As industries embrace the digitalization of Industry 4.0, the abundance of process data creates new opportunities to optimize industrial control systems. Traditional Proportional-Integral-Derivative (PID) controllers often require manual tuning to address changing conditions. This paper introduces an automated, adaptive PID tuning method using historical data and machine learning for a continuously evolving, data-driven approach. The method centers on training a surrogate model using historical process data to replicate real system behavior under various conditions. This enables safe exploration of control strategies without disrupting live operations. An RL (Reinforcement Learning) agent interacts with the surrogate model to learn optimal control policies, dynamically responding to the plant's state, defined by variables like operational conditions and measured disturbances. The agent adjusts PID parameters in real-time, optimizing metrics such as stability, response time, and energy... [more]

As the demand for resources continues to grow, pipelines have become critical for transporting water, fossil fuels, and chemicals. Monitoring pipeline systems is essential, as leaks can lead to severe environmental damage and safety hazards. This study aims to develop a pipeline leakage detection system based on digital twin technology and Physics-Informed Neural Networks (PINNs). By embedding physical principles, such as the continuity and momentum equations derived from the Navier-Stokes equation, into the neural network's loss function, the model can predict pressure and flow dynamics with high accuracy while adhering to physical constraints. PINNs are particularly advantageous as they require minimal data, maintain physical consistency, and provide reliable interpretations, making them well-suited for addressing pipeline safety challenges. The model is designed to simulate fluid dynamics under normal operating conditions, with deviations in prediction errors signaling potential lea... [more]

Pressure-swing distillation (PSD) is a frequently applied method to separate pressure-sensitive azeotropic mixtures; however, its energy demand is very high. In continuous mode, PSD is performed in a system consisting of a high- and a low-pressure column. If the composition of the feed is between the azeotropic compositions at the two pressures, it can be introduced into any of the columns, leading to two possible column sequences. Depending on the feed composition, one of the sequences is optimal whether in terms of energy demand or total annual cost (TAC). In the present work, surrogate model-based optimization is applied to determine the optimal TAC value as a function of the feed composition between the azeotropic ones. As a first step, the column sequence with feeding into the high-pressure column is studied here. The mixture to be separated consists of water and ethylenediamine, which form a maximum-boiling azeotrope. The columns are modeled separately and a large number of simul... [more]

A Digital Twin (DT) is a purposeful digital representation of a physical entity that employs data, algorithms, and software to enhance operations, making it possible to e.g., forecast failures, or evaluate new designs through the simulation of real-world scenarios. DTs are enablers for real-time monitoring, simulation, and optimization. However, traditional simulation DTs often rely on complex, non-linear mechanistic models with high computational demands, complex structures, and a large number of specific parameters and thus pose quite a challenge to maintainability. Surrogate models, on the other hand, are simplified approximations of more complex, higher-order models. These approximations are typically built using data-driven approaches, such as Random Forest Regression, facilitating faster simulations, simpler adaptation, and quicker deployment. This study analyzes the complexity of mechanistic and surrogate modeling approaches in the context of DTs to aid model selection. A model... [more]

Hydrogen-powered heavy-duty trucks have a high potential to significantly reduce CO2 emissions in the transportation sector. Therefore, efficient hydrogen storage onboard vehicles is a key enabler for sustainable transportation, as achieving high storage densities and extended driving ranges is essential for the competitiveness of hydrogen-powered trucks. Cryo-compressed hydrogen (CcH2), stored at cryogenic temperatures and high pressures, emerges as a promising solution. This study presents a comprehensive dynamic thermodynamic model that is capable of simulating the tank system across all operating conditions and, therefore, enables thermodynamic analysis of drive cycles. The core of the model is a differential-algebraic equation system that describes the thermodynamic state of the hydrogen in the tank. Additionally, surrogate models based on artificial neural networks are applied to efficiently describe quasi-steady-state heat exchangers integrated into the tank system. Several use... [more]

The food-energy-water nexus (FEWN) has been receiving increasing interest in the open literature as a framework to address the widening gap between natural resource availability and demand, towards more sustainable and cost-competitive solutions. The FEWN aims at holistically integrating the three interconnected subsystems of food, energy and water, into a single representative network. However, such an integration poses formidable challenges due to the complexity and multi-scale nature of the three subsystems and their respective interconnections. Additionally, the significant input data uncertainty and variability, such as energy prices and demands, or the evaluation of emerging technologies, contribute to the system’s inherent complexity. In this work, we revisit the FEWN problem in an attempt to elucidate and address in a systematic way issues related to its multi-scale complexity, uncertainty and variability. In particular, we provide a classification of the sources of data and te... [more]

