Transfer learning for batch process optimal control using LV-PTM and adaptive control strategy

In this study, we investigate a data-driven optimal control for a new batch process. Existing data-driven optimal control methods often ignore an important problem, namely, because of the short operation time of the new batch process, the modeling data in the initial stage can be insufficient. To address this issue, we introduce the idea of transfer learning, i.e., a latent variable process transfer model (LV-PTM) is adopted to transfer sufficient data and process information from similar processes to a new one to assist its modeling and quality optimization control. However, due to fluctuations in raw materials, equipment, etc., differences between similar batch processes are always inevitable, which lead to the serious and complicated mismatch of the necessary condition of optimality (NCO) between the new batch process and the LV-PTM-based optimization problem. In this work, we propose an LV-PTM-based batch-to-batch adaptive optimal control strategy, which consists of three stages, to ensure the best optimization performance during the whole operation lifetime of the new batch process. This adaptive control strategy includes model updating, data removal, and modifier-adaptation methodology using final quality measurements in response. Finally, the feasibility of the proposed method is demonstrated by simulations

Innovative Surveillance and Process Control in Water Resource Recovery Facilities

Water Resource Recovery Facilities (WRRF), previously known as Wastewater Treatment Plants (WWTP), are getting increasingly complex, with the incorporation of sludge processing and resource recovery technologies. Along with maintaining a stringent effluent water quality standard, the focus is gradually shifting towards energy-efficient operations and recovery of resources. The new objectives of the WRRF demand an economically optimal operation of processes that are subjected to extreme variations in flowrate and composition at the influent. The application of online monitoring, process control, and automation in WRRF has already shown a steady increase in the past decade. However, the advanced model-based optimal control strategies, implemented in most process industries, are less common in WRRF. The complex nature of biological processes, the unavailability of simplified process models, and a lack of cost-effective surveillance infrastructure have often hindered the implementation of advanced control strategies in WRRF. The ambition of this research is to implement and validate cost-efficient monitoring alternatives and advanced control strategies for WRRF by fully utilizing the powerful Internet of Things (IoT) and data science tools. The first step towards implementing an advanced control strategy is to ensure the availability of surveillance infrastructure for monitoring nutrient compositions in WRRF processes. In Paper A, a soft sensor, based on Extended Kalman Filter, is developed for estimating water-quality parameters in a Sequential Batch MBBR process using reliable and inexpensive online sensors. The model used in the soft sensor combines the mechanistic understanding of the nutrient removal process with a statistical correlation between nutrient composition and easy-to-measure parameters. Paper B demonstrates the universality of the soft sensor through validation tests conducted in a Continuous Multistage MBBR pilot plant. The drift in soft-sensor estimation caused by a mismatch between the mathematical model and process behavior is studied in Paper B. The robustness of the soft sensor is assessed by observing estimated nutrient composition values for a period of three months. A systematic method to calibrate the measurement model and update model parameters using data from periodic lab measurements are discussed in Paper B. The term SCADA has been ubiquitous while mentioning online monitoring and control strategy deployment in WRRFs. The present digital world of affordable communication hardware, compact single board processors, and high computational power presents several options for remote monitoring and deployment of soft sensors. In Paper C, a cost-effective IoT strategy is developed by using an open-source programming language and inexpensive hardware. The functionalities of the IoT infrastructure are demonstrated by using it to deploy a soft sensor script in the ContinuousMultistage MBBR pilot plant. A cost-comparison between the commercially available alternatives presented in Paper A and the open-source IoT strategy in Paper B and Paper C highlights the benefits of the new monitoring infrastructure. Lack of reliable control models have often been the cause for the poor performance of advanced control strategies, such as Model Predictive Controls (MPC) when implemented to complex biological nutrient removal processes. Paper D attempts to overcome the inadequacies of the linear prediction model by combining a recursive model parameter estimator with the linear MPC. The new MPC variant, called the adaptive MPC (AMPC), reduces the dependency of MPC on the accuracy of its prediction model. The performance of the AMPC is compared with that of a linear MPC, nonlinear MPC, and the traditional proportional-integral cascade control through simulator-based evaluations conducted on the Benchmark Simulator platform(BSM2). The advantages of AMPC compared to its counterparts, in terms of reducing the aeration energy, curtailing the number of effluent ammonia violations, and the use of computational resources, are highlighted in Paper D. The complex interdependencies between different processes in a WRRF pose a significant challenge in defining constant reference points for WRRFs operations. A strategy that decides control outputs based on economic parameters rather than maintaining a fixed reference set-point is introduced in Paper E. The model-based control strategy presented in Paper D is further improved by including economic parameters in the MPC’s objective function. The control strategy known as Economic MPC (EMPC) is implemented for optimal dosage of magnesium hydroxide in a struvite recovery unit installed in a WRRF. A comparative study performed on the BSM2 platform demonstrates a significant improvement in overall profitability for the EMPC when compared