Online model-based optimization and control for the combined optimal operation and runaway prediction and prevention in (fed-)batch systems

• An advanced model-based strategy for online optimization and optimal control is broached.
• The strategy is effective to handle batch systems subject to runaway conditions.
• It allows to provide profitable online optimization and predict potential hazardous situations
• It stops the batch process in advance when no operational solutions are possible.

An advanced model-based strategy for the online optimization and/or optimal control of (fed-)batch systems, the BSMBO&C, is applied to discontinuous equipment that can be subject to runaway phenomena. The aim is that of showing that it is simultaneously possible to provide profitable online optimization and/or optimal control policies, predict possible future hazardous situations in advance and automatically decide whether and when to (optimally) stop a production cycle in order to prevent safety risks (unavoidable runaways). All these actions are performed online, thus allowing for the effect of any external perturbation. A fed-batch process based on a well-known example of runaway reaction, i.e. the oxidation of 2-octanol to 2-octanone with nitric acid in aqueous solution, is selected as a benchmark to test the real attainability of simultaneous process profitability and safety.