GPC method of the polymerizer temperature
based on the piecewise afne is proposed in this paper and the stability of the controller is analyzed. In the end, simulation results show
the algorithm can better satisfy the control accuracy of polymerizer temperature.
4.1. Mechanism modeling of polymerizer temperature
PVC polymerizing process is a typically batch exothermic reaction process. According to the heat balance principle, the total calories
instantaneously released in polymerizing reaction is equal to the heat amount removed by jacket water and bafe plate water, the absorbed
heat by injection water and sealing water, and the heat making the polymerizer temperature change. Thus the following equations are
obtained.
HR m0 R c = Qj + Qb + Qi + Qs + Qf

(12)

where
Qj = Cw uj (Tj Tj0 )

(13)

Qb = Cw ub (Tb Tb0 )

(14)

Qi = Cw ui (T Ti0 )

(15)

Qs = Cw us (T Ts0 )

(16)

Qf = Cv mv T + Cp mp T + Cw w V T

(17)

The outlet temperature of the bafe plate water and jacket water is dened as follows [21].
Tj =

Tb =

T + j Tj0
1 + j

T + b Tb0
,
1 + b

j =

Cw uj

j =

(18)

Kj Aj
Cw ub
Kb Ab

(19)

Based on the Eqs. (12)(19), the differential equation of the polymerizer temperature is deduced as follows.
T =

HR m0 R c Cw uj (T Tj0 /1 + j ) Cw ub (T Tb0 /1 + b ) Cw (m0 w (p v )/p v )R c (T Ti0 )

m0 (Cv (1 Rc ) + Cp Rc + Cw w (Rc (p v )/p v ))

(20)

On the other hand, it is known from Eq. (3) that the polymerizing rate of VCM (conversion rate) is the nonlinear function of temperature,
while the temperature is an important factor affecting PVC production quality. To make sure the quality of PVC production, the polymerizer
temperature has to be controlled to a certain constant value. So the piecewise afne model is set up based on the conversion rate of VCM.
4.2. Piecewise afne system
4.2.1. Polyhedral elliptical set regional division
Consider the following piecewise afne system:

x(k + 1) = Ai x(k) + Bi u(k) + bi

y(k) = Ci x(k)

(21)

x(k) Xi , i I

where x(k) Rn is the system state vector, u(k) Rm is the control input, y(k) Rp is the output variable, Ai , Bi , Ci (i = 1, 2, ...N) is respectively
the state matrix and input matrix of the ith subsystem, bi is the constant afne vector, and N > 1 is the number of subsystems. Assuming
the state feedback controller of system (21) is:
u(k) = Ki x(k)

(22)

Substituting system (22) into system (21) to get:

x(k + 1) = Ai x(k) + bi

(23)

where
Ai = Ai + Bi Ki

(24)

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673

Based on the regional division of piecewise afne system, the regional division of subsystem can be represented in the form of elliptical
set, whose dimension is not more than the state space dimension. So Xi i , where i is ellipse, namely i = {x|||Ei x + ei || 1}. Rewrite it
into the quadratic inequality LIM:

x(k)

T 



EiT Ei

eiT Ei

1 + eiT ei

x(k)

(25)

Especially, when Xi = {x|d1 < ciT x < d2 } (d1 and d2 are constants representing the state boundary of subsystem working region), the
coefcients of the corresponding elliptical set i = {x||Ei x + ei || 1} can be represented as follows.

Ei = 2CiT /(d2 d1 )

(26)

ei = (d2 + d1 )/(d2 d1 )
4.2.2. Piecewise linearization
Linearizing system (20) at any point to obtain:
T =

f
f
f
f R c
T
+
Rc +
uj +
x R c
Rc
uj
T

(27)

where
f
R c

HR m0 Cw (m0 w (p v )/p v )(T Ti0 )

m0 (Cv (1 Rc ) + Cp Rc + Cw w (Rc (p v )/p v ))

(28)

HR m0 Cw (m0 w (p v )/p v )(T Ti0 )

(p v )
f
=
Cv + Cp + Cw w
2
p v
Rc
m0 (Cv (1 Rc ) + Cp Rc + Cw w (Rc (p v )/p v ))


(29)

Cw (T Tj0 )
1
f

=
uj
m0 (Cv (1 Rc ) + Cp Rc + Cw w (Rc (p v )/p v ))
(1 + 0.0232uj )2

(30)

(Cw uj /1 + j ) (Cw ub /1 + b ) Cw (m0 w (p v )/p v )R c

f
=
T
m0 (Cv (1 Rc ) + Cp Rc + Cw w (Rc (p v )/p v ))

(31)

Dene state variables:

x=

Rc

x =

y = [1 0]

T
R c


=

f/T

f/Rc

M(E/RT 2 )



T
Rc

 
+

f/uj
0


uj +

M +1

M +2

(32)

Rc

where M = A[M](Rt /2Kt )

1/2

, i are the higher order components and bi = M +i .

