
A Hardware-in-Loop Digital Twin Approach for Intelligent Optimization of Municipal Solid Waste Incineration
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An expert discussion of intelligent optimization control in complex industrial processes
In A Hardware-in-Loop Digital Twin Approach for Intelligent Optimization of Municipal Solid Waste Incineration: AI and Its Application to Complex Industrial Processes, a team of distinguished researchers delivers an innovative new approach to integrating virtual mechanism data generated through coupled numerical simulation and orthogonal experimental design with real historical data. The book explains how to create a heterogenous ensemble prediction model for carbon monoxide emissions in municipal solid waste incineration (MSWI) processes.
The authors focus on intelligent optimization control of MSWI processes based on hardware-in-loop DT platforms. They demonstrate AI-driven modeling, control, optimization algorithms in real-world applications, including virtual-real data hybrid-driven deep modeling and intelligent optimal controls based on multiple objectives.
Additional topics include:
- A thorough introduction to numerical simulation modeling of whole industrial processes
- Comprehensive explorations of the design, implementation, and validation of hardware-in-loop digital twin platforms
- Practical discussions of AI-driven modeling, control, and optimization
- Fulsome descriptions of the skills required to address challenges posed by complex industrial processes
Perfect for environmental engineers and researchers, A Hardware-in-Loop Digital Twin Approach for Intelligent Optimization of Municipal Solid Waste Incineration will also benefit MSWI plant operators and managers, as well as AI and machine learning researchers and developers of environmental monitoring and control systems.
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Persons
Jian Tang, PhD, is a Professor and Researcher with the Department of Artificial Intelligence and Automation in the Faculty of Information Technology at the Beijing University of Technology.
Wen Yu, PhD, is a Professor and Head of Department of the Departamento de Control Automatico at CINVESTAV-IPN (National Polytechnic Institute) in Mexico City, Mexico.
Junfei Qiao, PhD, is a Professor with the Beijing University of Technology and Director of Beijing Laboratory of Smart Environmental Protection in Beijing, China.
Content
List of Figures xvii
List of Tables xxix
About the Authors xxxiii
Preface xxxv
Abbreviations xxxvii
Symbol Meaning xliii
1 Introduction 1
1.1 Municipal Solid Waste Incineration (MSWI) Process and Optimal Control 1
1.2 AI-Based Modeling and Monitoring 17
1.3 Control and Optimization Based on AI and DT 32
1.4 Hardware-in-Loop DT for MSWI Processes 36
1.5 Book's Structure 42
Part I 42
Part II 45
Part III 47
References 48
Part I Modeling and Monitoring Based on AI 67
2 Numerical Simulation and Modeling Analysis on Whole Industrial Process by Coupling Multiple Software 69
2.1 Simulated Plant and Simulation Modeling 69
2.2 Modeling Strategy with Virtual Data-driven 92
2.3 Modeling Implementation for Whole Process 94
2.4 Numerical Simulation and Modeling Results 103
2.5 Conclusion 124
References 125
3 Conventional Pollutant Deep Modeling Using Virtual Data and Real Data Hybrid-Driven 129
3.1 Virtual-Real Data-Driven Conventional Pollutant Modeling 129
3.2 Real Data Hybrid-Driven Modeling Implementation 133
3.3 Deep Modeling Results and Discussion 142
3.4 Conclusion 157
References 160
4 Trace Pollutant Modeling Using the Selective Ensemble Algorithm 163
4.1 Selective Ensemble Modeling Strategy 163
4.2 Trace Pollutant Modeling Implementation 168
4.3 Data-Driven Ensemble Modeling Results and Discussion 176
4.4 Conclusion 201
References 201
5 Trace Pollutant Modeling Based on Semi-supervised Random Forest Optimization 205
5.1 Data-Driven Trace Pollutant Semi-supervised Random Forest Optimization Modeling Strategy 205
5.2 Data-Driven Trace Pollutant Modeling Implementation 212
5.3 Experimental Verification 221
5.4 Conclusion 238
References 239
6 Combustion State Identification Using ViT-IDFC with Global Flame Feature 243
6.1 Combustion State Identification and Global Flame Feature 243
6.2 State Monitoring Implementation Using ViT-IDFC 249
