Industrial control system oscillations pose significant operational challenges, causing economic losses through energy waste, equipment degradation, and reduced product quality. Traditional detection methods rely heavily on manual expert analysis, creating scalability constraints in facilities with thousands of control loops. This paper presents a novel framework integrating Large Language Models (LLMs) with specialized oscillation detection toolboxes through Retrieval-Augmented Generation (RAG). The system features a command-line interface enabling seamless programmatic interaction between LLMs and analytical tools, eliminating GUI dependencies. A domain-specific RAG architecture combines real-time analytical outputs with technical knowledge repositories, while natural language processing capabilities allow industrial personnel to query systems using everyday language. The framework incorporates triangle-like shape detection algorithms enhanced by intelligent LLM interpretation. Validation using industrial datasets from refinery operations, the International Stiction Database, and the Tennessee Eastman Process benchmark demonstrates substantial performance improvements, achieving excellent classification accuracy and correlation values exceeding 0.96, effectively democratizing access to advanced oscillation analysis capabilities.
{"title":"Oscillation analysis using Retrieval-Augmented Generation","authors":"Abhijeet Singh , Mohammadhossein Modir Rousta , Biao Huang","doi":"10.1016/j.compchemeng.2025.109489","DOIUrl":"10.1016/j.compchemeng.2025.109489","url":null,"abstract":"<div><div>Industrial control system oscillations pose significant operational challenges, causing economic losses through energy waste, equipment degradation, and reduced product quality. Traditional detection methods rely heavily on manual expert analysis, creating scalability constraints in facilities with thousands of control loops. This paper presents a novel framework integrating Large Language Models (LLMs) with specialized oscillation detection toolboxes through Retrieval-Augmented Generation (RAG). The system features a command-line interface enabling seamless programmatic interaction between LLMs and analytical tools, eliminating GUI dependencies. A domain-specific RAG architecture combines real-time analytical outputs with technical knowledge repositories, while natural language processing capabilities allow industrial personnel to query systems using everyday language. The framework incorporates triangle-like shape detection algorithms enhanced by intelligent LLM interpretation. Validation using industrial datasets from refinery operations, the International Stiction Database, and the Tennessee Eastman Process benchmark demonstrates substantial performance improvements, achieving excellent classification accuracy and correlation values exceeding 0.96, effectively democratizing access to advanced oscillation analysis capabilities.</div></div>","PeriodicalId":286,"journal":{"name":"Computers & Chemical Engineering","volume":"206 ","pages":"Article 109489"},"PeriodicalIF":3.9,"publicationDate":"2026-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145594796","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2026-03-01Epub Date: 2025-11-28DOI: 10.1016/j.compchemeng.2025.109504
Bo-Xun Wang, Victor M. Zavala
Supply chains are complex systems involving many assets and stakeholders that need to be carefully orchestrated to conduct a variety of functions (e.g., meeting demands, ensuring robust operations, and cut down costs). Traditional optimization models that maximize total profit often lead to unfair profit distribution among stakeholders, which could discourage stakeholder collaboration and impede sustainable business development (e.g., activate new market/economies). In this work, we propose a fairness-guided optimization framework for supply chain design. To motivate our developments, we consider the production of a valuable polyester known as polybutylene adipate terephthalate (PBAT) from biomass in the State of Wisconsin. Specifically, we aim to design a supply chain (a bioeconomy) that harnesses biomass from different counties (stakeholders) and that processes this in chemical facilities to produce PBAT. We study the total cost and greenhouse gas (GHG) emissions in the system with the optimal allocation of supplies and facilities installed. We introduce different optimization formulations that maximize the total profit and that maximize a fairness measure of the profit distribution. Our results demonstrate that the fairness-driven formulation can achieve a more equitable distribution of profit but at the expense of a lower total profit, highlighting the inherent trade-off between fairness and economic efficiency. This study aims to provide insights for decision-makers that aim to balance economy development, sustainability, and fairness when designing supply chains.