to a constant or a feed-forward flow proportional control strategy. The resilience of the EMPC strategy to variations in the market price of struvite is also presented in Paper E. A combination of cost-effective monitoring infrastructure and advanced control strategies using advanced IoTs and data science tools have been documented to overcome some of the critical problems encountered in WRRFs. The overall improvement in process efficiency, reduction in operating costs, an increase in resource recovery, and a substantial reduction in the price of online monitoring infrastructure contribute to the overall aim of transitioning WRRFs to a self-sustaining facility capable of generating value-added products.Water Resource Recovery Facilities (WRRF), tidligere kjent som avløpsrenseanlegg (WWTP), blir stadig mer komplekse ettersom flere prosess steg tillegges anleggene i form av slambehandling og ressursgjenvinningsteknologi. Foruten hovedmålet om å imøtekomme strenge avløpsvannskvalitetskrav, har anleggenes fokus gradvis skiftet mot energieffektiv drift og gjenvinning av ressurser. Slike nye mål krever økonomisk optimal drift av prosesser som er utsatt for ekstreme variasjoner i volum og sammensetning av tilløp. Bruk av online overvåking, prosesskontroll og automatisering i WRRF har jevnt økt det siste tiåret. Likevel er avanserte modellbaserte kontrollstrategier for optimalisering ikke vanlig i WRRF, i motsetning til de fleste prosessindustrier. Komplekse forhold i biologiske prosesser, mangel på tilgang til pålitelige prosessmodeller og mangel på kostnadseffektiv overvåkingsinfrastruktur har ofte hindret implementeringen av avanserte kontrollstrategier i WRRF. Ambisjonen med denne avhandlingen er å implementere og validere kostnadseffektive overvåkingsalternativer og avanserte kontrollstrategier somutnytter kraftige Internet of Things (IoT) og datavitenskapelige verktøy i WRRF sammenheng. Det første steget mot implementering av en avansert kontrollstrategi er å sørge for tilgjengelighet av overvåkingsinfrastruktur for måling av næringsstoffer i WRRF-prosesser. Paper A demonstrerer en virtuell sensor basert på et utvidet Kalman filter, utviklet for å estimere vannkvalitetsparametere i en sekvensiell batch MBBR prosess ved hjelp av pålitelige og rimelige online sensorer. Modellen som brukes i den virtuelle sensoren kombinerer en mekanistisk forståelse av prosessen for fjerning av næringsstoffer fra avløpsvann med et statistisk sammenheng mellom næringsstoffsammensetning i avløpsvann og parametere som er enkle å måle. Paper B demonstrerer det universale bruksaspektet til den virtuelle sensoren gjennom valideringstester utført i et kontinuerlig flertrinns MBBR pilotanlegg. Feilene i sensorens estimering forårsaket av uoverensstemmelse mellom den matematiske modellen og prosesseatferden er undersøkt i Paper B. Robustheten til den virtuelle sensoren ble vurdert ved å observere estimerte næringssammensetningsverdier i en periode på tre måneder. En systematisk metode for å kalibrere målemodellen og oppdatere modellparametere ved hjelp av data fra periodiske laboratoriemålinger er diskutert i Paper B. Begrepet SCADA har alltid vært til stede når online overvåking og kontrollstrategi innen WRRF er nevnt. Den nåværende digitale verdenen med god tilgjengelighet av rimelig kommunikasjonsmaskinvare, kompakte enkeltkortprosessorer og høy beregningskraft presenterer flere muligheter for fjernovervåking og implementering av virtuelle sensorer. Paper C viser til utvikling av en kostnadseffektiv IoT-strategi ved hjelp av et programmeringsspråk med åpen kildekode og rimelig maskinvare. Funksjonalitetene i IoT-infrastruktur demonstreres gjennom implementering av et virtuelt sensorprogram i et kontinuerlig flertrinns MBBR pilotanlegg. En kostnadssammenligning mellom de kommersielt tilgjengelige alternativene som presenteres i Paper A og åpen kildekode-IoT-strategi i Paper B og Paper C fremhever fordelene med den nye overvåkingsinfrastrukturen. Mangel på pålitelige kontrollmodeller har ofte vært årsaken til svake resultater i avanserte kontrollstrategier, som for eksempel Model Predictive Control (MPC) når de implementeres i komplekse biologiske prosesser for fjerning av næringsstoffer. Paper D prøver å løse manglene i MPC ved å kombinere en rekursiv modellparameterestimator med lineær MPC. Den nye MPC-varianten, kalt Adaptiv MPC (AMPC), reduserer MPCs avhengighet av nøyaktigheten i prediksjonsmodellen. Ytelsen til AMPC sammenlignes med ytelsen til en lineær MPC, ikke-lineær MPC og tradisjonell proportionalintegral kaskadekontroll gjennom simulatorbaserte evalueringer utført på Benchmark Simulator plattformen (BSM2). Fordelene med AMPC sammenlignet med de andre kontrollstrategiene er fremhevet i Paper D og demonstreres i sammenheng redusering av energibruk ved lufting i luftebasseng, samt redusering i antall brudd på utslippskrav for ammoniakk og bruk av beregningsressurser. De komplekse avhengighetene mellom forskjellige prosesser i en WRRF utgjør en betydelig utfordring når man skal definere konstante referansepunkter for WRRF under drift. En strategi som bestemmer kontrollsignaler basert på økonomiske parametere i stedet for å opprettholde et fast referansesettpunkt introduseres i Paper E. Den modellbaserte kontrollstrategien fra PaperDforbedres ytterligere ved å inkludere økonomiske parametere iMPCs objektiv funksjon. Denne kontrollstrategien kalles Economic MPC (EMPC) og er implementert for optimal dosering av magnesiumhydroksid i en struvit utvinningsenhet installert i en WRRF. En sammenligningsstudie utført på BSM2 plattformen viste en betydelig forbedring i den totale lønnsomheten ved bruk av EMPC sammenlignet med en konstant eller en flow proportional kontrollstrategi. Robustheten til EMPC-strategien for variasjoner i markedsprisen på struvit er også demonstrert i Paper E. En kombinasjon av kostnadseffektiv overvåkingsinfrastruktur og avanserte kontrollstrategier ved hjelp av avansert IoT og datavitenskapelige verktøy er brukt for å løse flere kritiske utfordringer i WRRF. Den samlede forbedringen i prosesseffektivitet, reduksjon i operasjonskostnader, økt ressursgjenvinning og en betydelig reduksjon i pris for online overvåkningsinfrastruktur bidrar til det overordnede målet om å gå over til bærekraftige WRRF som er i stand til å generere verdiskapende produkter.DOSCON A

