Predictive functional control for separation processes by liquid-liquid extraction

A separation process by liquid-liquid extraction is a well-known and widespread industrial technology implemented to quantitatively recover valuable chemical elements. In the nuclear industry, such processes have been used for decades to recover uranium and plutonium from spent fuel. The process is non-linear and time constants vary over a wide range. Former studies on a simplified model showed linear controllers such as PID were not adapted to regulate these separation processes. The objective of this study is to propose process monitoring by using available physical models within the PAREX code and to validate the feasibility to monitor a separation process by using directly the PAREX code as a black box. The Predictive Functional Control (PFC) command law manages to monitor non-linear separation processes by liquid-liquid extraction, when using an existing physical model implemented in the PAREX code. An online alignment of the model on process values is necessary to keep the model sufficiently representative to predict the future behaviour of the process. As a reference benchmark, the PID control loop is also simulated with the physical model. The PFC and PID regulations are compared to evaluate the gain of using physical models implemented in the PAREX code. A simulation tool has been developed to implement the PID and Predictive Functional Control (PFC) controllers for separation processes by liquid-liquid extraction. The PFC command law manages to monitor non-linear separation processes, when using a physical model connected to the PAREX code. Even if the PID controller may be locally more efficient, the great strength of the PFC controller is to enable good performances on wider operating conditions, with an easier parametrization. The PFC algorithm is a mean to deal with the process characteristic features, like non-linearity and time constant change. The PFC controller appears to be a good candidate for experimental tests. A mid-term objective is to include the state estimator tool in the control loop to consolidate the controlled variable measurements. These developments may be regarded as an add-on module in a digital factory concept. Results shown in this article are only from simulation. For the sake of data confidentiality, studies with the PAREX code cannot be published and numerical parameters of the process are normalized. These simulations will be validated during further experimental tests.