Integrating Model Predictive Control with Deep Reinforcement Learning for Robust Control of Thermal Processes with Long Time Delays

Thermal processes with prolonged and variable delays pose considerable difficulties due to unpredictable system dynamics and external disturbances, often resulting in diminished control effectiveness. This work presents a hybrid control strategy that synthesizes deep reinforcement learning (DRL) strategies with nonlinear model predictive control (NMPC) to improve the robust control performance of a thermal process with a long time delay. In this approach, NMPC cost functions are formulated as learning functions to achieve control objectives in terms of thermal tracking and disturbance rejection, while an actor–critic (AC) reinforcement learning agent dynamically adjusts control actions through an adaptive policy based on the exploration and exploitation of real-time data about the thermal process. Unlike conventional NMPC approaches, the proposed framework removes the need for predefined terminal cost tuning and strict constraint formulations during the control execution at runtime, which are typically required to ensure robust stability. To assess performance, a comparative study was conducted evaluating NMPC against AC-based controllers built upon policy gradient algorithms such as the deep deterministic policy gradient (DDPG) and the twin delayed deep deterministic policy gradient (TD3). The proposed method was experimentally validated using a temperature control laboratory (TCLab) testbed featuring long and varying delays. Results demonstrate that while the NMPC–AC hybrid approach maintains tracking control performance comparable to NMPC, the proposed technique acquires adaptability while tracking and further strengthens robustness in the presence of uncertainties and disturbances under dynamic system conditions. These findings highlight the benefits of integrating DRL with NMPC to enhance reliability in thermal process control and optimize resource efficiency in thermal applications.