4.3. Design of generalized predictive controller

Considering the piecewise afne system (21), the performance index of GPC in innite time domain is dened as follows.

min
J (k)

u(k+m|k),m=0,1, ...



T
T

J
(k)
=
x(k
+
m|k)
Q
x(k
+
m|k)
+
u(k + m|k) Ru(k + m|k)
I

m=0

(33)

m=0

where QI > 0 and R > 0 are the symmetric positive denite matrix, x(k + m|k) represents the state predictive value of model (23) at time
k + m, u(k + m|k) is the value of the controlled input sequence {u(k|k), u(k + 1|k), . . . , u(k + m|k)} at time k + m optimizing the rolling
indicator at time k.
According to the characteristic of GPC, the controlled input u(k + m|k) is fed into the control system, then at the next moment; recalculate
the optimization problem to receive different controlled input sequences. Then feed the rst term on the system, and so forth. That is to say
the rolling optimization is realized. The quadratic Lyapunov function of system (21) at the moment k is dend as V (x(k|k)) = xT (k|k)Px(k|k).
Let:
V (x(k + m + 1|k)) V (x(k + m|k)) xT (k + m|k)QI x(k + m|k) uT (k + m|k)Ru(k + m|k)

(34)

when x(|k) = 0, V (x(|k)) = 0.

Jn+1
(k) =

[xT (k + m|k)QI x(k + m|k) + uT (k + m|k)Ru(k + m|k)]

(35)

m=n+1

Accumulate Eq. (35) from m = 0 to m = to get:

V (x(k|k)) J (k)

(36)

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S.Z. Gao et al. / Journal of Process Control 23 (2013) 664681

Then the upper determinate bound of the performance index function J (k) is dened as follows.
J (k) V (x(k|k))

(37)

Thus, the minimum performance index is equal to minimize V (x(k|k)), that is to say:
min

u(k+m|k),m=0,1, ...

V (x(k|k))

(38)

In GPC algorithm, a group of the state feedback control inputs are obtained by minimizing V (x(k|k)). Then merely the rst term of control
sequences is fed into the controlled system. At the next sampling moment, the state x(k + 1|k) is measured again, and the corresponding
subsystem models as well as the corresponding state division are selected to calculate the feedback gain matrix Ki again.
4.4. Predictive control algorithm based on piecewise afne system
Theorem 1. Considering system (21), x(k|k) is the measured state value of the ith subsystem at time k, {Ai , Bi , bi } and {Ai+1 , Bi+1 , bi+1 } are
respectively parameter matrixes of the ith and the i + 1 th subsystems, where i I = {1, 2, . . . , N}. ||Ei+1 x + ei+1 || 1 is the description of
x Xi+1 in elliptical set. Control inputs u(k|k) u(k + n|k) are free variables. The system switches from Xi to Xi+1 after n steps, where n is
a known constant. If there exists Yi+1 = Ki+1 Q , Q 0,
> 0, > 0 and a group of control variables which meets the following LMI optimization problem. Then system (21) can switch to the equilibrium points in accordance with the desired order, and realize the asymptotic
stability. Scalar
is the optimization performance index under arbitrary switching sequence.
min

(39)

,u,Q,Yi

s.t.:

1
QI 0.5 x(k|k)

.
.
.
0.5
QI x(k + n|k)

0.5
R u(k|k)

.
.
.
0.5
R u(k + n|k)
x(k + n + 1|k)

..
.

..

..
.

..
.

..
.

..
.

..
.

..
.

..
.

..
.

..
.

..

..
.

..
.

