A Deep Learning-Based Acoustic Signal Analysis Method for Monitoring the Distillation Columns’ Potential Faults

Distillation columns are vital for substance separation and purification in various industries, where malfunctions can lead to equipment damage, compromised product quality, production interruptions, and environmental harm. Early fault detection using AI-driven methods like deep learning can mitigate downtime and safety risks. This study employed a lab-scale distillation column to collect passive acoustic signals under normal conditions and three potential faults: flooding, dry tray, and leakage. Signal processing techniques were used to extract acoustic features from low signal-to-noise ratios and weak time-domain characteristics. A deep learning-based passive acoustic feature recognition method was then applied, achieving an average accuracy of 99.03% on Mel-frequency cepstral coefficient (MFCC) spectrogram datasets. This method demonstrated robust performance across different fault types and limited data scenarios, effectively predicting and detecting potential faults in distillation columns.