This paper presents state-of-the-art object detection and object identification algorithms for digitizing and interpreting chemical engineering diagrams, including, Block Flow Diagrams (BFDs), Process Flow Diagrams (PFDs), and Piping and Instrumentation Diagrams (P&IDs), using computer vision techniques. These diagrams are essential for visualizing plant processes and equipment but are often stored as image-based PDFs, making manual digitization/interpretation labor-intensive and error-prone. The proposed algorithm automates tasks such as detecting unit operations and identifying them using a set of rule-based and predefined approaches including edge and contour-based rules, spatial arrangement rules, and geometric rules. This method avoids data requirements and computational requirements of deep learning approaches, offering a scalable and efficient solution for preliminary extraction of complex process information.

Phase transition enthalpies, such as those for fusion, vaporization, and sublimation, are vital for understanding thermodynamic properties and aiding early-stage process design. However, measuring these properties is often time-consuming and costly, leading to increased interest in computational methods for fast and accurate predictions. Graph neural networks (GNNs), known for their ability to learn complex molecular representations, have emerged as state-of-the-art tools for predicting various thermophysical properties. Despite their success, GNNs do not inherently obey thermodynamic laws. In this study, we present a multitask GNN designed to predict vaporization, fusion, and sublimation enthalpies of organic compounds. We modified the loss function of the GNN, accounting for the thermodynamic cycle of the three phase transition enthalpies. To train the model, we digitized the extensive Chickos and Acree compendium, which encompasses 32,023 experimental measurements. Two approaches we... [more]

A piping and instrumentation diagram (P&ID) is a central reference document in chemical process engineering. Currently, chemical engineers manually review P&IDs through visual inspection to find and rectify errors. However, engineering projects can involve hundreds to thousands of P&ID pages, creating a significant revision workload. This study proposes a rule-based method to support engineers with error detection and correction in P&IDs. The method is based on a graph representation of P&IDs, enabling automated error detection and correction, i.e., autocorrection, through rule graphs. We use our pyDEXPI Python package to generate P&ID graphs from DEXPI-standard P&IDs. In this study, we developed 33 rules based on chemical engineering knowledge and heuristics, with five selected rules demonstrated as examples. A case study on an illustrative P&ID validates the reliability and effectiveness of the rule-based autocorrection method in revising P&IDs.

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]

Chemical process models often involve high non-linearity due to thermodynamic and kinetic relationships, with non-convex bilinear terms adding complexity to process optimization. Recently, data-driven models, particularly artificial neural networks (ANNs), have gained traction for representing chemical processing units. The predictive accuracy of ANNs depends on data quality, variable interactions, and network architecture, the latter being an optimization challenge itself. This study proposes and evaluates two strategies to optimize ANN architecture for modeling a propylene glycol production process from glycerol. The process includes a reactor and two distillation columns, with training data generated through simulation in Aspen Plus by varying design and operating variables. Two approaches are compared: random ANN structure generation and architecture optimization using the ant colony algorithm, a method suitable for discrete problems. Decision variables include the number of hidden... [more]

Artificial neural networks (ANNs) have gained popularity in the last years as tools to develop data-driven models of chemical process units. However, representing a system only with such artificial intelligence models may lead to a loss in the comprehension of the occurring phenomena. Hybrid models allow combining the predictive capabilities of ANNs with the foundational knowledge of rigorous models. This study explores the impact of hybridization in designing and optimizing shell-and-tube heat exchangers, comparing a full ANN-based model with a hybrid model. The hybrid model incorporates ANN predictions for highly nonlinear components, such as heat transfer coefficients, while other calculations are performed using the rigorous Bell-Delaware model. To generate the necessary data, the rigorous model is solved under randomly selected conditions. Using Python, one ANN predicts the exchanger's cost, while another predicts the heat transfer coefficients. Both models are optimized using the... [more]

Detailed assessment of fuel production processes at an early stage of a project is crucial to identify potential technical challenges, optimize efficiency and minimize costs and environmental impact. While process simulations often are either very rigid and accurate or very flexible and unprecise, informed decision making can only be maintained by establishing a detailed process model as early as possible within the project lifecycle while keeping relevant aspects of the process flexible enough. In this work, we present the development of a framework based on a dynamic interface between AspenPlus® process simulations and Python, enabling enhanced flexibility and automation for process modeling and optimization. This integration leverages the powerful simulation capabilities of AspenPlus® with the versatility of Python for data analysis and optimization, delivering significant improvements in workflow efficiency and process control. By utilizing the dynamic simulation data exchange with... [more]

