Industrial batch dryer data mining using intelligent pattern classifiers: Neural network, neuro-fuzzy and Takagi–Sugeno fuzzy models

This contribution describes the pattern recognition based data analysis of an existing industrial batch dryer, and the comparison of three artificial intelligence techniques suited to perform classification tasks: neural networks trained using the Levenberg–Marquardt and the Levenberg–Marquardt method with Bayesian regularization, the neuro-fuzzy model based on clustering and grid partition, and the Takagi–Sugeno fuzzy models. The classifiers are used to quantify the dryer batch time and its variation during a certain production period, thus the motivation behind the work is genuine. The presented pattern recognition method implements a supervised learning approach and is based on pressure measurement profiles recorded by the plant data management software—the PI System from OSIsoft.It is found that the neural networks trained with the Bayesian regularization have shown the most robust classification performance with respect to separation threshold selection. Furthermore, it is concluded that the application of artificial intelligence techniques in real chemical manufacturing facilities is feasible and provides useful information for process performance monitoring purposes. The pattern recognition findings presented in this paper are not case specific and can be directly used for the monitoring of a large variety of drying processes since the pressure profile features – vacuum check, pressure decrease, vacuum break – do not depend on the chemicals which are dried. Since the development of the artificial intelligent classifiers is presented in detail and step by step, this work may be interesting as a pattern recognition tutorial for chemical engineers.