Chemical Process System Engineering

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Paper submitted for publication in the special issue in memory of

Professor Y.C. Chao of the Journal of Taiwan Institute of Chemical Engineers

META-MODELLING IN
CHEMICAL PROCESS SYSTEM ENGINEERING

Olumayowa T. Kajero1, Tao Chen1, Yuan Yao2, Yao Cheng Chuang2, and

David Shan Hill Wong2*


1
Department of Chemical and Process Engineering, University of Surrey, Guildford,

GU2 7XH, United Kingdom


2
Department of Chemical Engineering, National Tsing Hua University, Hsinchu,

Taiwan, R.O.C.

*corresponding author: [email protected]

ABSTRACT

Use of computational fluid dynamics to model chemical process system has

received much attention in recent years. However, even with state-of-the-art

computing, it is still difficult to perform simulations with many physical factors taken

into accounts. Hence, translation of such models into computationally easy surrogate

models is necessary for successful applications of such high fidelity models to process

design optimization, scale-up and model predictive control. In this work, the

methodology, statistical background and past applications to chemical processes of

meta-model development were reviewed. The objective is to help interested

researchers be familiarized with the work that has been carried out and problems that

remain to be investigated.

Keywords: Metal-modelling, chemical process system engineering


1. INTRODUCTION

Systematic accumulation of knowledge and drive towards optimal design is the

key to intelligent and rapid development of chemical processes and products.

Traditionally this is done in two distinct approaches: the first-principle approach and

data-driven or black-box approach.

First principles, or physical approach requires scientific understandings of the

workings of process and integrates them into deterministic input-output simulation

models. Simulation models can be developed at different physical scales, e.g.

steady state and dynamic process simulations model the operation performance of a

plant, computer fluid dynamic (CFD) simulations model the momentum, material and

heat transfer in an equipment, and molecular simulations model the relation between

molecular structure as input and material property as output.

The black-box or data-driven approach rooted on the statistical theory of design of

experiment (DOE) to direct experiments. DOE can be divided into two categories, the

exploration of design space, e.g. screening designs and finding the optimum, e.g.

response surface method. Traditional DOE theory were based on the assumptions that

the input-output relations are relatively simple, consisting of linear, interaction,

quadratic effects etc.

With the development of powerful computers, we can include more and more

details into first-principle simulation models so s to improve the fidelity of the model.

For example, we can model a continuous stirred tank reactor (CSTR) by assuming that

it is a well-mix reactor. The mixing and heat transfer can be modelled using a CFD

simulator and their effects can be integrated to the well-mix reactor through residence

time distribution and heat transfer rate. Alternatively, one can take into account
reactions and change in physical properties with change in composition and temperature

in a CFD simulation. Even we a given simulation model, the fidelity can increase by

including more mesh into the solver. As the fidelity of the physical model increases,

the number of parameters needed to be estimated, i.e. costs of calibrating the first-

principle model increase. However, the computer time required for simulation also

increase and the high cost the first-principle model becomes difficult to use.

This dilemma leads to a continuous effort to develop meta-models(models of

model, or surrogate models) so that knowledge accumulated in such high fidelity

models can be used efficiently in design, optimization and control. There have already

been many useful reviews and books in the development and application of meta model

and design of computer experiments, a brief list is provided here1,2,3,4,5,6,7,8. However,

to the best of our knowledge, there is no such review attempt specifically from the

perspective of a chemical process system engineer. Specifically, we shall attempt to

address the following important issues:

(1) model representation

(2) model construction and evolution, and

(3) applications in chemical process system engineering.

2. META-MODELS REPRESENTATION

2.1 INPUT-OUTPUT RELATION

Consider an actual process with input 𝒙 = [𝑥1 ⋯ 𝑥𝐾𝑥 ] and output 𝒚 = [𝑦1 ⋯ 𝑦𝐾𝑦 ].