{"title":"A fairness-guided supply chain framework for polyester production from biomass","authors":"Bo-Xun Wang, Victor M. Zavala","doi":"10.1016/j.compchemeng.2025.109504","DOIUrl":"10.1016/j.compchemeng.2025.109504","url":null,"abstract":"<div><div>Supply chains are complex systems involving many assets and stakeholders that need to be carefully orchestrated to conduct a variety of functions (e.g., meeting demands, ensuring robust operations, and cut down costs). Traditional optimization models that maximize total profit often lead to unfair profit distribution among stakeholders, which could discourage stakeholder collaboration and impede sustainable business development (e.g., activate new market/economies). In this work, we propose a fairness-guided optimization framework for supply chain design. To motivate our developments, we consider the production of a valuable polyester known as polybutylene adipate terephthalate (PBAT) from biomass in the State of Wisconsin. Specifically, we aim to design a supply chain (a bioeconomy) that harnesses biomass from different counties (stakeholders) and that processes this in chemical facilities to produce PBAT. We study the total cost and greenhouse gas (GHG) emissions in the system with the optimal allocation of supplies and facilities installed. We introduce different optimization formulations that maximize the total profit and that maximize a fairness measure of the profit distribution. Our results demonstrate that the fairness-driven formulation can achieve a more equitable distribution of profit but at the expense of a lower total profit, highlighting the inherent trade-off between fairness and economic efficiency. This study aims to provide insights for decision-makers that aim to balance economy development, sustainability, and fairness when designing supply chains.</div></div>","PeriodicalId":286,"journal":{"name":"Computers & Chemical Engineering","volume":"206 ","pages":"Article 109504"},"PeriodicalIF":3.9,"publicationDate":"2026-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145691685","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
This work presents a methodology for evaluating the effectiveness of hybrid modelling under varying conditions of mechanistic model quality and information available for model training, that is typically expressed as the amount of data available. While hybrid models – which integrate mechanistic and data-driven components – have gained significant attention in process systems engineering, their advantages over purely mechanistic or data-driven alternatives remain inadequately quantified. We address this gap by investigating two critical factors: (i) the impact of mechanistic model fidelity on hybrid model performance, and (ii) the influence of calibration dataset size on prediction accuracy. Our methodology is validated through an in-silico case study of baker's yeast cultivation and a real-world industrial application of ion-exchange chromatography in biopharmaceutical manufacturing. Results demonstrate that hybrid models consistently outperform purely mechanistic and data-driven approaches when the mechanistic component captures fundamental process behaviours, even with structural simplifications. Notably, hybrid models maintain superior predictive capability in extrapolative scenarios; however, when mechanistic knowledge is severely limited and insufficient information is available for compensation, hybridisation benefits diminish substantially. The work provides quantitative guidance for practitioners to determine when hybrid modelling represents a justified investment of modelling resources in process engineering applications.
{"title":"On the impact of mechanistic model quality and data availability in hybrid model development","authors":"Margherita Geremia , Tiziana Marella , Elaheh Ardalani , Samira Beyramysoltan , Sayantan Chattoraj , Pierantonio Facco , Massimiliano Barolo , Fabrizio Bezzo","doi":"10.1016/j.compchemeng.2025.109536","DOIUrl":"10.1016/j.compchemeng.2025.109536","url":null,"abstract":"<div><div>This work presents a methodology for evaluating the effectiveness of hybrid modelling under varying conditions of mechanistic model quality and information available for model training, that is typically expressed as the amount of data available. While hybrid models – which integrate mechanistic and data-driven components – have gained significant attention in process systems engineering, their advantages over purely mechanistic or data-driven alternatives remain inadequately quantified. We address this gap by investigating two critical factors: (<em>i</em>) the impact of