6.3 Experimental Results 256
6.4 Conclusion 273
References 273
7 Online Combustion Status Recognition of Using IDFC based on Convolutional Multi-Layer Feature Fusion 277
7.1 Convolutional Multi-layer Feature Fusion Based Online Combustion Identification 277
7.2 Convolutional-Feature-IDFC-Based Implementation 280
7.3 State Monitoring Results and Discussion 289
7.4 Conclusion 298
References 298
Part II Control and Optimization Based on AI and Digital Twin 301
8 Bayesian Optimization-Based Interval Type-2 Fuzzy Neural Network (IT2FNN) for Furnace Temperature Control 303
8.1 Bayesian Optimization-Based Interval Type-2 Fuzzy Neural Network Control Strategy 303
8.2 BO-Based Interval Type-2 Fuzzy Neural Network Control 309
8.3 Simulation Results 320
8.4 Conclusion 339
References 340
9 Interval Type-2 Fuzzy Control with Multiple Event Triggers for Furnace Temperature Control 345
9.1 Type-2 Fuzzy Broad Control with Multiple Event Triggers 345
9.2 METM-Based Interval Type-2 Fuzzy Broad Control 351
9.3 Stability Analysis 358
9.4 Simulation Results 362
9.5 Conclusion 376
References 377
10 Intelligent Optimal Control of Furnace Temperature Using Multi-loop Controller and PSO Optimization 381
10.1 Multi-loop Controller Using PSO Optimization 381
10.2 Data-Driven Furnace Temperature Optimization 392
10.3 Simulation Results 400
10.4 Conclusion 415
References 416
11 Data-Driven Multi-objective Intelligent Optimal Control of Industrial Process 419
11.1 Multiple Objectives Multiple Controlled Variables Optimization 419
11.2 Data-Driven Multiple Controlled Variables Optimization Implementation 429
11.3 Simulation Results 437
11.4 Conclusion 453
References 454
Part III Hardware-in-loop Digital Twin Platform Design and Validation 457
12 Description of Hardware-in-Loop Digital Twin Platform Requirements for Industrial Process 459
12.1 Overview 459
12.2 Laboratory Research on Platform Functionality Requirements 459
12.3 Industrial Applications on Platform Functionality Requirements 461
12.4 Platform Functional Requirements from a Flex Reconfiguration Perspective 463
12.5 Conclusion 466
13 Design and Realization of Hardware-in-Loop Digital Twin Platform 467
13.1 Digital Twin Functional Design 467
13.2 Hardware-in-Loop Structural Design 468
13.3 Hardware Setup 477
13.4 Software Design 479
13.5 Platform Realization 487
14 Testing and Validation of Hardware-in-Loop Digital Twin Platform 495
14.1 System Effectiveness Testing and Verification 495
14.2 Laboratory Scene Intelligent Algorithm Testing and Validation 500
14.3 Intelligent Algorithm Transplantation Application in Industrial Scenarios 512
15 Summary and Outlook of Hardware-in-Loop Digital Twin Platform 519
15.1 Summary 519
15.2 Future AI Algorithm Research and Validation End-Edge-Cloud Platform 520
Index 537
List of Figures
Figure 1.1 Process flow of a grate-type MSWI plant in Beijing Figure 1.2 MSW components ratios of different countries/regions Figure 1.3 Schematic diagram of manual control mode in the MSWI process in China Figure 1.4 Schematic diagram of operation optimization process in complex process industries Figure 1.5 Requirements and relationships in academic research and industrial applications Figure 1.6 Relationship between the incineration mechanism, the actual MSWI process, human brain cognitive theory, numerical simulation challenges, and DT model construction Figure 1.7 Structure of "Real-Real" simulation platform Figure 1.8 Structure of "Real-Virtual" simulation platform Figure 1.9 Structure of "Virtual-Real" simulation platform Figure 1.10 Structure of "Virtual-Virtual" simulation platform Figure 1.11 The book's structure Figure 2.1 Process flows of MSWI plants with a daily processing capacity of 800 tons Figure 2.2 Internal structure and zoning diagram of mechanical grate furnace Figure 2.3 Diagram of flue gas cleaning process Figure 2.4 Solid-phase combustion zone and gas-phase combustion zone for nitrogen element products Figure 2.5 Schematic diagram of NxOy generation in high-temperature combustion area Figure 2.6 Numerical simulation and modeling analysis framework Figure 2.7 Simulation modeling strategy for MSWI whole process Figure 2.8 Multi-software-coupled whole-process numerical simulation strategy under benchmark conditions Figure 2.9 Incinerator simplified structure (left side), its 2D