𝒚 = 𝚽(𝒙)

(1)

Let 𝚿 be a high-fidelity physical model with a set of parameters 𝜷 that predict an

output 𝒚𝚿 at a given set of input with a set of physical meaning parameters 𝝑


𝒚𝚿 = 𝚿(𝒙, 𝝑)

(2)

A meta-model is model that approximate the high fidelity model

𝚿(𝒙, 𝝑) = 𝛀(𝒙, 𝜷) + 𝚪(𝒙)

(3)

𝛀 are functional approximators with good flexibility, ability to achieve sufficient

accuracy, computational efficiency and simple implementation. 𝚪(𝒙) is the error of

the meta model at a specific input configuration. Common types of meta-models

include polynomial, kriging, radial basis function and artificial neural network, etc.

We should bear in mind that the definition of input 𝒙 and output 𝒚 may be different

in different applications. For example, let us consider the CFD model of a heat

exchanger with fixed geometry. We can try to construct a meta-model that only apply

to hot and cold streams with specific physical properties. The input parameters 𝒙 are

the inlet flowrates and temperatures of the inlet hot and cold streams. However, if we

want to construct a more general meta-model that can be applied to different fluids,

then physical properties such as viscosities and thermo-conductivities will also be

classified as inputs. Similarly we can define various sets of 𝒚. A simple version of

𝒚 will be the average temperature of outlet streams. A detailed version of 𝒚 can be

the temperatures and the velocities at different points inside the heat exchanger.

2.2 TYPES OF META-MODELS

2.2.1 POLYNOMIAL

Polynomial meta-model is perhaps the simplest form of model presentation used

in meta-modelling research. Some studies in the literature on this method are:

Simpson et al9, Palmer and Realff10, Dutournie et al11, Chen et al12. Simplicity implies

ease in construction and application but also inability to describe complex input-output
relationships.

2.2.2 Kriging, Gaussian Process Model, and Radial Basis Function:

The work of Krige13 was widely used in geostatistics14 and spatial statistics15.

Kriging assumes some form of correlation between points in the multi-dimensional

input space, with the correlation being used to predict response values between

observed points. A brief introduction to the formulation and construction of Kriging

model16,17 are described as follows.

̂ = [𝒙
Let 𝑿 ̂=
̂𝑁 ]𝑇 be a set of training data points (sites) and 𝒀
̂1 , ⋯ 𝒙

[𝒚 ̂𝑁 ]𝑇 be the corresponding response variables for development of a Kriging


̂1 , ⋯ 𝒚

model. The prediction for a new data point, 𝒙 is given by

̂ )−𝟏 (𝒀
𝒚(𝒙) = 𝒇𝑇 (𝒙)𝜷 + 𝒓𝑇 (𝒙)𝚺(𝑿 ̂ − 𝑭(𝑿
̂ )𝜷),

where 𝒇(𝒙) contains a set of regression functions of the input variables, and 𝜷 is the

corresponding regression coefficients to be estimated. ̂ ) = [𝒇(𝒙̂ 𝟏 ), ⋯ , 𝒇(𝒙̂ 𝑵 ))]𝑇 is


𝑭(𝑿

a matrix containing the regression functions calculated for all the training data points.

̂ ) is the correlation matrix which is obtained from correlation functions evaluated


𝑹(𝑿

at each pair of the training points:

𝜌(𝒙 ̂1 ) ⋯
̂1 , 𝒙 ̂𝑁 )
̂1 , 𝒙
𝜌(𝒙
̂) = [
𝚺(𝑿 ⋮ ⋱ ⋮ ].
𝜌(𝒙 ̂1 ) ⋯
̂𝑁 , 𝒙 ̂𝑁 )
̂𝑁 , 𝒙
𝜌(𝒙

A widely used correlation function is the Gaussian function

𝜌(𝒙, 𝒙′) = 𝑒𝑥𝑝[−(𝒙 − 𝒙′)𝑇 𝑑𝑖𝑎𝑔[𝜃1 ⋯ 𝜃𝐾𝑥 ](𝒙 − 𝒙′)],

while

𝒓(𝒙) = [𝜌(𝒙, 𝒙 ̂𝑁 )]
̂𝑁 ), ⋯ 𝜌(𝒙, 𝒙

is vector of the correlation between a general point in the input space and the training

sites. The parameters of the Kriging model are the parameters in the correlation

function 𝜽 = [𝜃1 ⋯ 𝜃𝐾𝑥 ] and the regression coefficient 𝜷. They can be estimated by
the following iterative procedure. First assume a value for 𝜽, estimate the regression