Post-combustion carbon capture technologies have the potential to contribute significantly to achieving the environmental goals of reducing CO2 emissions in the short term. However, these technologies are energy and cost-intensive, and the variability of flue gas represents important challenges. The optimal design and optimization of such systems are critical to reaching the net zero and net negative goals, in this context, the use of computer-aided process design can be very effective in overcoming these issues. In this study, we explore the implementation of carbon capture technologies within an industrial complex, by considering the pooling of CO2 streams. We present an optimization formulation to design carbon capture plants with the goal of enhancing efficiency and minimizing the capture costs. Capital and operating costs are represented via surrogate models (SMs) that are trained using rigorous process models in Aspen Plus, each data point is obtained by solving an optimization p... [more]

Machine learning presents opportunities to improve the scale-specific accuracy of mechanistic models in a data-driven manner. Here we demonstrate the use of a machine learning technique called Sparse Identification of Nonlinear Dynamics (SINDy) to improve a simple mechanistic model of algal growth. Time-series measurements of the microalga Chlorella Vulgaris were generated under controlled photobioreactor conditions at the University of Technology Sydney. A simple mechanistic growth model based on intensity of light and temperature was integrated over time and compared to the time-series data. While the mechanistic model broadly captured the overall growth trend, discrepancies remained between the model and data due to the model's simplicity and non-ideal behavior of real-world measurement. SINDy was applied to model the residual error by identifying an error derivative correction term. Addition of this SINDy-informed error dynamics term shows improvement to model accuracy while maint... [more]

Explicitly incorporating the effects of chemical phenomena such as chemical pretreatment and mineral scaling during the design of treatment systems is critical; however, the complexity of these phenomena and limitations on data have historically hindered the incorporation of detailed water chemistry into the modeling and optimization of water desalination systems. Thus, while qualitative assessments and experimental studies on chemical pretreatment and scaling are abundant in the literature, very little has been done to assess the technoeconomic implications of different chemical pretreatment alternatives within the context of end-to-end water treatment train optimization. In this work, we begin to address this challenge by exploring the impact of pH control during pretreatment on the cost and operation of a high-recovery desalination train. We compare three pH control methods used in water treatment (H2SO4, HCl, and CO2) and assess their impact on the operation of a desalination plant... [more]

Design problems for process systems engineering applications often require multi-scale modeling integrating detailed process models. Consequently, black-box optimization and surrogate modeling have continued to play a fundamental role in mission-critical design applications. Inherent in surrogate modeling applications, particularly those constrained by “expensive” function evaluations, are the questions of how to properly balance “exploration” and “exploitation” and how to do so while harnessing parallel computing in techniques. We devise and investigate a one-step look-ahead GRASP heuristic for balancing exploration and exploitation in a parallel environment. Computational results reveal that our approach can yield equivalent or superior surrogate quality with near linear scaling in the number of parallel samples.

Process simulation problems often involve systems of nonlinear and nonconvex equations and may run into convergence issues due to the existence of recycle loops within such models. To that end, surrogate models have gained significant attention as an alternative to high-fidelity models as they significantly reduce the computational burden. However, these models do not always provide a guarantee on the prediction accuracy over the domain of interest. To address this issue, we strike a balance between computational complexity by developing a data-driven branch and prune-based framework that progressively leads to a guaranteed solution to the original system of equations. Specifically, we utilize interval arithmetic techniques to exploit Hessian information about the model of interest. Along with checking whether a solution can exist in the domain under consideration, we generate error-bounded convex hull surrogates using the sampled data and Hessian information. When integrated in a bran... [more]

Regarding the difficulty of extracting fault information in the faulty status of UAV (unmanned aerial vehicle) engines and the high time cost and large data requirement of the existing deep learning fault diagnosis algorithms with many training parameters, in this paper, a small-sample transfer learning fault diagnosis algorithm is proposed. First, vibration signals under the engine fault status are converted into a two-dimensional time-frequency map by multiple simultaneous squeezing S-transform (MSSST), which reduces the randomness of manually extracted features. Second, to address the problems of slow network model training and large data sample requirement, a transfer diagnosis strategy using the fine-tuned time-frequency map samples as the pre-training model of the ResNet-18 convolutional neural network is proposed. In addition, in order to improve the training effect of the network model, an agent model is introduced to optimize the hyperparameter network autonomously. Finally, e... [more]

