The transformation of the chemical industry to renewable energy and feedstock supply requires new paradigms for the design of flexible plants, (bio-)catalysts, and functional materials. Recent breakthroughs in machine learning (ML) provide unique opportunities, but only joint interdisciplinary research between the ML and chemical engineering (CE) communities will unfold the full potential. We identify six challenges that will open new methods for CE and formulate new types of problems for ML: (1) optimal decision making, (2) introducing and enforcing physics in ML, (3) information and knowledge representation, (4) heterogeneity of data, (5) safety and trust in ML applications, and (6) creativity. Under the umbrella of these challenges, we discuss perspectives for future interdisciplinary research that will enable the transformation of CE.

Global optimization is desirable for the design of chemical and energy processes as design decisions have a significant influence on the economics. A relevant challenge for global flowsheet optimization is the incorporation of accurate thermodynamic models. A promising alternative to conventional thermodynamic property models is the integration of data-driven surrogate models into mechanistic process models and deterministic global optimization in a reduced space. In our previous works, we trained artificial neural networks (ANNs) on thermodynamic data and included the surrogate models in the global flowsheet optimization of subcritical organic Rankine cycles (ORC). In this work, we extend the framework to the optimization of transcritical ORCs operating at a supercritical high pressure level and subcritical low pressure level. We train separate ANNs for supercritical and subcritical thermodynamic properties. ANNs with a small number of neurons can learn the thermodynamic properties to sufficient accuracy. We identify the optimal working fluid among 122 available fluids in the thermodynamic library CoolProp via a deterministic global optimization of the hybrid process model using the solver MAiNGO. The results show that the process can be optimized efficiently and that transcritical operation can enable high power generation.

Economically viable water treatment process plants for drinking water purification are a prerequisite for sustainable supply of safe drinking water in the future. However, modern membrane process development experiences a disconnect in this domain: the synthesis of the membrane and the design of the process are decoupled. We propose an optimization strategy to simultaneously design the performance of layer-by-layer nanofiltration membrane modules along with the separation process. This approach achieves overall optimal performance by extending the search space and thus exploiting synergies. Better separation performances at a lower cost as compared to conventional optimization strategies can be achieved. The key feature of this optimization framework is the integration of artificial neural networks. This machine-learning technique describes the membrane performance as a function of its synthesis protocol. We optimize the design problem rigorously by a deterministic global nonlinear optimization method. Thus, this framework yields membrane synthesis protocols and membrane processes that are optimally tailored to the desired separation task. In a showcase, the simultaneous membrane synthesis and process optimization design achieve immediately favorable results with lower impurities at comparable costs. The process investment and operation costs are compared to a state of the art commercially available membrane for nanofiltration.

Extensive literature has considered reduced, but still highly accurate, nonlinear dynamic process models, particularly for distillation columns. Nevertheless, there is a need for continuing research in this field. Herein, opportunities from the integration of machine learning into existing reduction approaches are discussed. First, key concepts for dynamic model reduction and their limitations are briefly reviewed. Afterwards, promising model structures for reduced hybrid mechanistic/data-driven models are outlined. Finally, crucial future challenges as well as promising research perspectives are presented.

Innovative membrane technologies optimally integrated into large separation process plants are essential for economical water treatment and disposal. However, the mass transport through membranes is commonly described by nonlinear differential-algebraic mechanistic models at the nano-scale, while the process and its economics range up to large-scale. Thus, the optimal design of membranes in process plants requires decision making across multiple scales, which is not possible using standard tools. In this work, we embed artificial neural networks (ANNs) as surrogate models in the deterministic global optimization to bridge the gap of scales. This methodology allows for deterministic global optimization of membrane processes with accurate transport models – avoiding the utilization of inaccurate approximations through heuristics or short-cut models. The ANNs are trained based on data generated by a one-dimensional extended Nernst-Planck ion transport model and extended to a more accurate two-dimensional distribution of the membrane module, that captures the filtration-related decreasing retention of salt. We simultaneously design the membrane and plant layout yielding optimal membrane module synthesis properties along with the optimal plant design for multiple objectives, feed concentrations, filtration stages, and salt mixtures. The developed process models and the optimization solver are available open-source, enabling computational resource-efficient multi-scale optimization in membrane science.

