Methods and apparatus for process control using catalyst state estimation

A process control system for controlling a physical process of the type utilizing a catalyst to produce an end product from one or more substances, the system comprising:

• a set of input/output components configured to interface with the process;
• a process controller coupled to and configured to exchange electrical signals with the set of input/output components;
• a process server and an operator station coupled to the process controller over a network, the process server, operator station, and process controller configured to collectively perform the steps of:
• defining a state space model for the process, the state space model including a catalyst state comprising a hidden catalyst property in the form of a distribution of catalyst weight percent with respect to the one or more substances;
• defining a set of input variables for the state space model, wherein the input variables are empirically measurable properties of the process;
• defining a set of output variables for the state space model, wherein the output variables are empirically measurable properties of the process;
• measuring a set of input values corresponding to the set of input variables;
• measuring a set of output values corresponding to the set of output variables;
• and estimating the hidden catalyst property based on the input values, the output values, and the state space model;
• wherein the process controller is further configured to control the process in a manner responsive to the estimating step in order to produce the end product.