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Abstract

An adaptive process control system which is responsive to both process measurement input signals and economic environment inputs is provided. The process control system features an interactive optimization modeling system for periodically determining one or more manipulated process variables (also known as setpoints). These manipulated process variables are used to position directly controllable process parameters and attributes of a manufacturing system, such as a valve controlling the temperature of a coolant or a valve controlling the flow rate in a steam line. The interactive optimization modeling system comprises a plurality of mathematically-based models of the physical process and optimizing engines which are integrated by interactive communication paths to converge upon and determine 1) an optimized set of real-time input signals constrained by physical conservation laws ('data reconciliation'), 2) an optimized parameter-set for the model, representing the actual process behavior, ('process parameter estimation'), and 3) an economically optimized set of values for the manipulated process variables ('economic real-time process control setpoints'). In one form of the present invention, Lagrangian multipliers are used by the optimizing modeling system to facilitate the solution of the optimization models and establish a direct relationship between the current economic conditions and the status of the manufacturing system as a technical entity.

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