Organic Rankine cycles (ORCs) offer a high structural design flexibility. The best process structure can be identified via the optimization of a superstructure, which considers design alternatives simultaneously. In this contribution, we apply deterministic global optimization to a geothermal ORC superstructure, thus guaranteeing to find the best solution. We implement a hybrid mechanistic data-driven model, employing artificial neural networks as thermodynamic surrogate models. This approach is beneficial as we optimize the problem in a reduced space using the optimization solver MAiNGO. We further introduce redundant constraints that are only considered for the lower-bounding problem of the branch-and-bound algorithm. We perform two separate optimizations, one maximizing power output and one minimizing levelized cost of electricity. The optimal solutions of both objectives differ from each other, but both have three pressure levels. Global optimization is necessary as there exist suboptimal local solutions for both flowsheet configuration and design with fixed configurations.

Numerical optimization is very useful for design and operation of energy processes. As the design has a major impact on the economics of the system, it is desirable to find a global optimum in the presence of local optima. So far, deterministic global optimization with detailed thermodynamic models incorporated has been limited to single fluid energy systems. We extend our previously presented approach [Schweidtmann et int Mitsos, COMPUT CHEM ENG (2019)] from single-species working fluids to binary mixtures with variable composition. First, we create accurate thermodynamic data for two selected binary mixtures using a thermodynamic library. Using this data, we train artificial neural networks, select them based on desired accuracy, and include them in the process model. The resulting hybrid model is then optimized with the open-source solver MAiNGO. We perform thermodynamic optimizations of geothermal power plants, considering both organic Rankine and Kalina cycle. For each cycle, we identify the globally optimal design, operation, and working fluid composition for the selected binary fluid mixtures within tractable CPU times. We show how a second mixture component enables improved ORC performance.

Using nonlinear process models in discrete-time scheduling typically prohibits long planning horizons with fine temporal discretizations. Therefore, we propose an adaptive grid algorithm tailored for scheduling subject to time-variable electricity prices. The scheduling problem is formulated in a reduced space. In the algorithm, the number of degrees of freedom is reduced by linearly mapping one degree of freedom to multiple intervals with similar electricity prices. The mapping is iteratively refined using a wavelet-based analysis of the previous solution. We apply the algorithm to the scheduling of a compressed air energy storage. We model the efficiency characteristics of the turbo machinery using artificial neural networks. Using our in-house global solver MAiNGO, the algorithm identifies a feasible near-optimal solution with < 1% deviation in the objective value within < 5% of the computational time compared to a solution considering the full dimensionality.

The performance of an organic Rankine cycle (ORC) relies on process design and operation. Simultaneous optimization of design and operation for a range of working fluids (WFs) is therefore a promising approach for WF selection. For this, deterministic global process optimization can guarantee to identify a global optimum, in contrast to local or stochastic global solution approaches. However, providing accurate thermodynamic models for a large number of WFs while maintaining computational tractability of the resulting optimization problems are open research questions. We integrate accurate thermodynamic and transport properties via artificial neural networks (ANNs) and solve the design problems with MAiNGO in a reduced-space formulation. We illustrate the approach for an ORC process for waste heat recovery of a diesel truck. After an automated preselection of 122 WFs, ANNs are automatically trained for the 37 selected WFs based on data retrieved from the thermodynamic library CoolProp. Then, we perform deterministic global optimization of design and operation for every WF individually. Therein, the trade-off between net power generation and investment cost is investigated by multiobjective optimization. Further, a thermoeconomic optimization finds a compromise between both objectives. The results show that, for the given conditions, monoaromatic hydrocarbons are a promising group of WFs. In future work, the proposed method and the trained ANNs can be applied to the design of a variety of energy processes.

