Online nonlinear data reconciliation to enhance nonlinear dynamic process monitoring using conditional dynamic variational autoencoder networks with particle filters

In the chemical plants, data-driven process monitoring serves as a vital tool to ensure product quality and maintain production line safety. However, the accuracy of monitoring hinges directly upon the quality of process data. Given the inherently slow and complex nature of chemical processes, coupled with the potential for gross errors in process data leading to inaccuracies in model predictions, this paper proposes a method called Conditional Dynamic Variational Autoencoder combined with a Particle Filter (CDVAE-PF) for data reconciliation and subsequent process monitoring. CDVAE-PF leverages the capabilities of Conditional Dynamic Variational Autoencoder (CDVAE) to effectively model chemical process data in the presence of noise. This probabilistic model serves as the foundation for the Particle Filter (PF), which is employed for data reconciliation. Moreover, CDVAE-PF incorporates mechanisms to detect and rectify gross errors in process data, further enhancing its efficacy in data reconciliation. Subsequently, monitoring indices based on CDVAE are established to facilitate process monitoring. Through numerical simulations of a two-to-one variables Continuous Stirred Tank Reactor (CSTR) example and a fifteen-to-one variables dichloroethane distillation process from an actual chemical plant, CDVAE-PF demonstrates its effectiveness by reducing mean absolute error to 7.8 % and 12.8 % respectively in gross error data reconciliation. Moreover, in terms of monitoring performance, CDVAE-PF successfully mitigates misjudgments caused by gross errors, thereby significantly enhancing the reliability of process monitoring in chemical plants. • Conditional dynamic variational autoencoder (CDVAE) is proposed. • CDVAE, a probabilistic model, is more robust for processes data with noise. • Gross errors based on CDVAE predictions are effectively detected and reconciled. • CDVAE combined with particle filters forms a dynamic data reconciliation scheme. • Reconciliation and monitoring results are presented via real chemical processes.