Multivariable control experiments of non-linear

chemical processes using non-linear feedback

transformation
Kazuhiko

Nakamoto+

and Norihiro

Watanabe*

Department of Chemical Engineering, Nagoya University, Nagoya, 464-01,

(Received 30 August 1990; revised 15 February 1991)

Japan

The decoupling and linearization control theory based on non-linear feedback transformation for nonlinear systems was applied to two non-linear and interactive chemical control processes. The first is a level
and temperature control process and the second a level and pH control process. To compensate for the mismatch between the real process and the process model, external PI controllers, which track the outputs from
the reference model, were added. The experimental results showed that even if the process is both non-linear
and interactive and the process model is not exactly known, a satisfactory control performance can be
obtained by applying this theory.
(Keywords: non-linear process; decoupling; linearization)

It is well known that many chemical processes possess

non-linear dynamic characteristics.
The traditional
approach to design controllers for a non-linear process
is, in general, to linearize the process model around its
steady state and to apply the linear control theory to it.
However, when the process moves away from the steady
state around which the controller was designed, the characteristics of the process may vary from that of the
steady state. In this instance the linear controller does
not, in general, give a good control performance. Moreover, if there are interactions between components, the
design of the controllers becomes more difficult.
Much work has been recently carried out on decoupling and linearization control theory based on a nonlinear feedback transformation for non-linear control
systems. However, this control theory is developed
under the assumption that the process model is known
exactly. Therefore if there is a difference between the real
process and the process model, the straightforward
application of this theory may give an unsatisfactory
result. To compensate for this mis-match, an adaptive
non-linear controller can also be applied2.
The degree of the mis-match is not high in many
chemical processes. In such cases, it is sufficient to add
external controllers which compensate for the mismatch. Even if these are the conventional PI controllers,
a satisfactory control performance can be obtained as the
non-linear feedback transformed
system is almost
decoupled and linear. Kravaris and Soroush3 proposed a
To whom correspondence should be addressed.
Current address: Toyota Motor Co., Toyota, Aichi, Japan.

140

J. Proc. Cont. 1991, Vol 1, May

09Ss-1524/91/03014&06
0 1991 Butterworth-Heinemann

Ltd

control strategy which is called the multiinput/multioutput (MIMO) globally linearizing control, and this was
applied to a semi-batch co-polymerization
reactor
through numerical simulations. Paszkiewicti proposed
either a fuzzy logic controller or a saturation controller
as an external controller. These are both outer loop
controllers.
This paper reports the experimental application of the
decoupling and linearization control theory to two chemical control processes, a level and temperature control
process and a level and pH control process. The applicability of this theory to chemical processes will be examined.

Decoupling and linearization for non-linear

control systems
This section briefly reviews the decoupling and linearization control theory for non-linear systems. External controllers, which compensate the modelling errors, are
introduced.
Consider a non-linear system with the same number of
inputs and outputs:

i = f(X)

+fgj(X)U,

(la)

j=l

Y =

h(x)

(lb)

where x E Rn, uj E R, and y E Rm and f, gj and h are

assumed to be Cm functions with respect to their arguments.

Non-linear feedback transformation: K. Nakamoto and N. Watanabe

The decoupling and linearization problem is to determine a feedback law:

Let
(i=

vi = hay 7

24= a(x) + p(x)v

(2)

such that the ith output depends linearly on the ith new
input v. Let pi denote the largest integer such that for all
k < pi, 1 5 j 5 m, and x E Rm:

l,...,m)

(8)

where y f is a set point. Substituting Equation (8) into

Equation (7), then:
Pi+

(i=
L,L:hi(

x) = 0

where

L/ h.(x)
1

= i

f,(x)2

j=l

8Xj

(44

Lfhi( x) = Lf[ L:-hix)]

(4b)

The integer pi is called the characteristic number. Define

the m x m matrix A( x ) and the vector b( x ) as:
,,p,+ ,L,,LfPh,
...h,,

A(x)

+IL,~L;'~I

=
(54

b(x)

l,...,m)
(9)

(3)