mechanistic model fidelity on hybrid model performance, and (<em>ii</em>) the influence of calibration dataset size on prediction accuracy. Our methodology is validated through an <em>in-silico</em> case study of baker's yeast cultivation and a real-world industrial application of ion-exchange chromatography in biopharmaceutical manufacturing. Results demonstrate that hybrid models consistently outperform purely mechanistic and data-driven approaches when the mechanistic component captures fundamental process behaviours, even with structural simplifications. Notably, hybrid models maintain superior predictive capability in extrapolative scenarios; however, when mechanistic knowledge is severely limited and insufficient information is available for compensation, hybridisation benefits diminish substantially. The work provides quantitative guidance for practitioners to determine when hybrid modelling represents a justified investment of modelling resources in process engineering applications.</div></div>","PeriodicalId":286,"journal":{"name":"Computers & Chemical Engineering","volume":"206 ","pages":"Article 109536"},"PeriodicalIF":3.9,"publicationDate":"2026-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145836404","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2026-03-01Epub Date: 2025-12-19DOI: 10.1016/j.compchemeng.2025.109534
Busra Agan Celik, Murat Yulek, Serdar Celik
This study provides a comprehensive evaluation of crude oil price forecasting by systematically comparing stochastic models (GBM, FBM, BB), machine learning and time-series approaches (LSTM, ARIMA, VAR), and two hybrid strategies LSTM-GBM (time-varying drift estimation) and Bridge-ARIMA (terminal-level anchoring) across short-, medium-, and long-term horizons. Using daily price data spanning 34 years (1990–2024), the analysis encompasses major global crises, including the Asian Financial Crisis, Dot-com Bubble, Global Commodity Boom, Global Financial Crisis, Arab Spring, Oil Price Collapse, COVID-19 pandemic, and the Russia–Ukraine conflict. Stochastic models exhibited sensitivity to the number of simulation runs, with FBM yielding the most robust forecasts, BB demonstrating stability through mean-reversion, and GBM showing larger errors over extended horizons. LSTM consistently outperformed alternative methods, capturing nonlinear dynamics and long-term dependencies with high accuracy across all horizons. ARIMA performed adequately for short-term forecasts but declined over longer periods, whereas VAR consistently underperformed, reflecting its limited capacity to capture complex market dynamics. The hybrid methods further enhance performance: Bridge-ARIMA reduces bias by aligning simulated paths with an ARIMA-implied terminal, improving crisis-period tracking, whereas LSTM-GBM leverages learned drift to refine path forecasts and risk metrics (e.g., VaR). These results underscore the complementary advantages of stochastic and deep learning approaches and suggest that hybrid frameworks can enhance both volatility assessment and trend prediction. The findings offer practical insights for energy market planning, risk management, and strategic investment, particularly under crisis-driven volatility.
{"title":"Comparative performance of stochastic and deep learning models in forecasting crude oil prices under market shocks","authors":"Busra Agan Celik, Murat Yulek, Serdar Celik","doi":"10.1016/j.compchemeng.2025.109534","DOIUrl":"10.1016/j.compchemeng.2025.109534","url":null,"abstract":"<div><div>This study provides a comprehensive evaluation of crude oil price forecasting by systematically comparing stochastic models (GBM, FBM, BB), machine learning and time-series approaches (LSTM, ARIMA, VAR), and two hybrid strategies LSTM-GBM (time-varying drift estimation) and Bridge-ARIMA (terminal-level anchoring) across short-, medium-, and long-term horizons. Using daily price data spanning 34 years (1990–2024), the analysis encompasses major global crises, including the Asian Financial Crisis, Dot-com Bubble, Global Commodity Boom, Global Financial Crisis, Arab Spring, Oil Price Collapse, COVID-19 pandemic, and the Russia–Ukraine conflict. Stochastic models exhibited sensitivity to the number of simulation runs, with FBM yielding the most robust forecasts, BB demonstrating stability through mean-reversion, and GBM showing larger errors over extended horizons. LSTM consistently outperformed alternative methods, capturing nonlinear dynamics and long-term dependencies with high accuracy across all horizons. ARIMA performed adequately for short-term forecasts but declined over longer periods, whereas VAR consistently underperformed, reflecting its limited capacity to capture complex market dynamics. The hybrid methods further enhance performance: Bridge-ARIMA reduces bias by aligning simulated paths with an ARIMA-implied terminal, improving crisis-period tracking, whereas LSTM-GBM leverages learned drift to refine path forecasts and risk metrics (e.g., VaR). These results underscore the complementary advantages of stochastic and deep learning approaches and suggest that hybrid frameworks can enhance both volatility assessment and trend prediction. The findings offer practical insights for energy market planning, risk management, and strategic investment, particularly under crisis-driven volatility.