基于动力学线性化的先进过程控制策略在蛋氨酸结晶中的应用

Application of Advanced Process Control Strategy Based on Kinetic Linearization in Methionine Crystallization

摘要

蛋氨酸在工业结晶过程中存在稳定性差、工况复杂以及产品易团聚等诸多问题，导致产品质量不稳定，生产系统很难持续高效运行．本文使用了导流筒-挡板型结晶器，配备完整的控制系统、循环系统以及分离系统．控制系统依托单回路和串级控制，并使用可靠的质量流量计、在线粒度分析仪等工业仪表，获得二次成核过程关键参数，实现对结晶过程变量的间接感知．进一步将结晶动力学各控制变量通过变换进行线性化处理，并引入先进过程控制策略，成功构建了适用性较强的多变量动力学混合控制体系．工业化应用后，人工调控频率在进料不稳定的工况下由初始的 8 次/h 降至 0 次/h，实现搅拌转速和母液采出的自动控制，D₁₀、D₅₀ 和 D₉₀ 波动现象显著收敛．产品核心质量指标与市售产品相近，粒径分布由双峰现象趋向正态分布，产品堆积密度提高约 10%，显微形貌显示团聚情况得到有效抑制．先进过程控制策略的应用在强耦合与大时滞条件下仍具有较好的鲁棒性和可用性，能够大幅减少人工干预频次，实现蛋氨酸结晶产品质量的有效控制，显著提高蛋氨酸工业结晶过程的稳定性及产品一致性．

Abstract

Methionine crystallization faces numerous challenges in industrial crystallization processes，such as poor stability，complex operating conditions，and product agglomeration. These issues lead to unstable product quality and make it difficult to maintain sustained，efficient operation of the methionine production system. Herein，a draft tube-baffle crystallizer was employed，equipped with a complete control system，a circulation system，and a separation system. The control system used single-loop and cascade control strategies and incorporated reliable industrial instruments，such as mass flow meters and online particle size analyzers，to monitor key parameters of secondary nucleation，thereby enabling indirect observation of crystallization process variables. Furthermore，by transforming and linearizing the control variables of crystallization kinetics and introducing advanced process control strategies，a highly adaptable multivariable kinetic hybrid control system was successfully implemented. After industrial application，under conditions of unstable feed，the frequency of manual adjustments decreased from eight times per hour to zero，achieving automatic control of stirring speed and mother liquor discharge. Fluctuations in D₁₀，D₅₀，and D₉₀ significantly converged，and the core quality indicators of the product became comparable to those of commercially available methionine. Additionally，the particle size distribution shifted from a bimodal pattern toward a normal distribution. The bulk density of the product increased by about 10%，and microscopic analysis revealed that agglomeration was effectively suppressed. Even under conditions of strong coupling and significant time delays，the advanced process control strategies proved robust and effective. This approach substantially decreases manual intervention，ensures precise control of methionine product quality，and markedly improves the stability and uniformity of the industrial methionine crystallization process.

关键词

蛋氨酸 / 工业结晶 / 过程控制 / 模型开发

Key words

methionine / industrial crystallization / process control / model development

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基金资助

国家自然科学基金资助项目(22278300，22478284)