Advanced and novel modeling techniques for simulation, optimization and monitoring chemical engineering tasks with refinery and petrochemical unit applications

Engineers predict, optimize, and monitor processes to improve safety and profitability. Models automate these tasks and determine precise solutions. This research studies and applies advanced and novel modeling techniques to automate and aid engineering decision-making. Advancements in computational ability have improved modeling software’s ability to mimic industrial problems. Simulations are increasingly used to explore new operating regimes and design new processes. In this work, we present a methodology for creating structured mathematical models, useful tips to simplify models, and a novel repair method to improve convergence by populating quality initial conditions for the simulation’s solver. A crude oil refinery application is presented including simulation, simplification tips, and the repair strategy implementation. A crude oil scheduling problem is also presented which can be integrated with production unit models. Recently, stochastic global optimization (SGO) has shown to have success of finding global optima to complex nonlinear processes. When performing SGO on simulations, model convergence can become an issue. The computational load can be decreased by 1) simplifying the model and 2) finding a synergy between the model solver repair strategy and optimization routine by using the initial conditions formulated as points to perturb the neighborhood being searched. Here, a simplifying technique to merging the crude oil scheduling problem and the vertically integrated online refinery production optimization is demonstrated. To optimize the refinery production a stochastic global optimization technique is employed. Process monitoring has been vastly enhanced through a data-driven modeling technique Principle Component Analysis. As opposed to first-principle models, which make assumptions about the structure of the model describing the process, data-driven techniques make no assumptions about the underlying relationships. Data-driven techniques search for a projection that displays data into a space easier to analyze. Feature extraction techniques, commonly dimensionality reduction techniques, have been explored fervidly to better capture nonlinear relationships. These techniques can extend data-driven modeling’s process-monitoring use to nonlinear processes. Here, we employ a novel nonlinear process-monitoring scheme, which utilizes Self-Organizing Maps. The novel techniques and implementation methodology are applied and implemented to a publically studied Tennessee Eastman Process and an industrial polymerization unit

SensorSCAN: Self-Supervised Learning and Deep Clustering for Fault Diagnosis in Chemical Processes

Modern industrial facilities generate large volumes of raw sensor data during the production process. This data is used to monitor and control the processes and can be analyzed to detect and predict process abnormalities. Typically, the data has to be annotated by experts in order to be used in predictive modeling. However, manual annotation of large amounts of data can be difficult in industrial settings. In this paper, we propose SensorSCAN, a novel method for unsupervised fault detection and diagnosis, designed for industrial chemical process monitoring. We demonstrate our model's performance on two publicly available datasets of the Tennessee Eastman Process with various faults. The results show that our method significantly outperforms existing approaches (+0.2-0.3 TPR for a fixed FPR) and effectively detects most of the process faults without expert annotation. Moreover, we show that the model fine-tuned on a small fraction of labeled data nearly reaches the performance of a SOTA model trained on the full dataset. We also demonstrate that our method is suitable for real-world applications where the number of faults is not known in advance. The code is available at https://github.com/AIRI-Institute/sensorscan

Integrating Machine Learning Paradigms for Predictive Maintenance in the Fourth Industrial Revolution era

In the last decade, manufacturing companies have been facing two significant challenges. First, digitalization imposes adopting Industry 4.0 technologies and allows creating smart, connected, self-aware, and self-predictive factories. Second, the attention on sustainability imposes to evaluate and reduce the impact of the implemented solutions from economic and social points of view. In manufacturing companies, the maintenance of physical assets assumes a critical role. Increasing the reliability and the availability of production systems leads to the minimization of systems’ downtimes; In addition, the proper system functioning avoids production wastes and potentially catastrophic accidents. Digitalization and new ICT technologies have assumed a relevant role in maintenance strategies. They allow assessing the health condition of machinery at any point in time. Moreover, they allow predicting the future behavior of machinery so that maintenance interventions can be planned, and the useful life of components can be exploited until the time instant before their fault. This dissertation provides insights on Predictive Maintenance goals and tools in Industry 4.0 and proposes a novel data acquisition, processing, sharing, and storage framework that addresses typical issues machine producers and users encounter. The research elaborates on two research questions that narrow down the potential approaches to data acquisition, processing, and analysis for fault diagnostics in evolving environments. The research activity is developed according to a research framework, where the research questions are addressed by research levers that are explored according to research topics. Each topic requires a specific set of methods and approaches; however, the overarching methodological approach presented in this dissertation includes three fundamental aspects: the maximization of the quality level of input data, the use of Machine Learning methods for data analysis, and the use of case studies deriving from both controlled environments (laboratory) and real-world instances