Using traditional modelling approaches for a MBR system to investigate alternate approaches based on system identification procedures for improved design and control of a wastewater treatment process.

The specific research work described in this thesis forms part of a much larger research project that was funded by the Technology Programme of the UK Government. This larger project considered improving the design and efficiency of membrane bioreactor (MBR) plant by using modelling, simulation and laboratory methods. This research work uses phenomenological mechanistic models based on MBR filtration and biochemical processes to measure the effectiveness of alternative behavioural models based upon input-output system identification methods. Both model types are calibrated and validated using similar plant layouts and data sets derived for this purpose. Results prove that although both approaches have their advantages, they also have specific disadvantages as well. In conclusion, the MBR plant designer and/or operator who wishes to use good quality, calibrated models to gain a better understanding of their process, should carefully consider which model type is selected based upon on what their initial modelling objectives are (e.g. using either a physically mechanistic model or an input-output behaviourial model). Each situation usually proves unique. In this regard, this research work creates a "Model Conceptualisation Procedure" for a typical MBR which can be used by future researchers as a theoretical framework which underpins any newly created model type. There has been insufficient work completed to date on using a times series input-output approach in the model development of a wastewater treatment plant, so only general conclusions can be made from this research work. However, it can be stated that this novel approach seems to be applicable for a membrane filtration model if care it taken to select appropriate input-output model structures, such as those suggested in the "Model Conceptualisation Procedure". In the case of the development of a MBR biological model, it is thought that a conventional Activated Sludge model produced by the IWA could be coupled to a input-output model structure as suggested by this report to give a hybrid model structure that may have the advantages of both model types. Further research work is needed in this area. Future work that should follow on from this research study should focus on whether these input-output models could be used for predictive control purposes, whether an integrated model could be created, and whether a benchmark could be created for the three main MBR configurations.Technology Programme of the TSB (Technology Strategy Board) TP/3/DSM/6/I/1512