coefficient 𝜷 by

−1
̂ )𝑇 𝚺(𝑿
̃ = (𝑭(𝑿
𝜷 ̂ )−𝟏 𝑭(𝑿
̂ )) ̂ )𝑇 𝚺(𝑿
𝑭(𝑿 ̂ )−𝟏 𝒀

The process variance can be calculated as

𝜎𝑝2 =
1
(𝒀 − 𝑭(𝑿 ̂ )−𝟏 (𝒀 − 𝑭(𝑿
̂ ))𝑇 𝚺(𝑿 ̂ ))
𝑁

A new set of correlation parameters 𝜽 can be estimated by

̂ )|1/𝑁 𝜎𝑝2 )
̃ = min (|𝚺(𝑿
𝜽
𝜽

̃ converge.
̃ and 𝜷
The above procedure is repeated until values of 𝜽

Kriging is also termed Gaussian process in the literature with slightly different

formulation18,19,20.

Applications of Kriging, Gaussian process models in meta-model development

have been extensively investigated by many authors. A chronological, but far from

exhaustive, list is provided

here18,21,22,23,24,25,26,27,28,29,30,31,32,33,34,35,36,37,38,39,40,41,42,43,44, 45 46 47
, , . A review

was provided by Kleijin4 in 2009.

2.2.3 Support Vector Machine

Support vector machine (SVM)48 was originally developed as a supervised

learning classifier so that data in a (high dimensional) input space can be classified into

groups according to their locations. The SVM can also be formulated into an input-

output known as support vector regression (SVR)49. For a specific dimension in the

̂ = [𝒙
output space, given a training data set 𝑿 ̂𝑁 ]𝑇 and [𝑦̂1 , ⋯ 𝑦̂𝑁 ]𝑇 ; a
̂1 , ⋯ 𝒙

nonlinear SVR can be expressed as

𝑦(𝒙) = 𝛼𝑜 + ∑𝑁 ∗
̂𝑖 )
𝑖=1(𝛼𝑖 − 𝛼𝑖 ) 𝐾(𝑥, 𝒙

where 𝜶𝑖 , 𝜶∗𝑖 can be obtained by solving optimization problem


1
− ∑𝑁 ∑ 𝑁 ∗ ∗
𝑛′>𝑛[(𝛼𝑛 − 𝛼𝑛 )(𝛼𝑛′ − 𝛼𝑛′ )𝐾(𝒙 ̂𝑛′ )]
̂𝑛 , 𝒙
max { 2 𝑛=1 }
𝑚
+𝜀 ∑𝑁 (𝛼
𝑛=1 𝑛 + 𝛼𝑛
∗)
+ ∑ 𝑦
̂
𝑛=1 𝑛 (𝛼 𝑛 − 𝛼𝑛
∗)

∑𝑁 (𝛼 − 𝛼 ∗)
= 0
𝑠𝑢𝑏𝑗𝑒𝑐𝑡 𝑡𝑜: { 𝑛=1 𝑛 ∗ 𝑛
0 < 𝛼𝑛 , 𝛼𝑛 < 𝐶

The off-set parameter 𝛼𝑜 , tolerance parameter 𝜀 and constraint parameter 𝐶 are

parameters to be chosen in training50. The solution of the above problem can be

determined using a least square approach that uniquely determined by the input-output

training data; the resulting model is known as known as least square support vector

machine (LS-SVM)51. Several reports of using SVR in meta-modelling are given

here52,53,54,55,56.

2.2.4 Multivariate Adaptive Regression Spline

The multivariate adaptive regression spline (MARS) was introduced by

̂ = [𝒙
Friedmann57 attempts to fit a set of training data 𝑿 ̂=
̂𝑁 ]𝑇 and 𝒀
̂1 , ⋯ 𝒙

[𝒚 ̂𝑁 ]𝑇 by selections from a set of basis functions


̂1 , ⋯ 𝒚

𝒚(𝒙) = ∑𝑀
m=1 𝛽𝑚 𝑩𝑚 (𝒙)

The set of basis functions is given by:

𝐿 𝑞
𝑩𝑚 (𝒙) = ∏𝑙=1
𝑚
[𝑠𝑙,𝑚 (𝑥𝑣(𝑙,𝑚) − 𝑡𝑙,𝑚 )]+

𝑠𝑙,𝑚 can take values of ±1. 𝐿𝑚 is an interaction order of the 𝑚𝑡ℎ basis function.