We propose an algorithm for scheduling subject to time-variable electricity prices using nonlinear process models that enables long planning horizons with fine discretizations. The algorithm relies on a reduced-space formulation and enhances our previous work (Schäfer et al., Comput Chem Eng, 2020;132:106598) by a sensitivity-based refinement procedure. We therein expose the coefficients of the wavelet transform of the time series of independent process variables to the optimizer. The problem size is reduced by truncating the transform and iteratively adjusted using Lagrangian multipliers. We apply the algorithm to the scheduling of a multi-product air separation unit. The nonlinear power consumption characteristic is replaced by an artificial neural network trained on data from a rigorous model. We demonstrate that the proposed algorithm reduces the number of optimization variables by more than one order of magnitude, whilst furnishing feasible schedules with insignificant losses in objective values compared to solutions considering the full dimensionality.

Prediction of combustion-related properties of (oxygenated) hydrocarbons is an important and challenging task for which quantitative structure-property relationship (QSPR) models are frequently employed. Recently, a machine learning method, graph neural networks (GNNs), has shown promising results for the prediction of structure-property relationships. GNNs utilize a graph representation of molecules, where atoms correspond to nodes and bonds to edges containing information about the molecular structure. More specifically, GNNs learn physicochemical properties as a function of the molecular graph in a supervised learning setup using a backpropagation algorithm. This end-to-end learning approach eliminates the need for selection of molecular descriptors or structural groups, as it learns optimal fingerprints through graph convolutions and maps the fingerprints to the physicochemical properties by deep learning. We develop GNN models for predicting three fuel ignition quality indicators, i.e., the derived cetane number (DCN), the research octane number (RON), and the motor octane number (MON), of oxygenated and nonoxygenated hydrocarbons. In light of limited experimental data in the order of hundreds, we propose a combination of multitask learning, transfer learning, and ensemble learning. The results show competitive performance of the proposed GNN approach compared to state-of-the-art QSPR models, making it a promising field for future research. The prediction tool is available via a web front-end at www.avt.rwth-aachen.de/gnn.

Nonlinear model predictive control requires the solution of nonlinear programs with potentially multiple local solutions. Here, deterministic global optimization can guarantee to find a global optimum. However, its application is currently severely limited by computational cost and requires further developments in problem formulation, optimization solvers, and computing architectures. In this work, we propose a reduced-space formulation for the global optimization of problems with recurrent neural networks (RNN) embedded, based on our recent work on feed-forward artificial neural networks embedded. The method reduces the dimensionality of the optimization problem significantly, lowering the computational cost. We implement the NMPC problem in our open-source solver MAiNGO and solve it using parallel computing on 40 cores. We demonstrate real-time capability for the illustrative van de Vusse CSTR case study. We further propose two alternatives to reduce computational time: i) reformulate the RNN model by exposing a selected state variable to the optimizer; ii) replace the RNN with a neural multi-model. In our numerical case studies each proposal results in a reduction of computational time by an order of magnitude.

Global deterministic process optimization problems have recently been solved efficiently in a reduced-space by automatic propagation of McCormick relaxations (Bongartz and Mitsos, J. Global Optim, 2017). However, the previous optimizations have been limited to simplified thermodynamic property models. Herein, we propose a method that learns accurate thermodynamic properties via artificial neural networks (ANNs) and integrates those in deterministic global process optimization. The resulting hybrid process model is solved using the recently developed method for deterministic global optimization problems with ANNs embedded (Schweidtmann and Mitsos, J. Optim. Theory Appl., 2018). The optimal operation of a validated steady state model of an organic Rankine cycle is solved as a case study. It is especially challenging as the thermodynamic properties are given by the implicit Helmholtz equation of state. The results show that modeling of thermodynamic properties via ANNs performs favorable in deterministic optimization. This method can rapidly be extended to include properties from existing thermodynamic libraries, based on models or data.

beta version is available open-source works well for problems formulated in reduced space runs on parallel computing can be extended to the user's needs can be used as general-purpose solver.