The values of 6ik can be selected so that the decoupled

and linearized system has the desired dynamics. As this
eqUatiOn
does not 10% the generality even if one Of ljik
value (k=O, . . . , pi+ 1) is fixed to an arbitrary value for
fixed i, 6,pi+I will be fixed to 1 hereafter.
Although this control theory is attractive, it requires
an exact process model which cannot be practically constructed. When there are some modelling errors in the
process, the transformed system is not a decoupled and
linearized system. If this is so, then in the application of
this theory to real processes, some controllers should be
added to compensate the mis-match between the real
process and the process model. This can be achieved by
adding external controllers. When the modelling errors
are not so large, the feedback transformed system is
considered to be nearly decoupled and linear. It is then
expected that a satisfactory control behaviour will be
obtained even if conventional PI controllers are adopted
as the external controllers. In this case the new input is
revised as follows:

(5b)

(i=
with
constant
coefficients
6,
(i 1, . . . , m;
k=O,. . . ,pi+ 1).
It is known that the decoupling and linearization
problem is solvable if and only if the matrix A( x ) is nonsingularj. More general expressions of A( x ) and b( x ),
proposed by Kravaris and Soroush3, can be used. However, Equation (5) is sufficient for practical applications.
a( x ) and l3( x ) are given by:

- 0

l,...,m)

where yy is a reference value for the external PI controller and is the output from the reference model which
generates the desired output. For example, the following
reference model can be used, which is similar to Equation
(9):

Of33
Yiset

u(x)

= -A-(x)b(x)

(64

P(x)

= A-(x)

(6b)

and input-output

relationships are given by:

Pi+

c Sik2= vi

(i=

I,...,m)

(10)

(i=

l,...,m)
(11)

k=O

with an arbitrary order r, and constant coefficients (T&

(i= 1,. . . ,m;k=O,. . . ,rJ.
If there is no modelling error, the output from the ith
subsystem must follow Equation (9). A trajectory may
then be adopted as a solution to Equation (9) as y pf. In
this case Equations (9) and (11) are related by:

(7)

k=O

ri

(i=l,...
Note that from Equation (7) the relationships between
the new inputs and the outputs are split into m independent linear subsystems.

pi + 1

and

,m;k=O,l,

oik = 6&.
. . ,pi+ 1 )

(12)

In the following experimental section, this control strategy is used.

J. Proc. Cont. 1991, Vol 1, May

141

Non-linear feedback transformation: K. Nakamoto and N. Watanabe

couple are transmitted through the A/D converters into

the persona1 computer. The computed control values are
transmitted through the D/A converters to the control
valve and the thyristor which controls the current to the
heater. These processes were carried out by a program
written in BASIC. The sampling time and the control
interval were both 2 s. The measured values of the level
and the temperature were stored on a disk-memory for
subsequent plotting.
Based on the assumptions that (1) the tank is adiabatic, (2) the tank content is perfectly stirred, and (3) the
dynamics of the actuator can be negligible, the process
mode1 based on the mass and energy balances is given by:

c----

i,

Figure 1 Schematic diagram of the levei and the temperature

control
process. (a) Difference pressure level transmitter;
(b) thermocouple;
(c)
control valve; (d) thyristor; and (e) heater

Kravaris and co-workers3*Q proposed

strategy:

the following

= -

(gx:f (A)&

i, = (p)u,

(1%

+(&&)u*

(15b)

and the output equation is given by:

Yl = XI

(l6a)

Y2 =

U6b)

x2

t
vi = 6,q,yise + K,,[y,*t-

(i=

l,...,m)

yi + f

I s
i

y,)dt]

(y,-

(13)

This is the special case of Equation (11) when

OiO

= sio and oik = 0

(i= 1,. . . ,m;k=l,

. . ,ri)

(14)

Application to chemical control processes

To examine the applicability of the decoupling and
linearization control theory, two simple chemical control
processes were constructed.
Level and temperature control process
This process is shown schematically in Figure 1. The tank
is a stirred column of 75 cm height and 15.6 cm diameter.
The tank is heated electrically by the coil heater, but it is
not lagged for insulation. The aim of the control is to
keep the liquid level and the temperature in the tank at
the desired values. The liquid is water, and the level is
measured by the difference pressure level transmitter.
The temperature is measured by the thermocouple
installed in the tank. In general, the liquid level and the
temperature are controlled by adjusting the feed flowrate and the current to the heater, respectively. It is clear,
however, that an interaction exists in this process. If the
feed flow-rate is changed, the temperature as well as the
liquid level must change.
A persona1 computer (NEC FC-9801) with A/D and
D/A converters was used to process the input and output
data and to compute the control values. The signals from
the difference pressure level transmitter and the thermo-

