Kiln control and upset recovery using a model predictive control in series with forward chaining

1. A method for controlling a non-linear process, comprising the steps of:

providing a controller that is operable to receive inputs representing measured variables of the process and predicting on an output of the controller predicted control values for manipulatible variables that control the process, which controller defines the parameters of operation for the prediction operation;

providing an expert system that models the actions of an operator of the process over an operating region of the process that represents a set of rules for actions to be taken by an operator upon the occurrence of one of a plurality of predetermined conditions in the operation of the process, which predetermined conditions each represent an upset in the operation of the process; and

modifying the operation of the controller with the expert system when one of the predetermined conditions exists such that the controller is re parameterized to take account of the upset to the non-linear process.

2. The method of claim 1 , wherein the controller is operable to model the dynamics of the plant.

3. The method of claim 1 , wherein the dynamics of the plant are modeled over a defined region of the input space.

4. The method of claim 1 , wherein the controller comprises a Model Predictive Controller (MPC) and a feedback predictive control system, wherein the MPC is operable to provide result is a matrix of time responses, where each response reflects the dynamic interaction of a controlled variable to a manipulated variable.

5. The method of claim 4 , wherein the step of modifying comprises the step of adding a time response to the matrix of time responses that reflects the determined response of the non-linear process to the upset, which added time response was determined by manually forcing the upset on the non-linear process.

6. The method of claim 5 , wherein the step of modifying comprises modifying targets by setting targets for both controlled and manipulated variables, and the MPC will control the feedback predictive control system to try and force all variables to their desired targets.

7. The method of claim 5 , wherein the MPC controls the manner by which the feedback predictive control system controls the controlled variables and can effect such with different solutions by changing the manner by which control is effected based on multiple different solutions which are based upon predetermined relative priorities between manipulated variables and controlled variables and wherein the step of modifying is operable to modify such priorities.

8. The method of claim 5 , wherein the step of modifying comprises modifying upper and lower hard constraints for select ones of the manipulated and controllable process variables.

9. The method of claim 5 , wherein the step of modifying comprises modifying upper and lower soft constraints for select ones of the manipulated and controllable process variables.

10. The method of claim 1 , wherein the process comprises a fuel powered process and the upset comprises termination of one type of fuel and substitution of another type of fuel.

11. The method of claim 1 , and further comprising the step of overriding the operation of the controller with the expert system when one of the predetermined conditions exists and taking the associated action by the expert system to control the operation of the process by changing one or more of the manipulatible variables.

12. A method for controlling a non-linear cement kiln process that is operated on one of multiple fuel types, comprising the steps of:

providing a controller that is operable to receive inputs representing measured variables of the process and predicting on an output of the controller predicted control values for manipulatible variables that control the process, which controller defines the parameters of operation for the prediction operation;

providing an expert system that models the actions of an operator of the process over an operating region of the process that represents a set of rules for actions to be taken by an operator upon the occurrence of termination of one type of fuel and substitution of another fuel type, which substitution represents an upset in the operation of the process; and

modifying the operation of the controller with the expert system when the substitution occurs such that the controller is re parameterized to take account of the substitution to the non-linear process.

13. The method of claim 12 , wherein the controller comprises a Model Predictive Controller (MPC) and a feedback predictive control system, wherein the MPC is operable to provide result is a matrix of time responses, where each response reflects the dynamic interaction of a controlled variable to a manipulated variable.

14. The method of claim 13 , wherein the step of modifying comprises the step of adding a time response to the matrix of time responses that reflects the determined response of the non-linear process to the substitution, which added time response was determined by manually forcing the substitution on the non-linear process.

15. The method of claim 14 , wherein the step of modifying comprises modifying targets by setting targets for both controlled and manipulated variables, and the MPC will control the feedback predictive control system to try and force all variables to their desired targets.

16. The method of claim 14 , wherein the MPC controls the manner by which the feedback predictive control system controls the controlled variables and can effect such with different solutions by changing the manner by which control is effected based on multiple different solutions which are based upon predetermined relative priorities between manipulated variables and controlled variables and wherein the step of modifying is operable to modify such priorities.

17. The method of claim 14 , wherein the step of modifying comprises modifying upper and lower hard constraints for select ones of the manipulated and controllable process variables.

18. The method of claim 14 , wherein the step of modifying comprises modifying upper and lower soft constraints for select ones of the manipulated and controllable process variables.

19. The method of claim 12 , and further comprising the step of overriding the operation of the controller with the expert system when one of the predetermined conditions exists and taking the associated action by the expert system to control the operation of the process by changing one or more of the manipulatible variables.