model (middle), and mesh division (right side) Figure 2.10 Non-grate solid-phase combustion simulated by Aspen Plus Figure 2.11 Combustion results of solid MSW on the grate. (a) Rate; (b) Mass fraction Figure 2.12 Combustion results of gas-phase combustion under benchmark conditions: (a) temperature, (b) O2 mass fraction, and (c) CO2 mass fraction Figure 2.13 Temperature distribution in the incinerator under typical. (a-h) Case 1-Case 8 Figure 2.14 O2 distribution in the incinerator under typical. (a-h) Case 1-Case 8 Figure 2.15 CO2 distribution in the incinerator under typical. (a-h) Case 1-Case 8 Figure 2.16 Probability density of temperature in the incinerator under typical. (a-h) Case 1-Case 8 Figure 2.17 Exhaust emission results obtained from the simulation: (a) CO, (b) CO2, (c) O2, (d) SO2, and (e) NOx Figure 2.18 Single factor analysis curve in terms of feed rate based on MIMO-LRDT mechanism model. (a) CO concentration; (b) CO2 concentration; (c) O2 concentration; (d) SO2 concentration; (e) NOx concentration Figure 2.19 Single factor analysis curve in terms of primary air temperature based on MIMO-LRDT mechanism model. (a) CO concentration; (b) CO2 concentration; (c) O2 concentration; (d) SO2 concentration; (e) NOx concentration Figure 2.20 Dual-factor analysis curve based on MIMO-LRDT mechanism model. (a) Grate speed vs Feed rate; (b) Grate speed vs Primary air temperature Figure 3.1 Strategy diagram of the proposed virtual data and real data hybrid-driven modeling approach Figure 3.2 Aspen Plus model diagram Figure 3.3 Structure diagram of MISO LRDT model Figure 3.4 LSTM structure diagram Figure 3.5 Impact of three inputs on CO under multi-operating conditions Figure 3.6 Prediction curves of different models based on virtual mechanism data Figure 3.7 Prediction curves of different models based on real data Figure 3.8 Prediction curves of different models for offline training verification phase Figure 3.9 Prediction curves of the offline training verification phase Figure 3.10 Prediction curves of different models for the online testing verification phase Figure 3.11 Prediction curves of online testing verification phase Figure 3.12 Relationship between the hyperparameter and R2 indicator Figure 4.1 DXN generation mode during MSW combustion process Figure 4.2 DXN generation mode after MSW combustion process Figure 4.3 Schematic diagram of the generation mechanism and temperature range of DXN Figure 4.4 SEN modeling strategy based on Bayesian inference and binary tree Figure 4.5 Schematic diagram of BT candidate submodels construction Figure 4.6 Prediction curves of the candidate submodels for the benchmark datasets Figure 4.7 Posterior information of the candidate submodels for the benchmark datasets Figure 4.8 Posterior information of the selected ensemble submodels for the benchmark datasets Figure 4.9 Fitting curves of the SEN model for the benchmark datasets Figure 4.10 Posterior information of the SEN model for the DXN dataset Figure 4.11 Posterior information of the selected ensemble submodels for the DXN dataset Figure 4.12 Fitting curves of the DXN dataset Figure 4.13 Hyperparameter sensitivity analysis curves of the BBTSEN model Figure 5.1 Semi-supervised RF optimization strategy for DXN emission soft sensing Figure 5.2 Schematic of the parameter coding design for the semi-supervised RF optimization Figure 5.3 Particle decoding schematic for the semi-supervised RF optimization strategy Figure 5.4 Modeling results after CCS dataset optimization for the semi-supervised RF optimization strategy Figure 5.5 Prediction curve of the testing set on the CCS data for the semi-supervised RF optimization strategy Figure 5.6 Modeling results of the DXN dataset for the semi-supervised RF optimization strategy Figure 5.7 Prediction curve of the testing set on the DXN data for the semi-supervised RF optimization strategy Figure 5.8 Relationship between the hyperparameters and RMSE in the CCS original dataset for the semi-supervised RF optimization strategy Figure 5.9 Relationship between the hyperparameters and RMSE in the CCS mixed dataset for the semi-supervised RF optimization strategy Figure 5.10 Relationship between the hyperparameters and RMSE in the DXN original dataset for the...
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