Performance of predictive control for a continuous horizontal fluidized bed dryer

Advanced process control can benefit to the operation efficiency and quality of tablets produced by wet granulation lines. Following the development of a new fully continuous fluidized bed reactor as a potential substitute for the current batch dryer design, this paper examines the energy and product quality performances of two predictive control strategies using an experimentally validated simulator. The first one proposes an economic model predictive controller explicitly minimizing the dryer energy consumption. The second one follows the same objective, but uses a simpler classical predictive control framework implementing targets on manipulated variables to drive them toward low energy consumption operating points. Both controllers lead to similar performances, and consume about 20% less energy than a reference feedback scheme without manipulated variable setpoints. Results also show that tracking the product quality attribute significantly benefits from a feedforward action because of the long residence time. This article addresses a subject little explored by the literature, the control of continuous fluidized bed dryers, and clearly demonstrates that a standard linear strategy can reduce the operating costs with an appropriate design. (C) 2022 Elsevier Ltd. All rights reserved.

Automated summary

This paper examines the impact of advanced process control on the operation efficiency and product quality in wet granulation lines. The results show that using an economic model predictive controller or a classical predictive control framework can significantly reduce energy consumption and improve product quality.