Process synthesis is a fundamental step in process design. The aim is to determine the optimal configuration of unit operations and stream flows to enhance key performance metrics. Traditional methods provide just one optimal solution and are strongly dependent on user-defined technologies, stream connections, and initial guesses for unknown variables. Usually, a single solution is not sufficient for adequate decision-making, especially, when properties such as flexibility or reliability are considered in addition to the process economics. Wastewater Treatment network synthesis and design is a complex problem that demands innovative approaches in design, retrofits, and maintenance strategies. Considering this, an enhanced framework for improving reliability in wastewater transportation networks based on graph theory and machine learning is presented. Machine learning models were developed to predict failure probability, where the XGBoost model provided the best predictions. To select t... [more]

While bilevel optimization is gaining prominence across various domains, the field lacks standardized tools for generating test problems that can effectively evaluate and guide the development of efficient solution algorithms. We define the term "trivial bilevel optimization problem" as a bilevel problem whose high-point relaxation solution is also feasible. These easy-to-solve problems frequently arise in naïve implementations of random bilevel optimization problem generators, significantly impacting the evaluation of bilevel solution algorithms. However, this problem has not been addressed in the literature to our best knowledge. This work introduces a non-trivial mixed-integer bilevel optimization problem generator, NT-BMIPGen, and a problem library, designed to eliminate the generation of trivial bilevel problems. Through analysis of the bilevel problem structure, we identify key factors contributing to problem triviality. Particularly, the upper to lower variable ratios and the nu... [more]

The electrification of industrial heat is a promising pathway for decarbonization, yet challenges persist in balancing capital costs, operating costs, and emissions reduction. While previous studies have assessed electrification through heat integration and graphical methods, these approaches do not inherently determine the optimal hybrid technology configuration. This study introduces an optimization-based framework that systematically evaluates the cost-optimal allocation of electrified and conventional heating technologies. Formulated as a Mixed-Integer Linear Programming (MILP) model and implemented in Gurobi, the framework minimizes Total Annualized Cost (TAC) while satisfying heat demand, technology constraints, and emissions targets. Applied to an industrial case study, the model compares three scenarios: a fully conventional system relying on steam boilers and fired heaters, a fully electrified system utilizing high-temperature heat pumps, electrode boilers, and electric heater... [more]

This paper presents a novel fault detection method based on key variable forecasting models. The approach integrates future forecasts of key variables into a time window, allowing for early fault detection without modifying the offline training phase of the existing fault detection model. By incorporating predicted data into the detection process, the proposed method significantly improves fault detection rates and reduces detection delays. Experiments using the Continuous Stirred Tank Heater (CSTH) system demonstrate the superiority of our method over traditional approaches, showing the advantages of forecasting in enhancing detection performance. However, our results also highlight the dependency of the method's effectiveness on the quality of the forecasting model, suggesting the need for more advanced time-series forecasting techniques. Additionally, the current point forecasting method may not be sufficient in real-world applications, where probabilistic modeling of key variables... [more]

Large Language Models have demonstrated potential in accelerating scientific discovery, but they face challenges when making inferences in rapidly evolving and niche domains like Process Systems Engineering (PSE). To address this, we propose a Graph-based Retrieval-Augmented Generation (RAG) pipeline specifically designed for PSE papers. Our pipeline includes custom document parsing, knowledge graph construction, and refinement to enhance retrieval accuracy. We evaluate the effectiveness of our approach using an automatically generated benchmark consisting entirely of PSE-related questions. The results show that our pipeline outperforms both non-RAG and vanilla RAG implementations in terms of relevant document retrieval and overall answer quality. Additionally, our implementation is fully customizable, allowing users to select the papers most relevant to their specific tasks. This framework is openly available, providing a flexible solution for those working in PSE or similar domains.

