Enhancing Batch Chemical Manufacturing via Development of Deep Learning based Predictive Monitoring with Transfer Learning

Batch chemical processes face significant challenges due to frequent operational shifts and varying conditions, requiring models to be retrained for each new scenario. This high retraining demand limits the scalability of traditional process monitoring systems, making them unsuitable for dynamic batch operations. To address this, we propose a transfer learning-based framework that enhances adaptability by reusing learned features across different batch conditions, reducing the need for extensive retraining. Proposed method integrates Temporal Convolutional Networks (TCNs) for capturing temporal dependencies in batch data and predicting Quality-Indicative Variables (QIVs) to identify deviations. The core innovation lies in transfer learning, enabling the model to adapt to new process variations with minimal updates. This approach ensures robust, accurate monitoring even under evolving conditions. This framework is validated using the IndPenSim penicillin fermentation dataset, which simulates real-world batch process variability. Results show that the transfer learning-enhanced model effectively predicts QIVs and detects deviations across varying control strategies, demonstrating improved adaptability and reduced retraining requirements. This study highlights the potential of transfer learning to revolutionize batch process monitoring by addressing core challenges in dynamic chemical operations.