Learning Discriminative Feature Representations for Visual Categorization

Learning discriminative feature representations has attracted a great deal of attention due to its potential value and wide usage in a variety of areas, such as image/video recognition and retrieval, human activities analysis, intelligent surveillance and human-computer interaction. In this thesis we first introduce a new boosted key-frame selection scheme for action recognition. Specifically, we propose to select a subset of key poses for the representation of each action via AdaBoost and a new classifier, namely WLNBNN, is then developed for final classification. The experimental results of the proposed method are 0.6% - 13.2% better than previous work. After that, a domain-adaptive learning approach based on multiobjective genetic programming (MOGP) has been developed for image classification. In this method, a set of primitive 2-D operators are randomly combined to construct feature descriptors through the MOGP evolving and then evaluated by two objective fitness criteria, i.e., the classification error and the tree complexity. Later, the (near-)optimal feature descriptor can be obtained. The proposed approach can achieve 0.9% ∼ 25.9% better performance compared with state-of-the-art methods. Moreover, effective dimensionality reduction algorithms have also been widely used for obtaining better representations. In this thesis, we have proposed a novel linear unsupervised algorithm, termed Discriminative Partition Sparsity Analysis (DPSA), explicitly considering different probabilistic distributions that exist over the data points, simultaneously preserving the natural locality relationship among the data. All these above methods have been systematically evaluated on several public datasets, showing their accurate and robust performance (0.44% - 6.69% better than the previous) for action and image categorization. Targeting efficient image classification , we also introduce a novel unsupervised framework termed evolutionary compact embedding (ECE) which can automatically learn the task-specific binary hash codes. It is regarded as an optimization algorithm which combines the genetic programming (GP) and a boosting trick. The experimental results manifest ECE significantly outperform others by 1.58% - 2.19% for classification tasks. In addition, a supervised framework, bilinear local feature hashing (BLFH), has also been proposed to learn highly discriminative binary codes on the local descriptors for large-scale image similarity search. We address it as a nonconvex optimization problem to seek orthogonal projection matrices for hashing, which can successfully preserve the pairwise similarity between different local features and simultaneously take image-to-class (I2C) distances into consideration. BLFH produces outstanding results (0.017% - 0.149% better) compared to the state-of-the-art hashing techniques

2022 Review of Data-Driven Plasma Science

Data-driven science and technology offer transformative tools and methods to science. This review article highlights the latest development and progress in the interdisciplinary field of data-driven plasma science (DDPS), i.e., plasma science whose progress is driven strongly by data and data analyses. Plasma is considered to be the most ubiquitous form of observable matter in the universe. Data associated with plasmas can, therefore, cover extremely large spatial and temporal scales, and often provide essential information for other scientific disciplines. Thanks to the latest technological developments, plasma experiments, observations, and computation now produce a large amount of data that can no longer be analyzed or interpreted manually. This trend now necessitates a highly sophisticated use of high-performance computers for data analyses, making artificial intelligence and machine learning vital components of DDPS. This article contains seven primary sections, in addition to the introduction and summary. Following an overview of fundamental data-driven science, five other sections cover widely studied topics of plasma science and technologies, i.e., basic plasma physics and laboratory experiments, magnetic confinement fusion, inertial confinement fusion and high-energy-density physics, space and astronomical plasmas, and plasma technologies for industrial and other applications. The final section before the summary discusses plasma-related databases that could significantly contribute to DDPS. Each primary section starts with a brief introduction to the topic, discusses the state-of-the-art developments in the use of data and/or data-scientific approaches, and presents the summary and outlook. Despite the recent impressive signs of progress, the DDPS is still in its infancy. This article attempts to offer a broad perspective on the development of this field and identify where further innovations are required