Robust optimisation is a powerful approach for addressing uncertainty ensuring constraint satisfaction for all uncertain parameter realisations. While convex robust optimisation problems are effectively tackled using robust reformulations and cutting plane methods, extending these techniques to non-convex problems remains largely unexplored. In this work we propose a method that is based on a parallel robustness and optimality search. We introduce a novel spatial Branch-and-Bound algorithm integrated with robust cutting-planes for solving non-convex robust optimisation problems. The algorithm systematically incorporates global and robust optimisation techniques, leveraging McCormick relaxations. The proposed algorithm is evaluated on benchmark pooling problems with uncertain feed quality, demonstrating algorithm stability and solution robustness. The computational time for the examined case studies is within the same order of magnitude as state-of-the-art. The findings of this work hig... [more]

This work addresses the process design of Power-to-Ammonia plants (i.e. ammonia from renewable-powered electrolysis) by a novel methodology based on the multi-objective optimization of the “Three pillars of sustainability”: economic, environmental, and social. Specifically, we developed a tool estimating the installed capacities of every main process section typically featured by Power-to-Ammonia facilities (e.g., the renewable power plant, the electrolyzer, energy and hydrogen storage systems, etc.) to maximize the plant’s “Global Sustainability Score”.

Pressure swing adsorption (PSA) is an energy-efficient technology for gas separation, while the multi-objective optimization of PSA is a challenging task. To tackle this, we propose a hybrid optimization framework, which integrates three steps. In the first step, we establish surrogate models for the constraints using Gaussian processes (GPs) and employ multi-objective Bayesian optimization to search for feasible points that satisfy the constraints. In the second step, we establish surrogate models for the objective function and constraints using GPs and utilize constrained multi-objective Bayesian optimization to search for an approximate Pareto front. In the third step, we perform a local search based on the approximate Pareto front. By employing the trust region filter method, we construct quadratic models for each constraint and objective function and refine the Pareto front to achieve local optimality. This framework demonstrates the efficiency of Bayesian optimization and the loc... [more]

Individual-based modeling (IbM) has emerged as a powerful approach for studying microbial populations, offering a bottom-up framework to simulate cellular behaviors and their interactions. Unlike continuum-based models, IbM explicitly captures the heterogeneity and emergent dynamics of microbial communities, making it invaluable for studying spatially structured phenomena such as nutrient competition, biofilm formation, and colony interactions. However, IbM faces significant computational challenges, particularly in resolving spatial overlaps during simulations of large microbial populations. Traditional approaches, such as pairwise comparisons or kd-trees, are computationally expensive and scale poorly with population size. The Discretized Overlap Resolution Algorithm (DORA) introduces a novel grid-based solution to overcome these limitations. By encoding spatial information into an occupancy matrix, DORA achieves a time complexity of O(N), enabling efficient resolution of overlaps wh... [more]

Bayesian classification (BC) is a powerful supervised machine learning method for modelling the relationship between a set of continuous variables and a set of discrete variables that represent classes. BC has been successful in engineering and medical applications, including feasibility analysis and clinical diagnosis. Gaussian process (GP) models are widely used in BC methods to model the probability of assigning a class to an input point, typically through an indirect approach: a GP predicts a continuous function value based on Bayesian inference, which is then transformed into class probabilities using a nonlinear function like a sigmoid. The final class labels are assigned based on these probabilities. In this commonly used workflow, the uncertainty associated with the class prediction is usually evaluated as the uncertainty in the GP function values. A disadvantage of this approach is that it does not consider the uncertainty directly associated with the decision-making. In this... [more]

Currently, state-of-the-art approaches to solving complex optimization problems have focused solely on methods requiring high computational time and unable to find the global optimal solution. In this work, a methodology based on quantum computing is presented to overcome these drawbacks. The novelty of this framework stems from the quantum computer’s architecture and taking into consideration the quantum phenomena that take place to solve optimization problems with specific structure. The proposed methodology includes steps for the transformation of the initial optimization problem into an unconstrainted optimization problem with binary variables and its embedding onto a quantum device. Moreover, different resolution levels for the transformation step and different architectures for the embedding process are utilized. To illustrate the procedure, a case study based on Haverly’s pooling and blending problem is examined while demonstrating the potential of the proposed approach. The res... [more]

Prospective life-cycle design of emerging technologies is important in discussions of decarbonization and resource circulation strategies. This study demonstrates the role of computer-aided process engineering in reflecting technology information with appropriate granularity and accuracy using air conditioning as a case study. Process simulations involving heat exchangers (indoor/outdoor units), compressors, and expansion valves were developed to model air conditioners to quantify changes in performance and heat exchanger size as existing and alternative refrigerants are introduced. The process simulation results were incorporated into a material flow analysis and life cycle assessment to quantify the change in life cycle greenhouse gas (GHG) emissions through 2050 for each refrigerant installed. The results show that operational emissions dominate the life cycle GHG emissions of air conditioners, that decarbonization of electricity can significantly reduce life cycle GHG emissions, wi... [more]

