Nowcasting, predictive control, and feedback control for temperature regulation in a novel hybrid solar-electric reactor for continuous solar-thermal chemical processing

A novel 15 kW reactor for the hybridization of concentrated solar and conventional electric heat was fabricated for renewable and continuous chemical processing at temperatures up to 1700 °C. Solar-electric controllers based on feedback or predictive linear models were used to regulate the device at 925 °C for the production of syngas via the gasification of carbon. The system was challenged with cloud transients programmed on a 45 kW high-flux solar simulator that approximated weather observed in the San Luis Valley (Colorado, USA). In experiment it was found that model predictive control with a 1 min ahead nowcast of incipient clouding best regulated solar-electric reactor temperatures, potentially averting thermal fatigue. Upon clouding, model predictive control with a nowcast yielded temperature disturbances of ±10 °C, whereas feedback control alone featured ±25 °C excursions. Overall, the performance of model predictive control with a nowcast was 75% better than feedback as indicated by the integral squared error of temperature excursion residuals. The importance of nowcast accuracy was explored, and although the model-based controller was robust to forecast amplitude inaccuracy, temporal forecast inaccuracy wholly negated the benefits of predictive control.