Development of Multivariate Statistical Process Control for an industrial prototype wastewater bio-treatment plant

This research analyzes the feasibility of developing a Multivariate Statistical Process Control (MSPC) framework for monitoring and diagnosing a biological wastewater treatment plant. MSPC makes use of historical database of past successful operations as a reference to judge the normality of future operations. The projection method, Principal Component Analysis (PCA), is utilized not only to compress the originally correlated data but also to extract statistically meaningful information, by projecting the multivariate trajectory data onto a lower dimensional space, spanned by the Principal Components (PC s) retained. From the established \u27normal\u27 operation domain, departure of new operating points from that of \u27normal\u27 domain can be detected by the use of several MSPC monitoring plots. The proposed methodology generates monitoring charts by analyzing the process variables gathered in a reference database; new observations are analyzed by contrasting their projections onto the reference PC s space against that of normal, using a variety of monitoring charts. Possible root causes can sometimes be identified when abnormal deviations have been detected. The capability of such MSPC scheme in monitoring and assessing the behavior of new wastewater treatment operations against the reference is illustrated through simulations of the bio-wastewater treatment plant under a variety of operating conditions. The research first reviews the concepts and techniques of MSPC and the Activated Sludge Model No. 1. It then utilizes these techniques in creating the monitoring and diagnosis framework for a wastewater bio-treatment plant using the activated sludge model No. 1 description as the process model. Simulation is carried out using the Matlab (version 4.2c) and Simulink ^ as the programming platform. The MSPC framework is able to detect abnormal process deviations by comparing the projection of new observations onto the principal component subspace to the \u27normal operation\u27 region established from base case data. If current operating points fall inside this region, it implies that the current operation is \u27normal\u27; If they fall or show a trend of migrating toward outside of the region, it implies emergence of abnormal operations. Usually, it is possible to trace back from the abnormal behavior to their assignable causes by analyzing contribution plots. In this study, a reference database is generated based on the simulation of a large number of variations in the process operating conditions in the neighborhood of a nominal operating condition. These variations include: -21% to +21% changes in the influent nitrate concentration, [NO3 ], in the maximum growth rate of the heterotrophic biomass, pm, h, in the half-saturation constant of COD, Kg, [cod] and - 15% to +15% changes in the influent ammonia concentration, [NH4\u27^]. These deviations are defined as \u27normal operation\u27 deviations. Monitoring charts are obtained based on this simulated database. Acceptable regions are identified in these charts as the standards for monitoring all future processes. Three abnormal cases are simulated to validate the established base case PGA model. They represent 1) bigger than normal amount of changes in the operating conditions not affecting the biological model; 2) bigger than normal amount of changes in the bioprocess parameters altering the process model; 3) new biological event causing plant/model mismatch. Analysis results show that the indication of the migration, over time, toward a state of abnormality is clear and direct. Diagnosis is carried out by analyzing the contribution plot for each of the three abnormal cases. Results show that the PCA method can also identify the possible root causes for the observed abnormality. In addition, the interpretation of the principal components provides more insights to the behavior of the process variables. However, important implementation issues remain that must be addressed before it can proved to be effective when brought on line

A review of modeling approaches in activated sludge systems

The feasibility of using models to understand processes, predict and/or simulate, control, monitor and optimize WasteWater Treatment Plants (WWTPs) has been explored by a number of researchers. Mathematical modeling provides a powerful tool for design, operational assistance, forecast future behavior and control. A good model not only elucidates a better understanding of the complicated biological and chemical fundamentals but is also essential for process design, process start-up, dynamics predictions, process control and process optimization. This paper reviews developments and the application of different modeling approaches to wastewater treatment plants, especially activated sludge systems and processes therein in the last decade. In addition, we present an opinion on the wider wastewater treatment related research issues that need to be addressed through modeling.Key words: Mathematical modeling, water, wastewater, wastewater treatment plants, activated sludge systems