Batch chemical processes face significant challenges due to frequent operational shifts and varying conditions, requiring models to be retrained for each new scenario. This high retraining demand limits the scalability of traditional process monitoring systems, making them unsuitable for dynamic batch operations. To address this, we propose a transfer learning-based framework that enhances adaptability by reusing learned features across different batch conditions, reducing the need for extensive retraining. Proposed method integrates Temporal Convolutional Networks (TCNs) for capturing temporal dependencies in batch data and predicting Quality-Indicative Variables (QIVs) to identify deviations. The core innovation lies in transfer learning, enabling the model to adapt to new process variations with minimal updates. This approach ensures robust, accurate monitoring even under evolving conditions. This framework is validated using the IndPenSim penicillin fermentation dataset, which simu... [more]

This study presents a simple tool to provide decision-makers data that will facilitate informed decisions in selecting utilization for small- to medium-scale utilization of stranded natural gas resources that would otherwise be flared. The methodology involves the simulation of different natural gas utilization technologies on Aspen Plus simulation software and utilizing the results to develop a tool on python that enables the user to assess recoverable valuable products from different natural gas profiles. Ten utilization technologies were implemented and six different natural gas profiles (rich and lean) were used as case studies to ascertain the capabilities of the tool. The results provide the user with the Net Present Values (NPV) of different technologies and the most profitable or infeasible utilization technology. The results also show the potentials of utilizing the gas over flaring. For very small volumes of gas the results favored the compressed natural gas (CNG) with positi... [more]

The growing demand for sustainable alternatives to petroleum-based products drives the development of biomanufacturing using agriculture-based sugars. However, agricultural sugar production faces significant challenges due to limited production capacity and potential negative environmental impacts. This research examines chemical sugar synthesis as an alternative, assessing its environmental impact with conventional agricultural production methods through life cycle assessment. As formaldehyde serves as a primary substrate in chemical synthesis, four production cases were evaluated—comprising two pathways (conventional methods and CO2 capture and utilization (CCU) technologies), each implemented with either fossil fuels or renewable energy sources. The analysis revealed that semi-batch reactors in chemical synthesis substantially reduce environmental impacts compared to batch reactors. Chemical sugar synthesis demonstrated marked advantages in reducing eutrophication, land use change,... [more]

Optimization under uncertainty is inherent to many PSE applications ranging from process design to RTO. Reaching process true optima often involves learning from experimentation, but actual experiments involve a cost (economic, resources, time) and a budget limit usually exists. Finding the best trade-off on cumulative process performance and experimental cost over a finite budget is a Partially Observable Markov Decision Process (POMDP), known to be computationally intractable. This paper follows the nonmyopic Bayesian optimization (BO) approximation to POMDPs developed by the machine-learning community, that naturally enables the use of hybrid plant surrogate models formed by fundamental laws and Gaussian processes (GP). Although nonmyopic BO using GPs may look more tractable, evaluating multi-step decision trees to find the best first-stage candidate action to apply is still expensive with evolutionary or NLP optimizers. Hence, we propose modelling the value function of the first-st... [more]

Processes increasingly need to consider electricity markets, which shifts the traditional demand side management scope towards a more dynamic nature. Instead of only focusing on day-ahead energy trading, demand-side management scope should be broadened towards being able to support the power grid stability during frequency events. This paper studies an artificial example process, similar to the melt-shop process from the steel industry, highlighting the challenges and opportunities of an energy intensive process. We show the potential benefits of having a battery energy storage system on-site, as well as opportunities in lowering the electricity cost by participating in the bidding process of various ancillary products.

Rubber mixing (RM) is a vital batch process producing high-quality composites, which serve as input material for manufacturing different types of final products, such as tires. Due to its complexity, this process faces two main challenges regarding the final quality: i) lack of online measurement and ii) limited comprehension of the influence of the different factors involved in the process. While data-driven and machine learning (ML) based soft-sensing methods have been widely applied to address the first challenge, the second challenge, to the best of the author's knowledge, has not yet been addressed in the rubber industry. This work presents a data-driven method for extracting knowledge and providing explainability in the quality prediction in RM processes. The method centers on an XGBoost model while leveraging high-dimensional data collected over extended time periods from one of Michelin’s complex mixing processes. First, a recursive feature elimination-based procedure is used f... [more]