</div></div>","PeriodicalId":286,"journal":{"name":"Computers & Chemical Engineering","volume":"206 ","pages":"Article 109534"},"PeriodicalIF":3.9,"publicationDate":"2026-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145836366","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2026-03-01Epub Date: 2025-11-29DOI: 10.1016/j.compchemeng.2025.109516
Shoutao Hu , Zhiwei Zhang , Hao Gong , Zhong Guan , Meiqi Liu , Nana Wu
In order to investigate the effects and mechanisms of magnetic fields on the explosion characteristics of premixed gases, explosion experiments were conducted under both magnetic field and no-magnetic field conditions using CH4-air and C3H8-air premixed combustible gases. Explosion product analysis revealed variations in component types and concentrations under both conditions. Additionally, simulation studies related to product formation were carried out. The experimental results showed that the magnetic fields reduced maximum explosion pressure and flame velocity for both mixtures, while the detection of alkane products significantly increased. Numerical simulations revealed that ·H, ·O, ·OH, and ·CH3 play key roles in the generation of explosion products in CH4-air and C3H8-air premixed gases. The magnetic field caused changes in multiple free radical chain reaction pathways during the explosions of methane and propane. By simulating key elementary reactions using Materials Studio, it was found that in the methane explosion process, the reactions C2H2+·H, ·C3H5+·H, and ·C2H5+·CH3 exhibit the lowest energy gaps, with the minimum value being 0.043855 eV. In the case of propane explosion, the energy gaps of critical elementary reactions increase in the order of ·C2H3+·CH3, C2H4+·O, C2H2+·O, ·CH3+·H, and ·CH3+·HCO, with the lowest being 0.012061 eV. These low energy barriers indicate that little energy is needed to affect key reactions during methane and propane explosions. The applied magnetic field reduces collisions between free radicals, thereby inhibiting the consumption of reaction intermediates and ultimately increasing the concentration of explosion products.
{"title":"Study on explosion characteristics of premixed gas influenced by magnetic field based on product analysis","authors":"Shoutao Hu , Zhiwei Zhang , Hao Gong , Zhong Guan , Meiqi Liu , Nana Wu","doi":"10.1016/j.compchemeng.2025.109516","DOIUrl":"10.1016/j.compchemeng.2025.109516","url":null,"abstract":"<div><div>In order to investigate the effects and mechanisms of magnetic fields on the explosion characteristics of premixed gases, explosion experiments were conducted under both magnetic field and no-magnetic field conditions using CH<sub>4</sub>-air and C<sub>3</sub>H<sub>8</sub>-air premixed combustible gases. Explosion product analysis revealed variations in component types and concentrations under both conditions. Additionally, simulation studies related to product formation were carried out. The experimental results showed that the magnetic fields reduced maximum explosion pressure and flame velocity for both mixtures, while the detection of alkane products significantly increased. Numerical simulations revealed that ·H, ·O, ·OH, and ·CH<sub>3</sub> play key roles in the generation of explosion products in CH<sub>4</sub>-air and C<sub>3</sub>H<sub>8</sub>-air premixed gases. The magnetic field caused changes in multiple free radical chain reaction pathways during the explosions of methane and propane. By simulating key elementary reactions using Materials Studio, it was found that in the methane explosion process, the reactions C<sub>2</sub>H<sub>2</sub>+·H, ·C<sub>3</sub>H<sub>5</sub>+·H, and ·C<sub>2</sub>H<sub>5</sub>+·CH<sub>3</sub> exhibit the lowest energy gaps, with the minimum value being 0.043855 eV. In the case of propane explosion, the energy gaps of critical elementary reactions increase in the order of ·C<sub>2</sub>H<sub>3</sub>+·CH<sub>3</sub>, C<sub>2</sub>H<sub>4</sub>+·O, C<sub>2</sub>H<sub>2</sub>+·O, ·CH<sub>3</sub>+·H, and ·CH<sub>3</sub>+·HCO, with the lowest being 0.012061 eV. These low energy barriers indicate that little energy is needed to affect key reactions during methane and propane explosions. The applied magnetic field reduces collisions between free radicals, thereby inhibiting the consumption of reaction intermediates and ultimately increasing the concentration of explosion products.