A rigorous computationally effcient closed-loop system with a gain-scheduled model predictive controller (MPC) is developed for the first time, where a first-principle model of the steam methane reformer is utilized to represent the process dynamics. A dynamic model for a generic primary gas reformer is developed using a homogeneous-phase one-dimensional reaction kinetics model to describe the chemical reactions inside the reforming tubes and to compute the external heat transfer to the reformer tubes by radiation and convection. The gain-scheduled MPC considers critical process parameters of the steam methane reformer such as outlet methane molar concentration and outlet temperature of the reformed gas as the most appropriate and reliable process variables. The developed gain-scheduled MPC demonstrates adaptive and advanced operation of the steam methane reformer at three different steam-to-carbon ratios. By simulation of the set-point changes under the influence of the steam methane reformer critical disturbance rejection performances, it is shown that reformer tubes could operate in a safe temperature range. The model determines optimal trajectories of the reformed syngas outlet temperature and methane outlet molar concentration based on tracking the set point under the influence of the manipulated variables—temperature and mass rate of mixed feed and fuel flow rate for burners. The gain-scheduled MPC is compared with already proven standard process control solutions based on proportional-integral-derivative (PID) controllers. Proposed control strategy benefits include energy savings in the range from 3% to 5% and prolonged lifetime of the reformer tubes and catalyst.

中文翻译：

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基于增益调度模型预测控制的甲烷转化炉的高级运行

首次开发了具有增益调度模型预测控制器（MPC）的严格的计算有效闭环系统，其中蒸汽甲烷重整器的第一原理模型用于表示过程动力学。使用均相一维反应动力学模型开发了通用一次气体重整器的动力学模型，以描述重整管内部的化学反应，并通过辐射和对流计算外部热量传递至重整管。增益调度的MPC将蒸汽甲烷重整器的关键过程参数（例如出口甲烷摩尔浓度和重整气体的出口温度）视为最合适和可靠的过程变量。已开发的增益计划MPC演示了蒸汽甲烷重整器在三种不同的蒸汽碳比下的自适应和高级操作。通过模拟设定值在蒸汽甲烷重整器临界干扰抑制性能的影响下的变化，表明重整管可以在安全的温度范围内运行。该模型基于在受控变量（温度和混合进料的质量速率以及燃烧器的燃料流量）的影响下跟踪设定点，从而确定重整合成气出口温度和甲烷出口摩尔浓度的最佳轨迹。计划的增益的MPC与已经验证的基于比例积分微分（PID）控制器的标准过程控制解决方案进行了比较。