Advanced Soft-Sensor Systems for Process Monitoring, Control, Optimisation, and Fault Diagnosis

As processes become more complex and the need to measure each and every variable becomes more critical, the ability of physical sensors to always provide the sufficient accuracy and sampling time can be difficult. For many complex systems, such as nonideal mixtures, multiphase fluids, and solid-based systems, it may not be possible to even use a physical sensor to measure the key variables. For example, in a multiphase fluid, the concentration or density may only be able to be accurately estimated using a laboratory procedure that can only produce a limited number of samples. Similarly, the quality variables of steel may only be determinable once the final steel product has been produced, which limits the ability to effectively control the process with small time delays. In such cases, recourse has to be made to soft sensors, or mathematical models of the system that can be used to forecast the difficult-to-measure variables and allow for real-time process monitoring, control, and optimisation. Although the development of the soft-sensor model is well-established, the various applications and use cases have not been often considered and the key challenges examined. It can be seen that soft sensors have been applied to a wide range of processes from simple, chemical engineering systems to complex mining processes. In all cases, major improvements in the process operations have been observed. However, key challenges remain in updating the soft-sensor models over time, combining laboratory measurements, especially when they are infrequent or of uncertain quality, and the development of soft sensors for new conditions or processes. Copyright (c) 2023 The Authors.