</div></div>","PeriodicalId":286,"journal":{"name":"Computers & Chemical Engineering","volume":"206 ","pages":"Article 109516"},"PeriodicalIF":3.9,"publicationDate":"2026-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145691666","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2026-03-01Epub Date: 2025-11-27DOI: 10.1016/j.compchemeng.2025.109515
Maximilian Bloor , Max Mowbray , Ehecatl Antonio del Rio Chanona , Calvin Tsay
Sequential decision making under uncertainty is central to many Process Systems Engineering (PSE) challenges, where traditional methods often face limitations related to controlling and optimizing complex and stochastic systems. Reinforcement Learning (RL) offers a data-driven approach to derive control policies for such challenges. This paper presents a survey and tutorial on RL methods, tailored for the PSE community. We deliver a tutorial on RL, covering fundamental concepts and key algorithmic families including value-based, policy-based and actor-critic methods. Subsequently, we survey existing applications of these RL techniques across various PSE domains, such as in fed-batch and continuous process control, process optimization, and supply chains. We conclude with PSE-focused discussion of specialized techniques and emerging directions. By synthesizing the current state of RL algorithm development and implications for PSE this work identifies successes, challenges, trends, and outlines avenues for future research at the interface of these fields.
{"title":"A survey and tutorial of reinforcement learning methods in Process Systems Engineering","authors":"Maximilian Bloor , Max Mowbray , Ehecatl Antonio del Rio Chanona , Calvin Tsay","doi":"10.1016/j.compchemeng.2025.109515","DOIUrl":"10.1016/j.compchemeng.2025.109515","url":null,"abstract":"<div><div>Sequential decision making under uncertainty is central to many Process Systems Engineering (PSE) challenges, where traditional methods often face limitations related to controlling and optimizing complex and stochastic systems. Reinforcement Learning (RL) offers a data-driven approach to derive control policies for such challenges. This paper presents a survey and tutorial on RL methods, tailored for the PSE community. We deliver a tutorial on RL, covering fundamental concepts and key algorithmic families including value-based, policy-based and actor-critic methods. Subsequently, we survey existing applications of these RL techniques across various PSE domains, such as in fed-batch and continuous process control, process optimization, and supply chains. We conclude with PSE-focused discussion of specialized techniques and emerging directions. By synthesizing the current state of RL algorithm development and implications for PSE this work identifies successes, challenges, trends, and outlines avenues for future research at the interface of these fields.</div></div>","PeriodicalId":286,"journal":{"name":"Computers & Chemical Engineering","volume":"206 ","pages":"Article 109515"},"PeriodicalIF":3.9,"publicationDate":"2026-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145691667","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2026-03-01Epub Date: 2025-11-27DOI: 10.1016/j.compchemeng.2025.109514
Naveen G Jesubalan , Saxena Nikita , Shantanu Banerjee , Navnath Deore , Keshari Gupta , Anurag S Rathore
During the continuous production of monoclonal antibodies, the optimal management of surge tanks is crucial for process scheduling and mitigating disruptions caused by potential process variations, equipment failures, or calibration errors. This study presents a Q-learning-based reinforcement learning (RL) agent designed to regulate surge tank levels, offering a more sophisticated alternative to the conventional ON/OFF control strategy. To ensure an accurate representation of real-world conditions, the RL training environment was modeled with all process limitations and scheduling dynamics in place. The Q-learning agent was trained using surge tank heights as observational inputs, with a reward policy designed to accommodate a wide range of scenarios, from steady-state conditions to process deviations. A replay buffer function was incorporated to enhance the model's robustness.
