Modeling and Optimization of an Automatic Temperature Control System for the Catalytic Cracking Process

Modern oil refining is faced with the need to maximize raw material processing in the face of fierce competition and environmental requirements. Therefore, the fluid catalytic cracking (FCC) process, key to the production of high-octane gasoline, requires special attention to automation efficiency. Maintaining optimal reactor temperature is a complex scientific and technical challenge, the solution to which directly impacts the yield of target products and the service life of the catalyst. Existing automatic control systems often fail to cope with process transients, nonlinearities, and time delays, making the search for new control approaches highly relevant. The scientific significance of this study lies in the system analysis and quantitative comparison of the effectiveness of classical control laws (P, PI, PID) applied to a plant with a delay. For the first time, a rigorous comparative analysis of tuning methods—analytical (based on phase margin specifications) and automated (using the PID Tuner tool in MATLAB Simulink R2024b)—is performed for a plant characterized as a second-order system with time delay, formed by the series connection of two first-order lag elements with transport delay. The results contribute to automatic control theory by clearly demonstrating the limitations of the proportional controller and the insufficient speed of the integral controller, as well as confirming the hypothesis that a PID law is necessary to achieve a balance between accuracy and response speed under inertia conditions. The practical significance of the work is confirmed by the development of an optimized automatic temperature control system. Using the PID Tuner tool, we achieved critical industrial performance indicators: zero static error, minimal control time (44 s), and acceptable overshoot (9.6%). The system’s robustness (maintaining stability with changes in plant parameters by 30–40%) and its invariance to the main disturbance (catalyst temperature fluctuations), confirmed during simulation, guarantee the viability of the proposed solution under real-world production conditions. Implementation of such a controller will minimize deviations from the process conditions, leading to increased yield of light petroleum products and an extended service life of the expensive catalyst, providing direct economic benefits.