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In this paper, focusing on the slow time-varying characteristics, a series of works have been conducted to implement an accurate quality prediction for batch processes. To deal with the time-varying characteristics along the batch direction, sliding windows can be constructed. Then, the start-up process is identified and the whole process is divided into two modes according to the steady-state identification. In the most important mode, the process data matrix, used to establish the regression model of the current batch, is expanded to involve the process data of previous batches, which is called batch augmentation. Thus, the process data of previous batches, which have an important influence on the quality of the current batch, will be identified and form a new batch augmentation matrix for modeling using the partial least squares (PLS) method. Moreover, considering the multiphase characteristic, batch augmentation analysis and modeling is conducted within each phase. Finally, the proposed method is applied to a typical batch process, the injection molding process. The quality prediction results are compared with those of the traditional quality prediction method based on PLS and the ridge regression method under the proposed batch augmentation analysis framework. The conclusion is obtained that the proposed method based on the batch augmentation analysis is superior.

This paper proposed a quality-related online monitoring strategy based on time and batch two-dimensional evolution information for batch processes. In the direction of time, considering the difference between each phase and the steady part and the transition part in the same phase, the change trend of the regression coefficient of the PLS model is used to divide each batch into phases, and each phase into parts. The phases, the steady parts, and the transition parts are finally distinguished and dealt with separately in the subsequent modeling process. In the batch direction, considering the slow time-varying characteristics of batch evolution, sliding windows are used to perform mode division by analyzing the evolution trend of the score matrix T in the PLS model on the base of phase division and within-phase part division. Finally, an online monitoring model that comprehensively considers the evolution information of time and batch is obtained. In a typical batch operation process, injection molding is used as an example for experimental analysis. The results show that the proposed algorithm takes advantage of mixing the time-batch two-dimensional evolution information. Compared with the traditional methods, the proposed method can overcome the shortcomings caused by the single dimension analysis and has better monitoring results.

Techniques for monitoring calcium carbonate and silica deposits (scale) in geothermal power plants and hot spring facilities using fiber optic sensors have already been reported. These sensors continuously measure changes in light transmittance with a detector and, when applied to field tests, require the installation of a power supply and sensor monitoring equipment. However, on some sites, a power supply may not be available, or a specialist skilled in handling scale sensors is required. To overcome this problem, we have developed a method for evaluating scale formation that is based on a batch process that can be used by anyone. In brief, this method involves depositing scale on a section of the optical fiber sensor and then fusing this section to the optical fiber and measuring it. Using this sensor, a technician in the field can simply place the sensor in the desired location, collect the samples at any given time, and send them to the laboratory to measure their transmittance. This simple and easy method was achieved by using a hetero-core type of fiber optic. This evaluation method can measure with the same sensitivity as conventional real-time methods, while its transmittance response for the sensor corresponds to the saturation index (SI) changes in the scale components in the solution due to increases in temperature and concentration. In the field of carbon dioxide capture and storage (CCS), this evaluation method can be used to quantitatively measure the formation of carbonate minerals, and it can also be used as an indicator for determining the conditions for CO2 mineral fixation, as well as in experiments using batch-type autoclaves in laboratory testing. It is also expected to be used in geothermal power plants as a method for evaluating scale formation, such as that of amorphous silica, and to protect against agents that hinder stable operation.

Quality control and reaction monitoring are necessary to ensure the consistency of any kind of mixing or reaction process. In this context, a novel portable high-sensitivity sensor prototype based on the Raman effect is presented in this study. The elongated probe head is designed for (but not limited to) monitoring high temperature batch processes for quality assurance. Thanks to the highly sensitive special detectors, concentration differences of up to 50 mmol/L can currently be detected, which facilitates compliance with high product quality standards. In addition, seamless reaction tracking is possible. Small individual adjustments through simple, intuitive mechanical components provide a high degree of flexibility in reaction selection by the end user. Specially developed software automates the evaluation process and gives the user visual signals about the current status and progress of the batch as well as an emergency stop if temperature limits could damage individual components. By using all the individual components developed, the problem of the limited integration times of previous spectrometric measuring instruments could be reduced. The prototype was validated using concentration measurements of various substances that occur as standard in batch processes. In addition, this article provides an outlook on the fact that Raman measurements can also be carried out successfully and reliably in explosive environments in the future with the prototype presented.

To deal with the highly nonlinear and time-varying characteristics of Batch Process, a model named adaptive stacking approximate kernel based broad learning system is proposed in this paper. This model innovatively introduces the approximate kernel based broad learning system (AKBLS) algorithm and the Adaptive Stacking framework, giving it strong nonlinear fitting ability, excellent generalization ability, and adaptive ability. The Broad Learning System (BLS) is known for its shorter training time for effective nonlinear processing, but the uncertainty brought by its double random mapping results in poor resistance to noisy data and unpredictable impact on performance. To address this issue, this paper proposes an AKBLS algorithm that reduces uncertainty, eliminates redundant features, and improves prediction accuracy by projecting feature nodes into the kernel space. It also significantly reduces the computation time of the kernel matrix by searching for approximate kernels to enhance its ability in industrial online applications. Extensive comparative experiments on various public datasets of different sizes validate this. The Adaptive Stacking framework utilizes the Stacking ensemble learning method, which integrates predictions from multiple AKBLS models using a meta-learner to improve generalization. Additionally, by employing the moving window method—where a fixed-length window slides through the database over time—the model gains adaptive ability, allowing it to better respond to gradual changes in industrial Batch Process. Experiments on a substantial dataset of penicillin simulations demonstrate that the proposed model significantly improves predictive accuracy compared to other common algorithms.