[∙]𝑞+ is hinge function with the following form


𝑞
[𝑠𝑘,𝑚 (𝑥𝑣(𝑘,𝑚) − 𝑡𝑘,𝑚 )]+ = {[𝑠𝑘,𝑚 (𝑥𝑣(𝑘,𝑚) − 𝑡𝑘,𝑚 )] 𝑠𝑘,𝑚 (𝑥𝑣(𝑘,𝑚) − 𝑡𝑘,𝑚 ) > 0
𝑞

0 𝑜𝑡ℎ𝑒𝑟𝑤𝑖𝑠𝑒

𝑥𝑣(𝑘,𝑚) is value of one of the input variables, and 𝑡𝑘,𝑚 is hinge point so that the basis

function 𝑩𝑚 (𝒙) is cutoff either above or below the hinge point. The basis functions

are selected using a forward-backward stepwise selection. MARS offers a flexible

spline fit of an input and output relation that can be piecewise continuous. Use of

MARS in meta-modelling have been discussed by many authors58,59,10,60,61,62,63,64.


2.2.5 Radial Basis Function Network

A similar form of the above method is the radial basis function network (RBFN)65

𝒚(𝒙) = 𝜔𝑜 + ∑𝑛𝑖=1 𝜔𝑖 𝑓(‖𝒙 − 𝒄𝑖 ‖).

The function 𝑓 can take many forms such as linear, cubic, thin plate spline, Gaussian,

mult-quadratic, and inverse multi-quadratic etc. The parameters of the function

include the weighting coefficients 𝝎 and the basis function centers[𝒄1 ⋯ 𝒄𝑛 ]. They

can be obtained by three step algorithm as follows. First a set of basis function centers

were chosen by some clustering of training data in the input space (unsupervised

learning). Secondly the weighting coefficients were determined by linear regressions.

Then both the weighting coefficients and the basis function centers are updated by

gradient search. Applications of radial basis function in meta-modelling have also been

extensively investigated in the literature66,67,58,60,68,69,70,71,72,73.

2.2.6 Artificial Neural Network (ANN)

Artificial neural network (ANN) has been built with the aim of modelling how the

human brain functions. They were used in many fields of machine learning and artificial

intelligence research such as speech recognition, image processing etc. It should be

pointed out that RBFN and SVM are also forms of ANN interpreted in a general sense.

However, in this manuscript, we used ANN to denote a common form known as the

feed-forward multilayer perceptron (MLP). MLP can be expressed mathematically in

the following form:

𝐾𝑘−1
𝑦 𝑘 𝑖 = 𝑓 (∑𝑗=1 𝑤𝑖𝑗𝑘 𝑓 (𝑦 𝑘−1𝑗 ) + 𝑏𝑖𝑘 )

𝑦 𝑘 𝑖 is the output of the ith neuron in the kth layer. 𝑤𝑖𝑗 is a synaptic weight connecting

the output of the jth neuron in the (k − 1)th layer to the input of the the ith neuron in the

kth layer. 𝑏 𝑘 𝑖 is the bias of the ith neuron in the kth layer. 𝐾 𝑘 is the number of neurons

in the in the kth layer. 𝑓 is known as the activation function which can take many forms.
Sigmoids such as hyperbolic tangent and logistic functions are commonly used. It

was proved that a single layer of such network is able to approximate and continuous

function74. Applications of ANN in meta-modelling can also be found in wide variety

of areas75,58,76,77,78,79,80,81,82,83,84,85,86.