(40)

Ai+1 Q + Bi+1 Yi+1 Q + bi+1 bi+1

T
Ei+1 Q
ei+1 bi+1

0.5
0
QI Q
R0.5 Yi+1

T
(I ei+1 ei+1 ) 0 0 0

I 0
bi+1 ei+1

(41)

where x(k + 1|k) x(k + n + 1|k) is got by recursive. Its specic form is described as follows.
x(k + n + 1|k) = An+1
x(k|k) +
i

n

j=0

nj

Ai

Bi u(k + j|k) +

n


nj

Ai

bi

(42)

j=1

The control strategy of Theorem 1 contains two steps broadly, namely the control inputs divided into the free component input and the
feedback input constrained by terminal ellipsoid set.
(1) When the system does not switch to the terminally regional division, u(k + m|k), m = 0, . . . , n is free variable satisfying Theorem 1.
Control sequence u(k + m|k), m = 0, 1, . . . , n in limited time domain will compulse the system state x(k + m|k) from Xi into Xi+1 after
n steps to enter the terminal ellipsoid set in the end.
(2) When the system switches to the terminal ellipsoid set, Ut : u(k + m|k) = Ki+1 x(k + m|k), m n + 1, Ki+1 = Yi+1 Q 1 , where Ki+1 is the
(k) xT (k + n + 1|k)Px(k + n + 1|k)
state feedback matrix. State feedback controller makes the system state stable to the origin point. Jn+1
is the upper determine bound of cost function in the innite time domain, where the free component u(k + m|k), m = 0, . . . , n and the
state feedback matrix Ki+1 are all convex optimal solution of LMIs.

S.Z. Gao et al. / Journal of Process Control 23 (2013) 664681

675

0.9

* (243.9,0.82)

0.8
0.7

Rc

0.6
0.5

*(151.8,0.45)

0.4
0.3
0.2

* (82,0.15)

0.1
0

50

100

150

200

250

300

350

t(min)
Fig. 9. Oval plot of PWA system.

4.5. System simulation

4.5.1. Piecewise afne modeling
Based on the dynamic equation of the polymerizer temperature by the heat balance mechanism of polymerization process, the piecewise
afne model of the polymerizer temperature and conversion rate is set up. On the other hand, every state space subsystem is described by
ellipsoid set. Mechanism model is built as:
T =

18)
41600000x ((4.167/1 + 0.0232uj )uj + 61549 + 51853x)(T
(41366 + 39000x)

(43)

When control input is equal to zero, three equilibrium points are resolved, that is (Rc1 , u) = ([82, 0.15], 0), (Rc2 , u) = ([151.8, 0.45], 0)
and (Rc3 , u) = ([243.9, 0.82], 0). In accordance with the three equilibrium points, the state space is divided into three ellipsoid sets, which
is shown in Fig. 9. They are respectively E1 = 6.7, e1 = 1; E2 = 5.71, e2 = 2.7, E3 = 10 and e3 = 7.5.


  




2.802 105
0.0093 7.06 102
T
61.54

=
+
u
+
x

Rc
0.069

0
0

 0.01
  




5
3

2.143 10
0.01245 4.77 10
T
174.223
+
u+
x =
Rc
0.0636

0
0.056
0






 


5
2

1.712 10
0.005681 2.957 10
T
200.86

=
+
u
+
x

Rc
0.0844
0
0.036
0

where x (x1 , x2 , x3 ), x1 (0, 0.3), x2 (0.3, 0.65), x3 (0.65, 0.85). Within every ellipsoid set, the linearization is carried out near the
equilibrium point to obtain the piecewise afne model of polymerizer system (temperature T and conversion rate Rc).
4.5.2. GPC control based on piecewise afne model
According to the practical situation possibly occurred in polymerizering process, three main situations are studied in this section.
(1) While operation process is in good condition, the control effect curves are shown in Fig. 10. Sampling time is 6 s, predictive step is 40,
and control step is 10, as well as Q1 = 1, R1 = 8 1011 , Q2 = 1, R2 = 6 1012 , Q3 = 1, R3 = 6 101 . It can be seen from Fig. 10, the system
is able to trace the given output stably with good control effect.
(2) While operation process is affected by the step interference of uncertain factors, in which the interference amplitude is 3 C and the
amplitude width is 15 min, the control effect curves are shown in Fig. 11. It can be seen that the system may quickly overcome the
disturbance effect under the sudden step interference.
(3) While the controlled object is affected by the white noise disturbance with range (0.003, 0.003), the control effect curves are shown
in Fig. 12. It can be seen that the system has better robust performance and the temperature is controlled near the set-point value
under the white noise interference.
5. Application of advanced control strategy in PVC polymerizing process
5.1. Application results of advanced control strategy
The industrial application results of the proposed advance control strategy in PVC polymerizing process is shown in Fig. 13(a)(c). Due
to the application of the advanced control technology of PVC polymerizing temperature based on piecewise afne, the control accuracy
of polymerizing temperature has been effectively improved. It can be seen from Fig. 13 that the system has good tracking performance,

676

S.Z. Gao et al. / Journal of Process Control 23 (2013) 664681

Fig. 10. Control results of PVC process in normal working conditions.