Batch process monitoring datasets usually contain missing data, which decreases the performance of data-driven modeling for fault identification and optimal control. Many methods have been proposed to impute missing data; however, they do not fulfill the need for data quality, especially in sensor datasets with different types of missing data. We propose a hybrid missing data imputation method for batch process monitoring datasets with multi-type missing data. In this method, the missing data is first classified into five categories based on the continuous missing duration and the number of variables missing simultaneously. Then, different categories of missing data are step-by-step imputed considering their unique characteristics. A combination of three single-dimensional interpolation models is employed to impute transient isolated missing values. An iterative imputation based on a multivariate regression model is designed for imputing long-term missing variables, and a combination model based on single-dimensional interpolation and multivariate regression is proposed for imputing short-term missing variables. The Long Short-Term Memory (LSTM) model is utilized to impute both short-term and long-term missing samples. Finally, a series of experiments for different categories of missing data were conducted based on a real-world batch process monitoring dataset. The results demonstrate that the proposed method achieves higher imputation accuracy than other comparative methods.

•MVDA is key to extracting information from large multivariate process datasets.•We present MVDA as a PAT solution for biopharmaceutical cell culture processes.•Full PAT with MVDA control model for cell culture is unachieved due to complexity.•MVDA models should be routinely used preferably with multivariate process analyzers. Increasingly elaborate and voluminous datasets are generated by the (bio)pharmaceutical industry and are a major challenge for application of PAT and QbD principles. Multivariate data analysis (MVDA) is required to delineate relevant process information from large multi-factorial and multi-collinear datasets. Here the key role of MVDA for industrial (bio)process data is discussed, with a focus on progress and limitations of MVDA as a PAT solution for biopharmaceutical cultivation processes. MVDA based models were proven useful and should be routinely implemented for bioprocesses. It is concluded that although the highest level of PAT with process control within its design space in real-time during manufacturing is not reached yet, MVDA will be central to reach this ultimate objective for cell cultivations.

Quality prediction is a challenging task due to the nonlinearity and complexity of batch processes. In real batch processes, the presence of different sampling frequencies complicates data processing and information digging, making it difficult to fully investigate process information. To address this dilemma, this work developed a multi-flow multi-scale convolutional neural network (MFMSCNN) for the quality prediction of batch processes. MFMSCNN adopts a multi-branch structure to cope with data with different sampling frequencies. A multi-scale feature branch will be adopted to extract the multi-hierarchy features of data containing rich information. Meanwhile, a 1D convolution branch will be applied to the mining process characteristics of data containing less information. Finally, all features in each branch are fed into the fully connected layers to make a quality prediction. In this manner, the process data are fully exploited, and the multi-level features are extracted to better interpret the batch processes. MFMSCNN was evaluated on an industrial ethanol fermentation process and an injection molding process. It obtained remarkable performance on both batch processes. The prediction results of the proposed method are superior to many other methods.

Batch processing is a widely utilized technique in the manufacturing of high-value products. Traditional methods for quality assessment in batch processes often lead to productivity and yield losses because of offline measurement of quality variables. The use of soft sensors enhances product quality and increases production efficiency. However, due to the uneven batch data, the variation in processing times presents a significant challenge for building effective soft sensor models. Moreover, sensor failures, exacerbated by the manufacturing environment, complicate the accurate modeling of process variables. Existing soft sensor approaches inadequately address sensor malfunctions, resulting in significant prediction inaccuracies. This study proposes a fault-tolerant soft sensor algorithm that integrates two Long Short-Term Memory (LSTM) networks. The algorithm focuses on modeling process variables and compensating for sensor failures using historical batch quality data. It introduces a novel method for converting quality variables into process rates to align uneven batch data. A case study on simulated penicillin production validates the superiority of the proposed algorithm over conventional methods, showing its capacity for precise endpoint detection and effectiveness in addressing the challenges of batch process quality assurance. This study offers a robust solution to the issues of soft sensor reliability and data variability in industrial manufacturing.

For batch time-varying processeswith non-repetitive disturbances, a cross-coupling indirect iterative learning control (CC-iILC) is proposed. The set trajectory of the system on the single axis is accurately tracked by an indirect iterative learning control strategy with a PI controller for its time direction and a closed-loop feedback control strategy for the batch direction. Under the asymptotically stable condition of the two-dimensional (2D) dynamic model, the optimal control law is obtained by optimizing the H-infinity control function. To avoid the contour error during coupling, the cross-coupling technique is used to distribute the contour error to each axis for compensation. The stability condition of the indirect iterative learning controller is analyzed by a two-dimensional Fornasini-Marchesini (FM) batch dynamics model and two-dimensional robust H-infinity control theory. The feasibility and superiority of the proposed control method are verified by numerical simulation and experimental tests.