2.3 FEATURE SELECTION

In many high fidelity simulations, especially CFD, the output are not limited to a

few variables but maps of spatial and temporal variations. While such maps can be

discretized to generate a large number of variables, it is not clear how they should be

incorporated into the meta-model. Using a dynamic system that has an input vector

𝒙 and produces output in a period which can be discretized into 𝒚 = [𝑦1 , ⋯ 𝑦𝑇 ], Conti

et al87 explained different possible ways of creating an emulator (meta-model). A

multiple output (MO) emulator expressed the output at different time steps as a function

of input

𝒚 = 𝛀(𝒙)

A multiple single output (MS) emulator expressed the output at each time instant as

𝑦𝑖 = Ω𝒊 (𝒙)

A time input (TI) emulator expressed

𝑦 = Ω(𝒙, 𝑡)

Let us use Kriging model as an example, and 𝑛 be the number of regression functions

and 𝑚 be the number of training data. The training of the MO emulator will required

̂ )𝑇 𝚺(𝑿
̂ ) and 𝑇𝑛 × 𝑇𝑛 matrix 𝑭(𝑿
an inversion of 𝑚 × 𝑚 matrix 𝚺(𝑿 ̂ )−𝟏 𝑭(𝑿
̂) .

Hence the size of matrix being inverted is dependent of T . The training of the MS

̂ ) and 𝑛 × 𝑛 matrix in
emulator will required an inversion of 𝑚 × 𝑚 matrix in 𝚺(𝑿

̂ )𝑇 𝚺(𝑿
𝑭(𝑿 ̂ )−𝟏 𝑭(𝑿
̂) . The size of the matrix inversion is always limited but the

training time increases with T. In the TI emulator, the number of regression function
n has to be increased to account for variation due to time dependence. Similar

conclusions can also be extended to spatially distributed output and spatial-temporal

output.

One way of simplifying the meta-model representation is to reduce the dimension

of the output in a MO emulator using feature extraction method such as principle

component analysis (PCA)88. For example, Chen et al20 used PCA to reduce the

dimension of a two dimensional CFD simulation of dispersion dynamics of particulate

aerosols and showed that output variations of 182250 spatial-temporal grid points can

be reduced to scores of 8 principal components that can be efficiently modelled by a

GPR. Similar works were reported by Jia et al89 in real-time storm /hurricane risk

assessment and Wang and Chen90 in vapor cloud dispersion.

2.4 SUMMARY

In this section, we have examined several input and output relations commonly used

for meta-modelling. However, other forms of input and output relations may be used

depending on the nature of the problem. Meta-models used are often referred to being

parametric or nonparametric. Parametric models (e.g. MARS/RBFN/ANN) usually

assumed some forms of basis functions. The model coefficients are obtained from the

training data using regression analysis. In principle, we can forget the training data

set once the model is determined. The model complexity will increase as more basis

functions were added to the systems. Since the number of parameters are not prefixed,

therefore is always the danger of overfitting and the generalizability of the model is

compromised. Cross validation is usually used to ensure that there is no overfitting91.

Non-parametric models (e.g. Kriging/GPR/SVM) are basically interpolation models,

the training data constitute the essential part of model parameters and must be

memorized to make predictions. It should be noted that the need of data storage is not
really a disadvantage because data storage become less and less expensive with cloud

technology and recall of old training data to train new model is also necessary even

when a parametric model is used. As far as we know, there is no definitive conclusion

that a specific form of input-output relation is superior in meta-modelling. It is

generally assumed that input-output relation of a high fidelity first-principle model is

inherently complex. Therefore the meta-model must be flexible enough to capture the

complexity. Hence there must be an element in the meta model that ensure that it can

serve as a universal function approximator.

3. META-MODEL CONSTRUCTION

3.1 DESIGN OF COMPUTER EXPERIMENT

The intuitive approach to meta-model construction may view each simulation run

as an experiment and use traditional design of experiment (DOE) procedure to

determine the locations of each simulation runs to be executed. This area is known as

design of computer experiments18,21.

Traditional DOE methods can usually be classified as either one of the following

two objectives, (i) screening experiments that try to identify factors (input variables or

combination of input) that have statistically significant effects on the response (output);

and response surface experiments that try to build a input-output relation which can

predict the optimal input conditions92,93.

Classical screening experiments include Factorial Design, Fractional Factorial

Design, , etc. Another general class of screening are “optimal designs” that

optimize some form of metric of the information matrix |(𝑿 ̂ )−1 | where 𝑿
̂𝑇𝑿 ̂ is

matrix of the training data in a generalized parametric input space. For example the

D-optimal design minimizes the determinant of Fischer information matrix.