Fig. 11. Control results of PVC process under step noise.

Fig. 12. Control results of PVC process under white noise.

S.Z. Gao et al. / Journal of Process Control 23 (2013) 664681

677

Fig. 13. Real-time temperature curves of polymerize process.

makes the polymerizing temperature throughout controlled in a constant value of 55.4 in the reaction process, and has strong robustness
to the outside disturbance, which improves the PVC product quality.
5.2. Industrial application effect
Combined with the technical characteristics and requirements of 40 thousand tons/year PVC polymerizing process, the industrial application of the advanced control strategy of PVC polymerizing process is carried out. Its application value is mainly reected in two aspects:
increasing PVC product quality and reducing production cost of VCM.

678

S.Z. Gao et al. / Journal of Process Control 23 (2013) 664681

Table 4
VCM production costs before and after optimized control (RMB/ton).
Item
Carbide
Chlorine
Hydrogen
Liquid alkali
Catalyst
Water
Electric
Nitrogen

Material costs

Labor costs
Manufacturing costs
Sum

Unit

Number

Unit Price

Sum of money

Total cost ratio (%)

ton
ton
ton
ton
kg
Ton
KW h
nm3
Single

1.5
0.65
0.02
0.015
1.1
30
265
100
1

2250
1500
10,000
500
20.5
2
0.35
0.3
45 (41)
600 (560)

3375
975
200
7.5
22.55
60
92.75
30
45 (41)
600 (560)
5407.8 (5363.8)

62.41 (62.92)
18.03 (18.18)
3.70 (3.73)
0.14 (0.14)
0.42 (0.42)
1.11 (1.11)
1.72 (1.73)
0.55 (0.56)
0.83 (0.76)
11.09 (10.44)
100

Table 5
PVC product performance index (GB/T5761-2006, FDJH/JS01-0200.13).
Inspection
item

SG5 index
Superior
First
Eligible

Viscosity
(ml/g)

118107
118107
118107

Apparent
density
(g/ml)

100 g
plasticizer
absorption
capacity (g)

0.48
0.45
0.42

19
17

Volatile
matter (%)

0.40
0.40
0.50

Sieve residue %

250 m
sieve mesh

63 m
sieve mesh

2.0
2.0
8.0

95
90
85

Number of
impurity
particle

Whiteness
(%)

Number of
sheyes/
400 cm2

Residual
vinyl
chloride
(g/g)

16
30
80

78
75
70

20
40
90

5
10
30

5.2.1. Reducing production costs

VCM producing costs are composed of three parts: raw material costs, labor costs and the manufacturing costs. The raw material costs are
constant for the given production yield. When the proposed advanced control strategy is applied in the PVC production process, the articial
cost and the manufacturing cost are relatively reduced, so the total production costs declines. The VCM productions costs before and after
utilizing the optimized control method are listed in Table 4. The data in the brackets with bold fonts are the costs when the optimized
control method is used. The declining value of costs is 5407.85363.8 = 44 RMB/ton. For a 40 thousand tons/year PVC polymerizing process,
the economic benets obtained by reducing the cost is 44 RMB/ton 40,000 ton/year = 1760 thousand RMB/year.
5.2.2. Improve product quality
Production capacity of PVC device is 40,000 tons/year, the PVC production type is SG-5, and its performance index standard of product
quality is in accordance with GB standard described in Table 5.
Now collect ten batches of PVC product quality for comparison. The PVC products grades before and after utilizing the proposed advanced
optimization control strategy are shown in Tables 6 and 7. It can be seen from that the superior grade of PVC products is 40% and the rst
grade of PVC products is 60% before implementing the advanced control strategy. After implementing the advanced control methods, the
superior grade of PVC products is 60% and the rst grade of PVC products is 40%. In sum the product excellence rate of PVC product quality
improved 20%.