The agent underwent extensive training with 100,000 episodes and was evaluated using 100 random episodes for kernel density estimation (KDE)and 10 random episodes for in-depth analysis. In addition, a comparative analysis was conducted between the RL-based controller and a rule-based controller. This assessment aimed to highlight the reliability and robustness of the proposed control strategy. During the agent construction phase, each episode lasted 70 min, accounting for single process cycle. After training and testing, the agent was deployed in real-time and integrated with the PLC and other sensors using Python middleware. The reliability of the built agent was further tested through two unforeseen events introduced during the campaign. The results demonstrate the resilience and effectiveness of the proposed approach towards maintaining surge tank stability, thereby underscoring the robustness it offers and its suitability for implementation in commercial manufacturing.
{"title":"Q-learning agent-based level control of surge tanks for improved continuous manufacturing of monoclonal antibodies","authors":"Naveen G Jesubalan , Saxena Nikita , Shantanu Banerjee , Navnath Deore , Keshari Gupta , Anurag S Rathore","doi":"10.1016/j.compchemeng.2025.109514","DOIUrl":"10.1016/j.compchemeng.2025.109514","url":null,"abstract":"<div><div>During the continuous production of monoclonal antibodies, the optimal management of surge tanks is crucial for process scheduling and mitigating disruptions caused by potential process variations, equipment failures, or calibration errors. This study presents a Q-learning-based reinforcement learning (RL) agent designed to regulate surge tank levels, offering a more sophisticated alternative to the conventional ON/OFF control strategy. To ensure an accurate representation of real-world conditions, the RL training environment was modeled with all process limitations and scheduling dynamics in place. The Q-learning agent was trained using surge tank heights as observational inputs, with a reward policy designed to accommodate a wide range of scenarios, from steady-state conditions to process deviations. A replay buffer function was incorporated to enhance the model's robustness.</div><div>The agent underwent extensive training with 100,000 episodes and was evaluated using 100 random episodes for kernel density estimation (KDE)and 10 random episodes for in-depth analysis. In addition, a comparative analysis was conducted between the RL-based controller and a rule-based controller. This assessment aimed to highlight the reliability and robustness of the proposed control strategy. During the agent construction phase, each episode lasted 70 min, accounting for single process cycle. After training and testing, the agent was deployed in real-time and integrated with the PLC and other sensors using Python middleware. The reliability of the built agent was further tested through two unforeseen events introduced during the campaign. The results demonstrate the resilience and effectiveness of the proposed approach towards maintaining surge tank stability, thereby underscoring the robustness it offers and its suitability for implementation in commercial manufacturing.</div></div>","PeriodicalId":286,"journal":{"name":"Computers & Chemical Engineering","volume":"206 ","pages":"Article 109514"},"PeriodicalIF":3.9,"publicationDate":"2026-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145749130","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Batch distillation, as a widely applied separation technology, demonstrates significant advantages in small-scale, multi-component, and composition-variable separation tasks. Current research primarily focuses on two directions to enhance its overall performance, reduce energy consumption, and shorten separation time: development of novel process configurations and operational optimization. Among these, the dividing wall batch distillation column (DWBDC) remarkably improves separation efficiency of conventional batch distillation through its innovative batch dividing wall process intensification structure. However, as a highly nonlinear dynamic system, DWBDC presents considerable challenges in rigorous simulation and optimization, which is well worth further investigation. Bayesian optimization algorithms have gained extensive application in chemical engineering due to their efficient global search capability in recent years. This study innovatively applies Bayesian optimization to batch distillation processes, establishing an operational optimization framework based on this algorithm and implementing it in the optimal design of various batch distillation configurations. To systematically evaluate DWBDC's superiority, rigorous dynamic simulations were conducted on three configurations: conventional batch distillation column (BDC), middle vessel batch distillation column (MVBDC), and DWBDC, with corresponding concentration control systems developed. The research examined separation performances of these configurations for industrial waste solvents with different feed compositions (light-component-dominant, intermediate-component-dominant, and balanced light/intermediate-component feeds). Bayesian optimization was employed to optimize operational parameters for all three configurations, followed by comparative performance analysis under optimal conditions. Results demonstrate the superior performance of DWBDC in both operating time and economic efficiency, providing crucial theoretical foundations and practical guidance for industrial application of dividing wall batch distillation technology.
