Batch-to-batch optimization of an industrial reactor using modifier adaptation

We explore batch-to-batch optimization of a simulated semi-batch process, which represents an important industrial process at BASF. Our primary objectives are to ensure safe batch operations, to produce within specifications, and to increase the throughput. To achieve these goals, Modifier Adaptation with Quadratic Approximation (MAWQA) is employed to optimize key operational parameters iteratively over a sequence of batches. By integrating modifier adaptation with the quadratic approximation used in derivative-free optimization, sensitivity to noise is reduced, and the speed of convergence is improved. A challenging feature of the case considered here is that the constraints involve the maximum temperature and pressure over the batch, which depends on the interaction of feedback controllers with the plant, and that the product quality can only be determined at the end of the batch.