Table 6
PVC product inspection report (before optimization).
Inspection
item

Batch number
5-11001
5-11002
5-11003
5-11004
5-11005
5-11006
5-11007
5-11008
5-11009
5-11010

Viscosity
(ml/g)

112
114
114
114
113
113
114
114
113
112

Apparent
density
(g/ml)

0.54
0.54
0.55
0.54
0.54
0.55
0.54
0.54
0.54
0.54

100 g
plasticizer
absorption
capacity (g)

23
23
22
22
23
23
22
22
21
22

Volatile
matter (%)

0.12
0.18
0.14
0.16
0.16
0.12
0.12
0.30
0.20
0.18

Sieve residue (%)

250 m
sieve mesh

63 m
sieve mesh

2.0
1.2
1.2
1.2
1.2
1.2
1.2
1.2
1.2
1.2

98
98
98
98
98
97
98
98
98
98

Number of
impurity
particle

Whiteness
(%)

Number of
Fisheyes/
400cm2

Residual
vinyl
chloride
(g/g)

Grade

29
20
16
15
16
16
24
26
26
24

86
83
82
83
82
83
82
82
80
80

40
38
18
18
17
18
32
34
30
30

10
10
5
4
5
5
8
8
10
10

First
First
Superior
Superior
Superior
Superior
First
First
First
First

S.Z. Gao et al. / Journal of Process Control 23 (2013) 664681

679

Table 7
PVC product inspection report (after optimization).
Inspection
item

Batch number
5-11106
5-11107
5-11108
5-11109
5-11110
5-11114
5-11115
5-11116
5-11117
5-11118

Viscosity
(ml/g)

Apparent
density
(g/ml)

113
114
114
113
114
113
112
114
114
114

0.55
0.54
0.55
0.54
0.54
0.54
0.53
0.54
0.55
0.54

100 g
plasticizer
absorption
capacity (g)

23
22
23
23
22
23
23
23
22
22

Volatile
matter (%)

0.16
0.14
0.12
0.18
0.14
0.16
0.14
0.10
0.16
0.16

Sieve residue (%)

250 m
Sieve mesh

63 m
Sieve mesh

1.2
1.2
1.2
2.0
1.2
1.2
1.2
1.2
1.2
1.2

98
98
98
98
98
98
98
98
98
98

Number of
Impurity
particle

Whiteness
(%)

Number of
sheyes/
400 cm2

Residual
vinyl
chloride
(g/g)

Grade

29
14
10
10
16
14
16
17
10
9

86
85
86
85
84
82
83
83
82
82

20
18
18
26
25
13
20
34
10
24

5
5
5
5
5
5
5
5
5
5

Superior
Superior
Superior
First
First
Superior
Superior
First
Superior
First

6. Conclusions
PVC polymerizing process is a complex industrial process object and its temperature is nonlinear and difcult to control. This paper
applies soft-sensor method, piecewise afne technology and advanced control algorithm to control the temperature of polymerizing process and designs advanced control strategies consisted of multiple model soft-sensor measurement strategy based on harmony search
optimization and the piecewise afne based GPC strategy for polymerization kettle temperature. Simulation results and industrial application indicate the feasibility and validity of the proposed advanced control method. It can meet the requirements of real-time control for
PVC polymerizing process and further improve the PVC product quality and reduce the production costs.
Acknowledgments
This work was supported by the Key Program of National Natural Science Foundation of China (61034005), the Postgraduate Scientic
Research and Innovation Projects of Basic Scientic Research Operating Expenses of Ministry of Education (N100604001), the Program
for Liaoning Excellent Talents in University of China (LJQ2011027) and the Program for China Postdoctoral Science Foundation of China
(20110491510).
Appendix A. Stability analysis
The piecewise quadratic Lyapunov stability method based on elliptical set is used in this paper, in which the continuous state sets are
substituted with a group of elliptical sets. That is to say, in every state partition, a quadratic Lyapunov function is found to be positive in
the state partition. Consider the following discrete piecewise afne system:
x(k + 1) =

N


i (k)Ai x(k) +

i=1

N


i (k)Bi u(k) +

i=1

N


i (k)bi

i=1

x(k) Xi , i I

(44)

N

where i (k) is the switch symbol vector, satisfying i : Z + = {0, 1, 2, . . .} {0, 1},
(k) = 1. i (k0 ) = 1(i = {1, 2, . . . N}) represents
i=1 i
that the i subsystem works at the sampling time k0 , in which N > 1 is the number of the subsystems.
Theorem 2.
stable.

For system (44), if the following LMI has a solution, the controller u(k) = Yi Qi 1 x(k) can make the system asymptotically

Qi = QiT > 0, Qj = QjT > 0,

i > 0

(Ai Qi + Bi Yi )T (Ei Qi )T
Qi

i bi eiT
Ai Qi + Bi Yi Qj
>0

EQ

i ei bTi

i (I ei eiT )

i i

(45)

x(k) Xi , i, j I

The prove process of Theorem 1 is descried as follows.