Machine learning model selection with multi-objective Bayesian optimization and reinforcement learning

A machine learning system, including when used in reinforcement learning, is usually fed with only limited data, while aimed at training a model with good predictive performance that can generalize to an underlying data distribution. Within certain hypothesis classes, model selection chooses a model based on selection criteria calculated from available data, which usually serve as estimators of generalization performance of the model. One major challenge for model selection that has drawn increasing attention is the discrepancy between the data distribution where training data is sampled from and the data distribution at deployment. The model can over-fit in the training distribution, and fail to extrapolate in unseen deployment distributions, which can greatly harm the reliability of a machine learning system. Such a distribution shift challenge can become even more pronounced in high-dimensional data types like gene expression data, functional data and image data, especially in a decentralized learning scenario. Another challenge for model selection is efficient search in the hypothesis space. Since training a machine learning model usually takes a fair amount of resources, searching for an appropriate model with favorable configurations is by inheritance an expensive process, thus calling for efficient optimization algorithms. To tackle the challenge of distribution shift, novel resampling methods for the evaluation of robustness of neural network was proposed, as well as a domain generalization method using multi-objective bayesian optimization in decentralized learning scenario and variational inference in a domain unsupervised manner. To tackle the expensive model search problem, combining bayesian optimization and reinforcement learning in an interleaved manner was proposed for efficient search in a hierarchical conditional configuration space. Additionally, the effectiveness of using multi-objective bayesian optimization for model search in a decentralized learning scenarios was proposed and verified. A model selection perspective to reinforcement learning was proposed with associated contributions in tackling the problem of exploration in high dimensional state action spaces and sparse reward. Connections between statistical inference and control was summarized. Additionally, contributions in open source software development in related machine learning sub-topics like feature selection and functional data analysis with advanced tuning method and abundant benchmarking were also made

Novel Deep Learning Techniques For Computer Vision and Structure Health Monitoring

This thesis proposes novel techniques in building a generic framework for both the regression and classification tasks in vastly different applications domains such as computer vision and civil engineering. Many frameworks have been proposed and combined into a complex deep network design to provide a complete solution to a wide variety of problems. The experiment results demonstrate significant improvements of all the proposed techniques towards accuracy and efficiency

Mantenimiento Predictivo: Historia, una guía de implementación y enfoques actuales

Debido al aumento del número de sensores utilizados en las plantas de producción, la posibilidad de obtener datos de estas ha incrementado considerablemente. Esto conlleva la posibilidad de detectar fallos antes de que estos ocurran y futuras paradas que afecten a las plantas de producción. Las tecnologías de mantenimiento predictivo permiten predecir eventos futuros, convirtiéndolas en herramientas para afrontar los retos que surjan en los mercados competitivos. Esta tesis está dividida en cinco partes. La primera, describe el mantenimiento a lo largo de la historia, mientras que la segunda está enfocada en el mantenimiento predictivo. El tercer punto es una guía de implementación de un programa de mantenimiento predictivo para cualquier organización interesada en el tema. Finalmente, las dos últimas partes hacen referencia a los enfoques más comunes en inteligencia artificial donde se explican técnicas importantes como “Artificial Neural Networks” y “Machine Learning”, describiendo algunos ejemplos donde fueron usadas para realizar mantenimiento predictivo.Departamento de Organización de Empresas y Comercialización e Investigación de MercadosHochschule Albstadt-SigmaringenGrado en Ingeniería en Organización Industria

CLADAG 2021 BOOK OF ABSTRACTS AND SHORT PAPERS

The book collects the short papers presented at the 13th Scientific Meeting of the Classification and Data Analysis Group (CLADAG) of the Italian Statistical Society (SIS). The meeting has been organized by the Department of Statistics, Computer Science and Applications of the University of Florence, under the auspices of the Italian Statistical Society and the International Federation of Classification Societies (IFCS). CLADAG is a member of the IFCS, a federation of national, regional, and linguistically-based classification societies. It is a non-profit, non-political scientific organization, whose aims are to further classification research