Data-driven Soft Sensors in the Process Industry

In the last two decades Soft Sensors established themselves as a valuable alternative to the traditional means for the acquisition of critical process variables, process monitoring and other tasks which are related to process control. This paper discusses characteristics of the process industry data which are critical for the development of data-driven Soft Sensors. These characteristics are common to a large number of process industry fields, like the chemical industry, bioprocess industry, steel industry, etc. The focus of this work is put on the data-driven Soft Sensors because of their growing popularity, already demonstrated usefulness and huge, though yet not completely realised, potential. A comprehensive selection of case studies covering the three most important Soft Sensor application fields, a general introduction to the most popular Soft Sensor modelling techniques as well as a discussion of some open issues in the Soft Sensor development and maintenance and their possible solutions are the main contributions of this work

Composition Prediction of Debutanizer Column using Neural Network

In oil refining industries, debutanizer column is one of the important unit operations. Debutanizer column is the main column used to produce the main product in oil refinery process. The online composition prediction of top and bottom product of debutanizer column using neural network will be an aid to increase product quality monitoring in oil refining industry. In this work, a single dynamic neural network model is used in order to achieve the objective which is to generate composition prediction online of the top and bottom product of debutanizer column. Neural network is a computing system with several of simple and highly interconnected processing elements that will process information using their dynamic state response to external inputs. It is a software based sensor method or known as “soft sensor” which is a helpful technology that utilizes software techniques to infer the value of important but difficult-to-measure process variables from available process variables which are requisite from physical sensor observation or lab measurements. The neural network development and equation based model for ibutane, i-pentane, n-butane, n-pentane and propane has been obtained. Then, these results will be compared with proportional integral derivatives (PID) controller design to show its supremacy over this method

Simulation, optimization and instrumentation of agricultural biogas plants

During the last two decades, the production of renewable energy by anaerobic digestion (AD) in biogas plants has become increasingly popular due to its applicability to a great variety of organic material from energy crops and animal waste to the organic fraction of Municipal Solid Waste (MSW), and to the relative simplicity of AD plant designs. Thus, a whole new biogas market emerged in Europe, which is strongly supported by European and national funding and remuneration schemes. Nevertheless, stable and efficient operation and control of biogas plants can be challenging, due to the high complexity of the biochemical AD process, varying substrate quality and a lack of reliable online instrumentation. In addition, governmental support for biogas plants will decrease in the long run and the substrate market will become highly competitive. The principal aim of the research presented in this thesis is to achieve a substantial improvement in the operation of biogas plants. At first, a methodology for substrate inflow optimization of full-scale biogas plants is developed based on commonly measured process variables and using dynamic simulation models as well as computational intelligence (CI) methods. This methodology which is appliquable to a broad range of different biogas plants is then followed by an evaluation of existing online instrumentation for biogas plants and the development of a novel UV/vis spectroscopic online measurement system for volatile fatty acids. This new measurement system, which uses powerful machine learning techniques, provides a substantial improvement in online process monitoring for biogas plants. The methodologies developed and results achieved in the areas of simulation and optimization were validated at a full-scale agricultural biogas plant showing that global optimization of the substrate inflow based on dynamic simulation models is able to improve the yearly profit of a biogas plant by up to 70%. Furthermore, the validation of the newly developed online measurement for VFA concentration at an industrial biogas plant showed that a measurement accuracy of 88% is possible using UV/vis spectroscopic probes

Deep Learning-Based Machinery Fault Diagnostics

This book offers a compilation for experts, scholars, and researchers to present the most recent advancements, from theoretical methods to the applications of sophisticated fault diagnosis techniques. The deep learning methods for analyzing and testing complex mechanical systems are of particular interest. Special attention is given to the representation and analysis of system information, operating condition monitoring, the establishment of technical standards, and scientific support of machinery fault diagnosis

Intra and inter-brand calibration transfer for near infrared spectrometers

Robust modeling methods were implemented for the transfer of near-infrared calibration models in intra and inter-brand situations. A network of four instruments from two brands (Foss Infratecs and Bruins OmegAnalyzerGs) was used to implement spectral pretreatment methods, local and variable selection techniques, and orthogonal methods to transfer protein, oil, and linolenic acid models across instruments of the same brand and across instruments of different brands. A total of fifty seven techniques were implemented among which spectral filtering methods based on the smoothing of high frequency components of Fourier and wavelet transforms. A new approach to local similarity was introduced. Results showed that the effectiveness of the various methods was instrument, parameter, and validation set dependent. In some situations, no differences could be observed between master and secondary unit predictions. Local methods appeared to be the weakest methods, most likely due to a problem of over-fitting (specialization) of the calibration set. The transfer of calibrations across brands was possible with performances similar, or better, than in intra-brand calibration transfer

Applications of Computational Intelligence to Power Systems

In power system operation and control, the basic goal is to provide users with quality electricity power in an economically rational degree for power systems, and to ensure their stability and reliability. However, the increased interconnection and loading of the power system along with deregulation and environmental concerns has brought new challenges for electric power system operation, control, and automation. In the liberalised electricity market, the operation and control of a power system has become a complex process because of the complexity in modelling and uncertainties. Computational intelligence (CI) is a family of modern tools for solving complex problems that are difficult to solve using conventional techniques, as these methods are based on several requirements that may not be true all of the time. Developing solutions with these “learning-based” tools offers the following two major advantages: the development time is much shorter than when using more traditional approaches, and the systems are very robust, being relatively insensitive to noisy and/or missing data/information, known as uncertainty

On robust and adaptive soft sensors.