{"title":"Dynamic simulation and operational optimization of dividing wall batch distillation columns based on rigorous models","authors":"Xing Qian , Jiayi Du , Gonghan Guo , Shengkun Jia , Chao Zhang","doi":"10.1016/j.compchemeng.2025.109542","DOIUrl":"10.1016/j.compchemeng.2025.109542","url":null,"abstract":"<div><div>Batch distillation, as a widely applied separation technology, demonstrates significant advantages in small-scale, multi-component, and composition-variable separation tasks. Current research primarily focuses on two directions to enhance its overall performance, reduce energy consumption, and shorten separation time: development of novel process configurations and operational optimization. Among these, the dividing wall batch distillation column (DWBDC) remarkably improves separation efficiency of conventional batch distillation through its innovative batch dividing wall process intensification structure. However, as a highly nonlinear dynamic system, DWBDC presents considerable challenges in rigorous simulation and optimization, which is well worth further investigation. Bayesian optimization algorithms have gained extensive application in chemical engineering due to their efficient global search capability in recent years. This study innovatively applies Bayesian optimization to batch distillation processes, establishing an operational optimization framework based on this algorithm and implementing it in the optimal design of various batch distillation configurations. To systematically evaluate DWBDC's superiority, rigorous dynamic simulations were conducted on three configurations: conventional batch distillation column (BDC), middle vessel batch distillation column (MVBDC), and DWBDC, with corresponding concentration control systems developed. The research examined separation performances of these configurations for industrial waste solvents with different feed compositions (light-component-dominant, intermediate-component-dominant, and balanced light/intermediate-component feeds). Bayesian optimization was employed to optimize operational parameters for all three configurations, followed by comparative performance analysis under optimal conditions. Results demonstrate the superior performance of DWBDC in both operating time and economic efficiency, providing crucial theoretical foundations and practical guidance for industrial application of dividing wall batch distillation technology.</div></div>","PeriodicalId":286,"journal":{"name":"Computers & Chemical Engineering","volume":"206 ","pages":"Article 109542"},"PeriodicalIF":3.9,"publicationDate":"2026-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145880239","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2026-03-01Epub Date: 2025-12-10DOI: 10.1016/j.compchemeng.2025.109518
Yash Barhate , Yung Shun Kang , Neda Nazemifard , C․Benjamin Renner , Yihui Yang , Charles Papageorgiou , Zoltan K. Nagy
This study presents a generic statistical machine learning (ML)-driven modeling workflow for designing crystallization processes, serving as a practical alternative in situations where traditional mechanistic population-balance modeling approaches are impractical. Key highlights of the proposed workflow include synthetic data augmentation to reduce dependency on extensive experimental datasets; the incorporation of active learning strategies to iteratively suggest experimental conditions and refine experimental datasets; and the successful deployment of ML models within the Quality-by-Digital-Design (QbDD) framework. The effectiveness of the proposed approach is demonstrated through two case studies: (1) an in-silico study involving an agrochemical compound, and (2) an experimental case study with an industrial pharmaceutical compound. ML models trained in these scenarios achieved prediction errors below 10 % when predicting critical quality attributes (CQAs). These models subsequently enabled deterministic and probabilistic design space analyses, followed by model-based process optimization, and were confirmed through experimental validation. While the approaches are exemplified using crystallization processes, it provides a generic and systematic framework for the ML model, development applicable to reactions and other complex process systems.