142

J. Proc. Cont. 1991, Vol 1, May

where x, and x2 are the liquid level and the temperature

in the tank, respectively. u, and u2 are the feed flow-rate
to the tank and the heat flow-rate from the heater, respectively. S, C,, p and k are the cross-sectional area of
the tank, the specific heat, the density and the constant
coefficient, respectively, and these have the following
values: S = 191 cm2; C, = 4.2 J g-, K-,; p = 1.0 g cm-3;
and k = 1.8 cmsi2 SK,. To is the temperature of the feed
and was about 18C, but this value varied from experiment to experiment according to the atmospheric temperature. The feed flow-rate and the heat flow-rate are
constrained as follows: 0 5 u, s 22 cm3 s-l and 0 5 u2
5 2700 J s-.
According to the decoupling and linearization control
theory:
u(x) =
kx, - 6,0Sx,
I C,pk(

sc-4 =

x2 -

TON kx,lS

6,0x, ) -

C,PS(

x2 -

S
To)

~,oQSx,

c,psx,

1
(174
(17b)

as the characteristic numbers are p, = p2 = 0. Then from

Equation (2), the decoupling and linearization control is
given by:
u, = kx, + S( v, - 6,,Sx, )
~2 =

C,P[(X,

ToI{ kx?

+
sx,

(1W

S(v,

(v2 -

b-41
62flx,)l

+
U8b)

As the values of y, and y2 can be measured by the sensors,

the values xl and x2 are also obtained by Equation (16).

Non-linear feedback transformation: K. Nakamoto and N. Watanabe

2o0

600

1200

1600

I
600

I
1200

1600

20

600

1200

1800

3025-

2o0

Time

1
2o0

Time

tsecl

Figure 2 Output responses for the step change in the level set points.
With no external PI controllers: (-) measured values; (- - - -) set
points

The reference trajectories

trollers are given by:
Y,ref =

yiW

( ydd

y,W

for the external PI con-

)e-6af

600

i= 1,2 )

1200

1600

Esecl

Figure 3 Output responses for the step changes in the level and
temperature set points. With no external PI controllers: (-) measured
values; (- - - -) set points

45

(19)

by using Equations (11) and (12). Here, ylgfis the initial

value of Yirefand is set to the initial value Of Yi.The values
U, and u2 are computed using Equations (19), (10) and
(1%
The selection of the values of &, is important. If the
larger value is selected, the control action becomes larger
and may reach the constraints. In this instance, the
decoupling and linearization cannot be realized. In contrast, if the smaller value is selected, the response is slow.
An appropriate selection must then be made. In this
study, these values were fixed as Fro = a,,, = 0.005.
At first, the control experiments without the external
PI controllers were carried out to examine the influence
of the modelling errors. Figure 2 shows the output responses of the level and the temperature when the set
point of the level was changed from 25 to 40 cm. Figure 3
shows the output responses of the level and the temperature when the set points of the level and the temperature
were changed from 25 to 40 cm and from 25 to 40C
respectively, at the same time. In both instances the final
values of the level and the temperature do not reach each
set point, although the influence of interaction can be
removed. This is caused by the modelling errors.
Next, the external PI controllers were added. These are
given by Equation (IO). The same experiments were performed and the parameter values of the controller were
tuned as: &, = Kp2 = 0.0166 and T,, = T+ = 51.2.

201

600

1200

1800

4oa--3530 25 -

I
2o0

600
Time

1200

1600

[secl

Figure 4 Output responses for the step change in the level set points.
With external PI controllers: (-) measured values; (- - - -) set points

These experimental results are shown in Figures 4 and 5.

It can be seen from these figures that the influence of the
modelling errors is removed and the control performance
is improved.

J. Proc. Cont. 1991, Vol 1, May

143

Non-linear feedback transformation: K. Nakamoto and N. Watanabe

point of neutrality, even if the control system is a SISO

system. The reactor used is the same vessel as for the
first process and a similar measuring and control system
was used. The process model under the appropriate
assumptions is given by:
g

I
600

201
0

I
1200

I
1600

= -

dxz _ -dt

(;)x;/f + (;)(U,

~a%lorlw

+ u*)

(204

1
)

[K(~2)

C*&,

where&x,) = - 10x2-14+ 10-XZandn(xZ) = 1Ox2-4 +

10mX2.The output equation is given by:
Yl

Y2 =

600
Time

1200
[SeCl

Figure 5 Output
responses for the step changes in the level and
temperature
set points. With external PI controllers:
(-) measured
values; (- - - -) set points

a
Figure 6 Schematic
Difference pressure
valves; (e) pH meter

diagram for the level and pH control process. (a)

level transmitter;
(b) pH sensor; (c,d) control

Xl

(214

x2

@lb)

