Machine Learning Based Fault Classification in Pilot Plant Batch Reactor: Using Support Vector Machine.

Identifying and diagnosing faults is a critical task in process industries to maintain effective monitoring of process and plant safety. Minimizing process downtime is critical for enhancing the quality of the product and minimizing production costs. Real-time categorization of issues across several levels is essential for the monitoring of processes. However, there are still notable obstacles, that must be addressed, such as the existence of robust correlations, the complexity of the data, and the lack of linearity. This study introduces a novel fault identification technique in batch reactor experimental trials that employs multikernel support vector machines (SVMs) to categorize internal and external issues, specifically reactor temperature, coolant temperature, and jacket temperature. The data set was obtained from empirical research. The classification has been conducted using a multikernel SVM. This article identified that the nonlinear classifier using the radial bias function results in an accuracy that is at least 22.08% superior to other methods.

Neural Network-Based Hammerstein Model Identification of a Lab-Scale Batch Reactor.

This paper focuses on two types of neural network-based Hammerstein model identification methods for the acrylamide polymerization reaction of a batch reactor process. The first neural-based identification type formulates the weights of the multilayer network directly as parameters of the nonlinear static and linear dynamic blocks of the Hammerstein model and trains the weights using a gradient-based backpropagation algorithm. In the second identification type, the nonlinear static block of the Hammerstein model is framed as a single hidden-layer feedforward network and both nonlinear and linear block parameters are trained using an extreme learning machine, where the training procedure is exempted from gradient calculation. The primary focus of the paper is neural-based model identification of a complex nonlinear system, which facilitates ease of linear/nonlinear controller design with good learning speed and less computations. A future work toward the machine learning-based nonlinear model predictive controller implementation using the Jetson Orin Nano board is also described.

Development of a Nonlinear Model Predictive Control-Based Nonlinear Three-Mode Controller for a Nonlinear System.

This paper presents the novelty on a nonlinear proportional integral derivative (NPID) controller developed from the gain values obtained using the Lyapunov-based nonlinear model predictive controller (LyNMPC). The tuning parameters of the proposed controller are taken from the dynamics of the nonlinear system, and these parmeters are dynamic with their value varying according to the error in the system. In this article, the authors have considered two highly nonlinear systems, namely, batch polymerization reactor and quadrotor unmanned aerial vehicle systems. The nonlinear mathematical modeling of the batch reactor as well as the quadrotor system considered from the past literature of authors. The acrylamide polymerization reaction under consideration is an exothermic reaction, thereby making the temperature profile tracking and control a challenging task. The primary aim of this article is to develop the NPID controller based on the LyNMPC algorithm and to validate the NPID on a batch reactor bench-scale plant and on an hardware-in-the-loop platform for the quadrotor hardware. A comparative study of trajectory tracking and control capabilities of LyNMPC on derived non-linear models of the batch reactor and quadrotor system is presented. The system mathematical models are obtained with the help of the first-principle energy balance equation for the batch reactor and with the nonlinear dynamics of the quadrotor which is derived based on Newton-Euler formulations. With LyNMPC, the stability of the nonlinear systems can be improved because the error sensitivity is considered in the cost function.

Wiener-Neural-Network-Based Modeling and Validation of Generalized Predictive Control on a Laboratory-Scale Batch Reactor.

Batch reactors are large vessels in which chemical reactions take place. They are mostly found to be used in process control industries for processes such as reactant mixing, waste treatment of leather byproducts, and liquid extraction. Modeling and controlling of these systems are complex due to their highly nonlinear nature. The Wiener neural network (WNN) is employed in this work to predict and track the temperature profile of a batch reactor successfully. WNN is different from artificial neural networks in various aspects, mainly its structure. The brief methodology that was deployed to complete this work consisted of two parts. The first part is modeling the WNN-based batch reactor using the provided input-output data set. The input is feed given to the reactor, and the reactor temperature needs to be maintained in line with the optimal profile. The objective in this part is to train the neural network to efficiently track the nonlinear temperature profile that is provided from the data set. The second part is designing a generalized predictive controller (GPC) using the data obtained from modeling the reactor to successfully track any arbitrary temperature profile. Therefore, this work presents the experimental modeling of a batch reactor and validation of a WNN-based GPC for temperature profile tracking.

Development and Validation of Advanced Nonlinear Predictive Control Algorithms for Trajectory Tracking in Batch Polymerization.

In this work, a computationally efficient nonlinear model-based control (NMBC) strategy is developed for a trajectory-tracking problem in an acrylamide polymerization batch reactor. The performance of NMBC is compared with that of nonlinear model predictive control (NMPC). To estimate the reaction states, a nonlinear state estimator, an unscented Kalman filter (UKF), is employed. Both algorithms are implemented experimentally to track a time-varying temperature profile for an acrylamide polymerization reaction in a lab-scale polymerization reactor. It is shown that in the presence of state estimators the NMBC performs significantly better than the NMPC algorithm in real time for the batch reactor control problem.

Data-Driven Modeling of a Pilot Plant Batch Reactor and Validation of a Nonlinear Model Predictive Controller for Dynamic Temperature Profile Tracking.

Batch process plays a very crucial and important role in process industries. The increased operational flexibility and trend toward high-quality, low-volume chemical production has put more emphasis on batch processing. In this work, nonlinearities associated with the batch reactor process have been studied. ARX and NARX models have been identified using open-loop data obtained from the pilot plant batch reactor. The performance of the batch reactor with conventional linear controllers results in aggressive manipulated variable action and larger energy consumption due to its inherent nonlinearity. This issue has been addressed in the proposed work by identifying the nonlinear model and designing a nonlinear model predictive controller for a pilot plant batch reactor. The implementation of the proposed method has resulted in smooth response of the manipulated variable as well as reactor temperature on both simulation and real-time experimentation.

Optimal Energy Consumption of the Distillation Process and Its Product Purity Analysis Using Ultraviolet Spectroscopy.

This paper addresses the energy consumption of distillation process via an actuator, which is a challenging problem in process industries. Precise control action would enhance energy consumption and improve the productivity. This paper is an experimental validation of EPC-PI control algorithm and analysis of distillate purity of a lab-scale distillation column. The PI control scheme uses closed-loop data of extended predictive controller (EPC) that has been performed through off-line simulation. The performance of control method is compared with different schemes such as Hägglund's one-third rule and Skogestad's overshoot method. The issue of integral windup in the multivariable process is addressed in the aspect of optimal energy consumption. The energy consumption calculations are made with respect to power utility of actuators throughout the process. The distillate product of post-controller implementation is processed to qualitative analysis using UV spectroscopy. Performance index is carried out via integral time absolute error (ITAE) by perturbing plant parameters up to 30% uncertainty.

Parameter Estimation and an Extended Predictive-Based Tuning Method for a Lab-Scale Distillation Column.

The present study proposes a new PI controller tuning method using extended predictive control (EPC). The PI controller parameter values are calculated using the EPC controller output and its closed-loop response. This provides a simple and an effective tuning strategy which results in an improved closed-loop response compared to conventional tuning methods. The tuning methodology is applicable for single input single output and multi input multi output stable processes. Simulation and experimental results reveal the efficacy of the method under plant uncertainty conditions.