Assume u(k) = Ki x(k) and substitute it into the discrete-time piecewise afne system (46), then get:
x(k + 1) =

N

i=1

i = Ai + Bi Ki .
where A

i x(k) +
i (k)A

N

i=1

i (k)bi ,

x(k) Xi ,

iI

680

S.Z. Gao et al. / Journal of Process Control 23 (2013) 664681

Structure the quadratic piecewise Lyapunov function:

N


V (k) = xT (k)(

i (k)Pi )x(k)

i=1

where Pi > 0. If and only if x(k) = 0, V (k) = 0. Because

N


V (k + 1) V (k) = xT (k + 1)(

N


i (k + 1)Pi )x(k + 1) xT (k)(

i=1

i (k)Pi )x(k) 0

i=1

It is suitable for all i I. When i (k) = 1, l =/ i (k) = 0, j (k + 1) = 1, l =/ j (k + 1) = 0, the same formula was established. Thus, V (k + 1)
/ 0) is equal to the following formula:
V (k) < 0 (x(k) =
T Pj A
T Pj bi + bT Pj A
i Pi )x(k) + xT (k)A
i x(k) + bT Pj bi < 0,where i, j I.
V (k + 1) V (k) = xT (k)(A
i
i
i
i
Transform it to the matrix style:

x(k)
1

T 

T Pj A
i Pi
A
i
i
bTi Pj A

T Pj bi
A
i
bTi Pj bi



x(k)
1


<0

where x(k) Xi . It can be expressed as the elliptical set Ei+1 x(k) + ei  1. Therefore:

x(k)
1

T 

EiT Ei
eiT Ei

EiT ei
1 + eiT ei



x(k)
1


0

According to S procedure, there exists  to make the following formula established.

T Pj A
i Pi E T Ei
A
i
i
T
i eT Ei
bi Pj A
i

T Pj bi E T ei
A
i
i
bTi Pj bi (1 + eiT ei )

<0

Transform it into the following equation:

Pi + EiT Ei
eiT Ei

EiT ei
(1 + eiT ei )

 

T
A
i
bTi

i
Pj A

bi

>0

Based on the shur-supply theorem, the above formula is equal to:

Pi + EiT Ei
eiT Ei
i
A

 
Multiply diag

T
A
i
bTi > 0
Pj1

EiT ei
(1 + eiT ei )
bi
I,

0
I

Qi1 + EiT Ei
A i
eiT Ei

I
0



on the both sides of the above equation and let Pi = Qi1 , Pj = Qj1 , then obtain:

T
A
i
Qj
bTi

EiT ei
>0
bi
(1 eiT ei )

Multiply diag[Q, I, I] on the both sides of the above equation, then obtain:

T
Qi A
i
Qj
bTi

Qi + Qi EiT Ei Qi
A i Qi
eiT Ei Qi

Qi EiT ei
>0
bi
T
(1 ei ei )

Based on the shur-supply theorem, the above formula is equal to:

Qi + Qi EiT Ei Qi
i Qi
A

Due to (I eT e)

Qi
i Qi
A

i Qi )
(A
Qj

i Qi )
(A
Qj

 
+

= I + eT (I eeT )

 
T
+

Qi EiT ei
bi
1


1 (1 eiT ei )

eiT Ei Qi

Qi
i Qi
A

i Qi )
(A
Qj

 

Qi EiT (I ei eiT )
bi eiT (I ei eiT )

Qi EiT
1
 bi eiT

>0

e, obtain:
1

Ei Qi

Qi EiT (I ei eiT )

ei bTi

1 bi eiT (I ei eiT )

Ei Qi

ei bTi

It is equal to the following equation.

bTi

(I ei eiT )

Ei Qi

1 ei bTi

>0


>0

S.Z. Gao et al. / Journal of Process Control 23 (2013) 664681

681

Apply the shur-supply theorem, the above formula is equal to:

Qi
A i Qi
Ei Qi

i Qi )
(A
Qj

1 ei bTi

Qj
1 bi eiT
(I

>0

1
ei eiT )

Let Yi = Ki Qi , that is to say Ki = Yi Qi1 . So the theorem is proved.

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[14]
[15]
[16]
[17]
[18]
[19]
[20]
[21]

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