Here xl and x2 are the liquid level and the value of pH,
respectively. uI and u2 are the feed flow-rate of the strong
acid and the strong base, respectively. As the procedure
to obtain the decoupled and linearized system based on
Equations (20) and (21) is the same as the previous
procedure, only the experimental results are given.
The values S and k are the same as the previous process. The feed concentrations were chosen as C,, = Cr,,,
= 0.03 mol cm-3. The feed flow-rates are constrained as
0 I ul, u2 5 22 cm3 s-r. The reference trajectories are
given by Equation (19) and the following parameters
were used: &, = i& = 0.02.
The control experiment with the external PI controllers was carried out as follows. At first, the set points
of the level and the pH were changed from 15 to 30 cm
and from 2.8 to 4, respectively, at the same time. At 900
s, the level set point only was changed from 30 to 35 cm
to examine the effect of the decoupling. This result is
shown in Figure 7. This figure shows that the influence of
the interaction is very small. In this experiment, the
following parameters were used: KP, = 3.0, Tll = 100,
KP = 0.3, and T, = 100.
fn the next expiriment, the set points of the level and
the pH were changed from 2.8 to 7.0 and from 15 to 30
cm, respectively, at the same time. To obtain a satisfactory result, however, the parameters of the external PI
controllers used in this experiment had to be changed to:
KP, = 0.1, Tl, = 300, KP2 = 0.03 and T12 = 300. This
experimental result is shown in Figure 8. The control
result is not good, but is satisfactory.

Level and pH control process

A neutralization reaction process, which is schematically

shown in Figure 6, of a strong acid (HCl) at a concentration C,, and a strong base (NaOH) at a concentration
CsO, was also studied. This process is more non-linear
than the level and temperature control process and an
interaction also exists between the parameters. The aim
of this control process is to keep the liquid level and the
pH at the desired values. It is known that this control
problem is very difficult when the set point is near the

144

J. Proc. Cont. 1991, Vol 1, May

Conclusions
The decoupling and linearization control theory was
experimentally applied to two non-linear MIMO chemical control processes. The control experiments showed
that even if the processes are non-linear and interactive
and modelling errors are present, a satisfactory control
performance can be obtained.

Non-linear feedback transformation: K. Nakamoto and N. Watanabe

I
600

lo0

I
1200

I00

1600

600

1200

I
1600

765-

2O

600

1200

Time

2O

Time
Figure 8

points. (-)

References
1 Isidori, A., Nonlinear Control Systems: An Introduction, 2nd edn,
Springer-Verlag, Berlin, 1989, p. 234
2 Sastry, S. and Bodson, M., Adaptive control: stability, convergence
and robustness, Prentice-Hall, New Jersey, 1989, p. 294
3 Kravaris, C. and Soroush, M. AIChE J. 1990,36,249
4 Paszkiewicz, D. P., IFAC Adaptive Control of Chemical Processes,
Cqpenhagen, Denmark, 1988, p. 75
5 Kravaris, C. and Chung, C.-B., AIChE J. 1987,33,592
6 Daoutidis, P. and Kravaris, C., AIChE J. 1989,35, 1602
7 Buchholt;F. and Kiimmel, M., Automafica 1979,15,665

g,
h

c
CP

KP
k
Lf
m
n

I
1600

[secl

Output responses for the step changes in the level and pH set
Measured values; (- - - -) set points
order of the reference model defined in Equation (I 1)
cross-sectional area of tank
temperature
resf3 time of external PI controller
input variable
new input variable
state variable
output variable

Greek letters
defined in Equation (6a)
defined in Equation (6b)
parameter
parameter
density
characteristic number

Nomenclature
matrix, defined in Equation (Sa)
vector, defined in Equation (5b)
function
function
function
concentration
specific heat
proportional gain of external PI controller
constant coefficient
Lie derivative defined in Equation (4)
number of input and output
number of state variable

I
1200

600

[secl

Figure 7 Output responses for the step changes in the level and pH set
points. (-) Measured values; (- - - -) set points

A
b

I
1800

hydrochloric acid, HCl

sodium hydroxide, NaOH
feed

Superscripts
ref
set

reference trajectory
set point

J. Proc. Cont. 1991, Vol 1, May

145