The process design of hot air reflow soldering is one of the key factors affecting the quality of PCBA (Printed Circuit Board Assembly) component products. In order to improve the product quality during the design process, this paper proposes a robust optimization-based finite element simulation analysis method including significant influencing factor screening, robustness evaluation, robust optimization, and reliability verification for the reflow soldering process. The simulation model of the reflow soldering process temperature field based on experiments is constructed and validated. Sensitivity analysis is used to select important influencing factors, such as the last five set temperature zones (T5 to T9) in the reflow oven and the thermal properties of materials such as PCBs (printed circuit boards), BGAs (ball grid arrays), and solder paste, as well as noise factors like the heating environment during the soldering process. Several surrogate models are used to construct the respo... [more]

Precise and efficient calculations are necessary to accurately assess the effects of thermal protection system (TPS) uncertainties on aerospacecrafts. This paper presents a probabilistic design methodology for TPSs based on physics-informed neural networks (PINNs) with parametric uncertainty. A typical thermal coating system is used to investigate the impact of uncertainty on the thermal properties of insulation materials and to evaluate the resulting temperature distribution. A sensitivity analysis is conducted to identify the influence of the parameters on the thermal response. The results show that PINNs can produce quick and accurate predictions of the temperature of insulation materials. The accuracy of the PINN model is comparable to that of a response surface surrogate model. Still, the computational time required by the PINN model is only a fraction of the latter. Considering both computational efficiency and accuracy, the PINN model can be used as a high-precision surrogate mo... [more]

A number of canisters need to be lightweight designed to store the spherical fuel elements (SFE) used in high-temperature gas-cooled reactors (HTGR). The main challenge for engineering is pursuing high-accuracy and high-efficiency optimization simultaneously. Accordingly, a hybrid surrogate model-based multi-objective optimization method with the numerical method for the lightweight and safe design of the SFE canister is proposed. To be specific, the drop analysis model of the SFE canister is firstly established where the finite element method—discrete element method (FEM−DEM) coupled method is integrated to simulate the interaction force between the SFE and canister. Through simulation, the design variables, optimization objectives, and constraints are identified. Then the hybrid radial basis function—response surface method (RBF−RSM) surrogate method is carried out to approximate and simplify the accurate numerical model. A non-dominated sorting genetic algorithm (NSGA-II) is used fo... [more]

In this paper, an improved immune algorithm (IIA) was proposed for the torque ripple reduction optimal design of an interior permanent magnet synchronous motor (IPMSM) for a fuel cell electric vehicle (FCEV) traction motor. When designing electric machines, both global and local solutions of optimal designs are required as design result should be compared in various aspects, including torque, torque ripple, and cogging torque. To lessen the computational burden of optimization using finite element analysis, the IIA proposes a method to efficiently adjust the generation of additional samples. The superior performance of the IIA was verified through the comparison of optimization results with conventional optimization methods in three mathematical test functions. The optimal design of an IPMSM using the IIA was conducted to verify the applicability in the design of practical electric machines.

To achieve high efficiency and low degradation of a polymer electrolyte fuel cell (PEMFC), it is necessary to maintain an appropriate level of humidification in the fuel cell membrane. Thus, membrane humidifiers are typically used in PEMFC systems. Parameter studies are important to evaluate membrane humidifiers under various operating conditions to reduce the amount of physical tests. However, simulative studies are computationally expensive when using detailed models. To reduce the computational cost, surrogate models are set up. In our study, a 3D computational fluid dynamics (CFD) model of a hollow fibre membrane humidifier is presented and validated using measurement data. Based on the results of the validated CFD model, a surrogate model of the humidifier is constructed using proper orthogonal decomposition (POD) in combination with different interpolation methods. To evaluate the surrogate models, their results are compared against reference solutions from the CFD model. Our res... [more]

This paper develops a reliable deep-learning framework to extract latent features from spatial properties and investigates adaptive surrogate estimation to sequester CO2 into heterogeneous deep saline aquifers. Our deep-learning architecture includes a deep convolutional autoencoder (DCAE) and a fully-convolutional network to not only reduce computational costs but also to extract dimensionality-reduced features to conserve spatial characteristics. The workflow integrates two different spatial properties within a single convolutional system, and it also achieves accurate reconstruction performance. This approach significantly reduces the number of parameters to 4.3% of the original number required, e.g., the number of three-dimensional spatial properties needed decreases from 44,460 to 1920. The successful dimensionality reduction is accomplished by the DCAE system regarding all inputs as image channels from the initial stage of learning using the fully-convolutional network instead of... [more]

Using aerodynamic resistance to provide braking force for trains is an economical braking method. It has few components to wear out and requires no energy. But the aerodynamic braking plate will significantly affect train’s aerodynamics behaviors. This paper studies the effect of the braking plates’ layout on the aerodynamic force of head car when a train is running under a crosswind. The results show that the braking plate will not only increase the drag force, but also significantly affect the lift and lateral force of the train’s head car. The installation position of the braking plates will also have a great effect on the aerodynamic force. In order to increase the drag force and weaken other aerodynamic force changes of the head car, we suggest that the first braking plate be arranged at the end of a streamlined shape, and the second braking plate be arranged at the middle of the car body. Compared with trains without braking plates, the head car’s drag force increases by 85.7%, l... [more]