Dynamic modeling and control of a crystallization process using neural networks

Nos processos industriais de cristalização, o controle do tamanho e da forma dos cristais é de considerável importância. Nesse trabalho, dados experimentais são utilizados para desenvolver modelos de redes neuronais para o processo de cristalização em batelada do sulfato de potássio (K2SO4). Primeiramente, um modelo dinâmico do sistema capaz de prever seu estado em um futuro próximo dadas as suas condições atuais é desenvolvido. Em seguida, um modelo inverso do processo capaz de calcular a próxima ação de controle a ser implementada para conduzir o sistema a uma trajetória de referência é desenvolvido. Finalmente, o desempenho desse controlador é investigado através da simulação de uma malha fechada em que um modelo de balanço populacional é utilizado como processo real. Nós mostramos que a escolha da trajetória de referência tem forte influência sobre o tempo de duração da batelada, erro final entre estado do sistema e set-point e esforço de controle. Em termos dos critérios acima, a melhor trajetória apresentou resultados de 70% a 140% melhores que as demais

Developing Multi-Scale Models for Water Quality Management in Drinking Water Distribution Systems

Drinking water supply systems belong to the group of critical infrastructure systems that support the socioeconomic development of our modern societies. In addition, drinking water infrastructure plays a key role in the protection of public health by providing a common access to clean and safe water for all our municipal, industrial, and firefighting purposes. Yet, in the United States, much of our national water infrastructure is now approaching the end of its useful life while investments in its replacement and rehabilitation have been consistently inadequate. Furthermore, the aging water infrastructure has often been operated empirically, and the embracement of modern technologies in infrastructure monitoring and management has been limited. Deterioration of the water infrastructure and poor water quality management practices both have serious impacts on public health due to the increased likelihood of contamination events and waterborne disease outbreaks. Water quality reaching the consumers’ taps is largely dependent on a group of physical, chemical, and biological interactions that take place as the water transports through the pipes of the distribution system and inside premise plumbing. These interactions include the decay of disinfectant residuals, the formation of disinfection by-products (DBPs), the corrosion of pipe materials, and the growth and accumulation of microbial species. In addition, the highly dynamic nature of the system’s hydraulics adds another layer of complexity as they control the fate and transport of the various constituents. On the other hand, the huge scale of water distribution systems contributes dramatically to this deterioration mainly due to the long transport times between treatment and consumption points. Hence, utilities face a considerable challenge to efficiently manage the water quality in their aging distribution systems, and to stay in compliance with all regulatory standards. By integrating on-line monitoring with real-time simulation and control, smart water networks offer a promising paradigm shift to the way utilities manage water quality in their systems. Yet, multiple scientific gaps and engineering challenges still stand in the way towards the successful implementation of such advanced systems. In general, a fundamental understanding of the different physical, chemical, and biological processes that control the water quality is a crucial first step towards developing useful modeling tools. Furthermore, water quality models need to be accurate; to properly simulate the concentrations of the different constituents at the points of consumption, and fast; to allow their implementation in real-time optimization algorithms that sample different operational scenarios in real-time. On-line water quality monitoring tools need be both reliable and inexpensive to enable the ubiquitous surveillance of the system at all times. The main objective of this dissertation is to create advanced computational tools for water quality management in water distribution systems through the development and application of a multi-scale modeling framework. Since the above-mentioned interactions take place at different length and time scales, this work aims at developing computational models that are capable of providing the best description of each of the processes of interest by properly simulating each of its underlying phenomena at its appropriate scale of resolution. Molecular scale modeling using tools of ab-initio quantum chemical calculations and molecular dynamics simulations is employed to provide detailed descriptions of the chemical reactions happening at the atomistic level with the aim of investigating reaction mechanisms and developing novel materials for environmental sensing. Continuum scale reactive-transport models are developed for simulating the spatial and temporal distributions of the different compounds at the pipe level considering the effects of the dynamic hydraulics in the system driven by the spatiotemporal variability in water demands. System scale models are designed to optimize the operation of the different elements of the system by performing large-scale simulations coupled with optimization algorithms to identify the optimal operational strategies as a basis for accurate decision-making and superior water quality management. In conclusion, the computational models developed in this study can either be implemented as stand-alone tools for simulating the fundamental processes dictating the water quality at different scales of resolution, or be integrated into a unified framework in which information from the small scale models are propagated into the larger scale models to render a high fidelity representation of these processes