In process industries, there is a great demand for additional process information such as the product quality level or the exact process state estimation. At the same time, there is a large amount of process data like temperatures, pressures, etc. measured and stored every moment. This data is mainly measured for process control and monitoring purposes but its potential reaches far beyond these applications. The task of soft sensors is the maximal exploitation of this potential by extracting and transforming the latent information from the data into more useful process knowledge. Theoretically, achieving this goal should be straightforward since the process data as well as the tools for soft sensor development in the form of computational learning methods, are both readily available. However, contrary to this evidence, there are still several obstacles which prevent soft sensors from broader application in the process industry. The identification of the sources of these obstacles and proposing a concept for dealing with them is the general purpose of this work. The proposed solution addressing the issues of current soft sensors is a conceptual architecture for the development of robust and adaptive soft sensing algorithms. The architecture reflects the results of two review studies that were conducted during this project. The first one focuses on the process industry aspects of soft sensor development and application. The main conclusions of this study are that soft sensor development is currently being done in a non-systematic, ad-hoc way which results in a large amount of manual work needed for their development and maintenance. It is also found that a large part of the issues can be related to the process data upon which the soft sensors are built. The second review study dealt with the same topic but this time it was biased towards the machine learning viewpoint. The review focused on the identification of machine learning tools, which support the goals of this work. The machine learning concepts which are considered are: (i) general regression techniques for building of soft sensors; (ii) ensemble methods; (iii) local learning; (iv) meta-learning; and (v) concept drift detection and handling. The proposed architecture arranges the above techniques into a three-level hierarchy, where the actual prediction-making models operate at the bottom level. Their predictions are flexibly merged by applying ensemble methods at the next higher level. Finally from the top level, the underlying algorithm is managed by means of metalearning methods. The architecture has a modular structure that allows new pre-processing, predictive or adaptation methods to be plugged in. Another important property of the architecture is that each of the levels can be equipped with adaptation mechanisms, which aim at prolonging the lifetime of the resulting soft sensors. The relevance of the architecture is demonstrated by means of a complex soft sensing algorithm, which can be seen as its instance. This algorithm provides mechanisms for autonomous selection of data preprocessing and predictive methods and their parameters. It also includes five different adaptation mechanisms, some of which can be applied on a sample-by-sample basis without any requirement to store the on-line data. Other, more complex ones are started only on-demand if the performance of the soft sensor drops below a defined level. The actual soft sensors are built by applying the soft sensing algorithm to three industrial data sets. The different application scenarios aim at the analysis of the fulfilment of the defined goals. It is shown that the soft sensors are able to follow changes in dynamic environment and keep a stable performance level by exploiting the implemented adaptation mechanisms. It is also demonstrated that, although the algorithm is rather complex, it can be applied to develop simple and transparent soft sensors. In another experiment, the soft sensors are built without any manual model selection or parameter tuning, which demonstrates the ability of the algorithm to reduce the effort required for soft sensor development. However, if desirable, the algorithm is at the same time very flexible and provides a number of parameters that can be manually optimised. Evidence of the ability of the algorithm to deploy soft sensors with minimal training data and as such to provide the possibility to save the time consuming and costly training data collection is also given in this work

Advanced Process Monitoring for Industry 4.0

This book reports recent advances on Process Monitoring (PM) to cope with the many challenges raised by the new production systems, sensors and “extreme data” conditions that emerged with Industry 4.0. Concepts such as digital-twins and deep learning are brought to the PM arena, pushing forward the capabilities of existing methodologies to handle more complex scenarios. The evolution of classical paradigms such as Latent Variable modeling, Six Sigma and FMEA are also covered. Applications span a wide range of domains such as microelectronics, semiconductors, chemicals, materials, agriculture, as well as the monitoring of rotating equipment, combustion systems and membrane separation processes

A Review of Kernel Methods for Feature Extraction in Nonlinear Process Monitoring

Kernel methods are a class of learning machines for the fast recognition of nonlinear patterns in any data set. In this paper, the applications of kernel methods for feature extraction in industrial process monitoring are systematically reviewed. First, we describe the reasons for using kernel methods and contextualize them among other machine learning tools. Second, by reviewing a total of 230 papers, this work has identified 12 major issues surrounding the use of kernel methods for nonlinear feature extraction. Each issue was discussed as to why they are important and how they were addressed through the years by many researchers. We also present a breakdown of the commonly used kernel functions, parameter selection routes, and case studies. Lastly, this review provides an outlook into the future of kernel-based process monitoring, which can hopefully instigate more advanced yet practical solutions in the process industries