Control of a complex multistep process for the production of mesalazine

• Published in: Journal of process control Vol. 122; pp. 59 - 68
• Main Authors: Castillo, Ismael, Rehrl, Jakob, Sagmeister, Peter, Lebl, René, Kruisz, Julia, Celikovic, Selma, Sipek, Martin, Kirschneck, Dirk, Horn, Martin, Sacher, Stephan, Cantillo, David, Williams, Jason D., Khinast, Johannes G., Kappe, C. Oliver
• Format: Journal Article
• Language: English
• Published: Elsevier Ltd 01.02.2023
• Subjects: Data driven models; LoLiMoT identification; Multi-step continuous flow process; Non-linear model predictive control; Synthesis of active pharmaceutical ingredient; Non-linear model predictive control; Synthesis of active pharmaceutical ingredient; Multi-step continuous flow process; Data driven models; LoLiMoT identification
• ISSN: 0959-1524; 1873-2771
• DOI: 10.1016/j.jprocont.2022.12.009

This paper presents the application of Data Driven Modelling (DDM) and Non-Linear Model Predictive Control (NMPC) for the control implementation of a continuous reactor for the production of the Active Pharmaceutical Ingredient (API), Mesalazine. The contribution of this work is to present the overall control architecture, the step-by-step controller design based on DDM, i.e. Neuro-Fuzzy/Local Linear Model Tree Models (LoLiMoT) and NMPC. We demonstrate the advantages of DDM and NMPC, in the presence of non-linear, distributed parameter, multi-variable systems as a suitable, powerful and practical way to approach complex process control challenges. Compared to conventional concepts, the inherent optimization structure of NMPC allows to obtain the desired behaviour of the multi-variable non-linear plant considering the physical constraints of operation regions. The control concept has been implemented in the real system on one central computer, XamControl (Evon),11https://evon-automation.com/. with all measurement devices and actuators centrally interconnected. •Integration of a multistep continuous flow process with Process Analytical Technology•Multistep continuous flow synthesis of Active Pharmaceutical Ingredient, Mesalazine•Control of a multistep continuous flow process by a single process unit XamControl•Digital Twin development via Data Driven Neuro Fuzzy Model and Local Linear Model Tree•Nonlinear Model Predictive Control including reactor physical-chemical constraints