We recently demonstrated the potential of deterministic global optimization in a reduced-space formulation for flowsheet optimization. However, the consideration of implicit unit operations such as flash calculations is still challenging and the solution of complex flowsheets incorporating such operations can be intractable. We show that the solution of flash equations can be integrated in global optimization via artificial neural networks (ANNs). Thus, flash calculations are no longer performed within the flowsheet optimization. Instead, flash equations are solved offline and then learned using ANNs. ANNs have been used successfully in the literature to learn flash equilibria but have not yet been included in deterministic global optimization for this task. We embed the ANNs in a hybrid model and use deterministic global optimization to solve it. In addition, we utilize deterministic global optimization to calculate a guaranteed worst-case accuracy of ANNs compared to a rigorous model. We demonstrate the proposed approach on an illustrative five-component vapor-liquid equilibrium flash using our in-house solver MAiNGO.

Deterministic global optimization of process flowsheets has so far mostly been limited to simplified thermodynamic models. Herein, we demonstrate a way to integrate accurate thermodynamic models for the optimal process design of an organic Rankine cycle (ORC) via the use of artificial neural networks (ANNs). We generate training data using the thermodynamic library Coolprop and learn thermodynamic properties. The ANNs are subsequently embedded in the process design optimization problem in a reduced-space, which is solved to global optimality using our in-house optimization software MAiNGO. The importance of accurate thermodynamics is illustrated for the design of an ORC for geothermal power generation. We show that the use of an accurate thermodynamic model leads to different design decisions in comparison to a simplified model. Furthermore, we investigate the influence of the network architecture and complexity on accuracy, optimization results and computational performance.

Synthetic membranes for desalination and ion separation processes are a prerequisite for the supply of safe and sufficient drinking water as well as smart process water tailored to its application. This requires a versatile membrane fabrication methodology. Starting from an extensive set of new ion separation membranes synthesized with a layer-by-layer methodology, we demonstrate for the first time that an artificial neural network (ANN) can predict ion retention and water flux values based on membrane fabrication conditions. The predictive ANN is used in a local single-objective optimization approach to identify manufacturing conditions that improve permeability of existing membranes. A deterministic global multi-objective optimization is performed in order to identify the upper bound (Pareto front) of the delicate trade-off between ion retention characteristics and permeability. Ultimately, a coupling of the ANN into a hybrid model enables physical insight into the influence of fabrication conditions on apparent membrane properties.

Artificial neural networks are used in various applications for data-driven black-box modeling and subsequent optimization. Herein, we present an efficient method for deterministic global optimization of optimization problems with artificial neural networks embedded. The proposed method is based on relaxations of algorithms using McCormick relaxations in a reduced space (Mitsos et al. in SIAM J Optim 20(2):573–601, 2009) employing the convex and concave envelopes of the nonlinear activation function. The optimization problem is solved using our in-house deterministic global solver. The performance of the proposed method is shown in four optimization examples: an illustrative function, a fermentation process, a compressor plant and a chemical process. The results show that computational solution time is favorable compared to a state-of-the-art global general-purpose optimization solver.

A techno-economic optimization of a commercial-scale, amine-based, post-combustion CO₂ capture process is carried out. The most economically favorable process configuration, sizing and operating conditions are identified using a superstructure formulation. The superstructure has 12 288 possible process configurations and unit operations in the superstructure are described using rigorous, rate-based models. In order to simplify the optimization problem, the problem is decomposed and process simulations are explicitly handled in the process simulator. Optimization is performed externally using a genetic algorithm. The best found process configuration includes the absorber intercooling, the rich vapor recompression, and the cold solvent split. The result of this study is compared in terms of the cost of capture basis and shows 38% reduction on the annual operation cost, compared to the conventional amine-based CO₂ capture process. Moreover, the savings on the total annualized cost is ∼13%, which is an increase of 30% on the annualized investment cost resulting from additional unit operations. (Figure Presented).