Fatigue damage of turbine components is typically computed by running a rain-flow counting algorithm on the load signals of the components. This process is not linear and time consuming, thus, it is non-trivial for an application of wind farm control design and optimisation. To compensate this limitation, this paper will develop and compare different types of surrogate models that can predict the short term damage equivalent loads and electrical power of wind turbines, with respect to various wind conditions and down regulation set-points, in a wind farm. More specifically, Linear Regression, Artificial Neural Network and Gaussian Process Regression are the types of the developed surrogate models in this work. The results showed that Gaussian Process Regression outperforms the other types of surrogate models and can effectively estimate the aforementioned target variables.

The application of white box models in digital twins is often hindered by missing knowledge, uncertain information and computational difficulties. Our aim was to overview the difficulties and challenges regarding the modelling aspects of digital twin applications and to explore the fields where surrogate models can be utilised advantageously. In this sense, the paper discusses what types of surrogate models are suitable for different practical problems as well as introduces the appropriate techniques for building and using these models. A number of examples of digital twin applications from both continuous processes and discrete manufacturing are presented to underline the potentials of utilising surrogate models. The surrogate models and model-building methods are categorised according to the area of applications. The importance of keeping these models up to date through their whole model life cycle is also highlighted. An industrial case study is also presented to demonstrate the app... [more]

The installation potential of ground-source heat pump (GSHP) systems has been studied based on the spatial interpolation of numerical simulation results using ground heat exchanger (GHE) models. This study is the first to create an estimation formula for the heat exchange rate (HER) to obtain a solution equivalent to the numerical analysis results considering the average method when supplying three-dimensional (3D) hydrogeological information that affects the HER to a two-dimensional (2D) map. It was found that the main factors affecting the HER were groundwater flow velocity, subsurface temperature, and thermal conductivity. The response surface methodology was utilized to approximate the HER using the above-mentioned three parameters. The estimated HER showed very strong agreement with that calculated by the GHE models. The application of the estimation formula to the simulation of the 3D groundwater flow and heat transport model of the Sendai Plain (Japan) better reflects the hydrog... [more]

Wind farm load assessment is typically conducted using Computational Fluid Dynamics (CFD) or aeroelastic simulations, which need a lot of computer power. A number of applications, for example wind farm layout optimisation, turbine lifetime estimation and wind farm control, requires a simplified but sufficiently detailed model for computing the turbine fatigue load. In addition, the effect of turbine curtailment is particularly important in the calculation of the turbine loads. Therefore, this paper develops a fast and computationally efficient method for wind turbine load assessment in a wind farm, including the wake effects. In particular, the turbine fatigue loads are computed using a surrogate model that is based on the turbine operating condition, for example, power set-point and turbine location, and the ambient wind inflow information. The Turbine to Farm Loads (T2FL) surrogate model is constructed based on a set of high fidelity aeroelastic simulations, including the Dynamic Wak... [more]

This study developed a data-driven surrogate model based on a deep neural network (DNN) to evaluate gas−liquid multiphase flow occurring in horizontal pipes. It estimated the liquid holdup and pressure gradient under a slip condition and different flow patterns, i.e., slug, annular, stratified flow, etc. The inputs of the surrogate modelling were related to the fluid properties and the dynamic data, e.g., superficial velocities at the inlet, while the outputs were the liquid holdup and pressure gradient observed at the outlet. The case study determined the optimal number of hidden neurons by considering the processing time and the validation error. A total of 350 experimental data were used: 279 for supervised training, 31 for validating the training performance, and 40 unknown data, not used in training and validation, were examined to forecast the liquid holdup and pressure gradient. The liquid holdups were estimated within less than 8.08% of the mean absolute percentage error, while... [more]

Two-dimensional design and analysis issues on the meridional surface, which is important in the preliminary design procedure of compressors, are highly dependent on the accuracy of empirical models, such as the prediction of total pressure loss model and turning flow angle. Most of the widely used models are derived or improved from experimental data of some specific cascades with low-loading and low-speed airfoil types. These models may work for most conventional compressors but are incapable of accurately estimating the performance for some specific cases like transonic compressors. The errors made by these models may mislead the final design results. Therefore, surrogate models are developed in this work to reduce the errors and replace the conventional empirical models in the through-flow calculation procedure. A group of experimental data considering a two-stage transonic compressor is used to generate the airfoils database for training the surrogate models. Sensitivity analysis i... [more]