Modeling and Model Predictive Control of an Industrial Hydraulic System

This thesis aims to illustrate the construction of a mathematical model of a hydraulic system, oriented to the design of a model predictive control (MPC) algorithm. The modeling procedure starts with the basic formulation of a piston-servovalve system. The latter is a complex non linear system with some unknown and not measurable effects that constitute a challenging problem for the modeling procedure. The first level of approximation for system parameters is obtained basing on datasheet informations, provided workbench tests and other data from the company. Then, to validate and refine the model, open-loop simulations have been made for data matching with the characteristics obtained from real acquisitions. The final developed set of ODEs captures all the main peculiarities of the system despite some characteristics due to highly varying and unknown hydraulic effects, like the unmodeled resistive elements of the pipes. After an accurate analysis, since the model presents many internal complexities, a simplified version is presented. The latter is used to linearize and discretize correctly the non linear model. Basing on that, a MPC algorithm for reference tracking with linear constraints is implemented. The results obtained show the potential of MPC in this kind of industrial applications, thus a high quality tracking performances while satisfying state and input constraints. The increased robustness and flexibility are evident with respect to the standard control techniques, such as PID controllers, adopted for these systems. The simulations for model validation and the controlled system have been carried out in a Python code environment.

Re-wetting potential of limestone filter cakes under mechanical decompression

During pressure filtration, the filter cake can experience deformation. When the filter cake exhibits elastic rheological behaviour, it expands while the pressure is released and, if adjacent liquid is present, re-wetting may occur. Such an expanding filter cake can pick up liquid already removed, worsening solid-liquid separation performances. Undesired phenomena such as filter cake re-wetting run contrary to solid-liquid separation performances and, specifically, to the separation target of obtaining a high dry solid content. At the industrial level, even a small quantity of liquid that can be additionally removed is beneficial. Re-wetting phenomenon is investigated using two different limestone materials and different filters and felts, respectively. Water storage capacity of filters and felts and elastic properties of filters, felts, and filter cakes are investigated. The elastic tests performed show that the filters and the felts are non-linear viscoelastic materials and can have a potential for re-wetting, while the limestone filter cakes are not showing measurable elastic deformation under decompression. However, during a filtration test an additional felt layer placed under the filter seems to result in a slightly higher cake dryness, i.e., an increase of the cake dryness by around 1% only. This difference may not be attributed to the re-wetting effect.