{"title":"Digital design of crystallization processes using statistical machine learning","authors":"Yash Barhate , Yung Shun Kang , Neda Nazemifard , C․Benjamin Renner , Yihui Yang , Charles Papageorgiou , Zoltan K. Nagy","doi":"10.1016/j.compchemeng.2025.109518","DOIUrl":"10.1016/j.compchemeng.2025.109518","url":null,"abstract":"<div><div>This study presents a generic statistical machine learning (ML)-driven modeling workflow for designing crystallization processes, serving as a practical alternative in situations where traditional mechanistic population-balance modeling approaches are impractical. Key highlights of the proposed workflow include synthetic data augmentation to reduce dependency on extensive experimental datasets; the incorporation of active learning strategies to iteratively suggest experimental conditions and refine experimental datasets; and the successful deployment of ML models within the Quality-by-Digital-Design (QbDD) framework. The effectiveness of the proposed approach is demonstrated through two case studies: (1) an <em>in-silico</em> study involving an agrochemical compound, and (2) an experimental case study with an industrial pharmaceutical compound. ML models trained in these scenarios achieved prediction errors below 10 % when predicting critical quality attributes (CQAs). These models subsequently enabled deterministic and probabilistic design space analyses, followed by model-based process optimization, and were confirmed through experimental validation. While the approaches are exemplified using crystallization processes, it provides a generic and systematic framework for the ML model, development applicable to reactions and other complex process systems.</div></div>","PeriodicalId":286,"journal":{"name":"Computers & Chemical Engineering","volume":"206 ","pages":"Article 109518"},"PeriodicalIF":3.9,"publicationDate":"2026-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145797290","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2026-02-15Epub Date: 2025-11-18DOI: 10.1016/j.compchemeng.2025.109484
Elia Arnese-Feffin , Nidhish Sagar , Luis A. Briceno-Mena , Birgit Braun , Ivan Castillo , Caterina Rizzo , Linh Bui , Jinsuo Xu , Leo H. Chiang , Richard D. Braatz
Data-driven modeling enables the pursuit of model-based solutions when no or partial knowledge is available on the process of interest. The typically poor generalization performance of data-driven models can be improved by incorporating all available knowledge into the model development workflow, i.e. by hybrid modeling. However, how to incorporate this knowledge and what kind of knowledge to use have been strictly problem-dependent questions: whether a general framework for hybrid modeling can be devised remains an open research topic. In this article, we make the first step towards such an objective: we propose a method relying on theoretically sound modification of the objective function of data-driven models by incorporation of constraints derived from process knowledge, an approach that can be readily implemented in existing software packages with minimal overhead. We focus on an underutilized source of knowledge, i.e. qualitative knowledge. The proposed approach is demonstrated in two case studies, where we employ qualitative and quantitative process knowledge with varying degrees of complexity and discuss their effectiveness. Results show promising performance, paving the way for a truly general hybrid modeling framework.
{"title":"The incorporation of qualitative knowledge in hybrid modeling","authors":"Elia Arnese-Feffin , Nidhish Sagar , Luis A. Briceno-Mena , Birgit Braun , Ivan Castillo , Caterina Rizzo , Linh Bui , Jinsuo Xu , Leo H. Chiang , Richard D. Braatz","doi":"10.1016/j.compchemeng.2025.109484","DOIUrl":"10.1016/j.compchemeng.2025.109484","url":null,"abstract":"<div><div>Data-driven modeling enables the pursuit of model-based solutions when no or partial knowledge is available on the process of interest. The typically poor generalization performance of data-driven models can be improved by incorporating all available knowledge into the model development workflow, i.e. by hybrid modeling. However, how to incorporate this knowledge and what kind of knowledge to use have been strictly problem-dependent questions: whether a general framework for hybrid modeling can be devised remains an open research topic. In this article, we make the first step towards such an objective: we propose a method relying on theoretically sound modification of the objective function of data-driven models by incorporation of constraints derived from process knowledge, an approach that can be readily implemented in existing software packages with minimal overhead. We focus on an underutilized source of knowledge, i.e. <em>qualitative</em> knowledge. The proposed approach is demonstrated in two case studies, where we employ qualitative and quantitative process knowledge with varying degrees of complexity and discuss their effectiveness. Results show promising performance, paving the way for a truly general hybrid modeling framework.</div></div>","PeriodicalId":286,"journal":{"name":"Computers & Chemical Engineering","volume":"205 ","pages":"Article 109484"},"PeriodicalIF":3.9,"publicationDate":"2026-02-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145620087","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}