Common experimental design for response surface experiments Central Composite


Design and Box-Behnken Design. Such designs usually possess the desirable

property of having low prediction error.

In design of experiments, two kinds of errors are considered: (i) random errors that

is measured by the variance of the predictions, (ii) systematic errors caused by

mismatch of the model assumed and the actual response, i.e. bias. In design of

computer experiments, the random error is expected to be small. Therefore designs

that are based upon a preselected model and the assumption that bias is small compared

to variance, such as the D-optimal design may not be appropriate.

Furthermore, even simulations are relative inexpensive compared to experiments,

their execution takes time and effort. Therefore the number of runs a major concern.

Relatively large number of runs are still required for some of these designs, especially

when the dimensionality design space increases. Small response surface design can

be used to reduce the number of runs Plackett-Burman Design94, small composite

design95, saturated design96 (see review by Draper and Lin97 and Meyers and

Montgomery93). However, as pointed out by Allen and Yu98, the desirable properties

of having prediction error may be compromised. Therefore design methods that

sufficiently accounted for the effects of bias while without sacrificing variance, e.g.

based on expected integral mean square error should be considered (Allen et al99).

Alternatively, another approach is to explore the design space so as to minimize un-

sampled region. Examples of space filling design include: random or Monte Carlo

sampling100, orthogonal arrays101, uniform design102, Latin Hypercubes Sampling

(LHS)103,104, Hammersley Sampling (HSS)105. To measure the space filling nature of

the design, a measure of the space filling nature should be defined, e.g. the modified

𝐿2 discrepancy is often used for input variables scaled between [-1,1]

4 𝐾𝑥 21−𝐾𝑥 𝐾𝑥 2 )
𝑀𝐿2 = ( ) − ∑𝑁
𝑛=1 ∏𝑘=1(3 − 𝑥
̂𝑛𝑘 +
3 𝑁
1 𝑁 𝐾𝑥
∑𝑁 ̂𝑛𝑘 , 𝑥̂𝑛′𝑘 ))
𝑛=1 ∑𝑛′ =1 ∏𝑘=1(2 − 𝑚𝑎𝑥(𝑥
𝑁2

The smaller the value, the better is the space filling properties. Another measure is

the minimum Euclidean distance between the design points106

𝑀𝑚 = min‖𝒙 ̂𝑛′ ‖
̂𝑛 − 𝒙
𝑛,𝑛′

The larger the value is the better. To balance between space-filling properties and

orthgonality, Cioppa and Lucas107 proposed a design that created the best space filling

properties, subject to constraints of orthogonality measures such as the maximum

̂𝑘′ ) and conditional


̂𝑘 , 𝒙
correlation between various dimensions 𝜌𝑚𝑎𝑥 = max 𝑐𝑜𝑟(𝒙
𝑘,𝑘′

̂ 𝑇 𝑿) in the design space.


number of the information matrix of sampling points 𝑐𝑜𝑛𝑑(𝑿

3.2 ITERATIVE APPROACH

Despite the development of numerous sampling schemes, it is generally not realistic

to expect a reliable meta-model can be build or the optimum of the actual model can be

located using a single set of sampling data. It is necessary to balance between

optimization and the fidelity of the approximate-model using iterative approach108.

Early work in this area, reviewed by Wang and Shan3 include reducing the dimension

of design space by eliminating unimportant variables109,110. An alternate approach is

to survey a small design space and move limits towards the optimal region111,112,113,114.

Wang and Simpson115 used a preliminary meta-model to generate a large number of

points in the large design space and then cluster promising points. Meta-models for

local region around cluster centers are then generated to refine the optimum. The

above are optimization iterations designed for finding the optimum. Khu et al60 also

developed an evolutionary strategy using genetic algorithm for determination of the

sample points. However, the objective function to be optimized is the sum square

error between the actual model and predicted values of a validation data set. Thus the
iterative approach is designed to increase the fidelity of the model. Chen et al 116

argued that, even in optimization, with limited data, the initial meta-model cannot be

completely trusted. Thus in early stages of the search, we need to focus on exploring

under-sampled region. At later stages focus should be on finding the optimum since

enough data has been accumulated for building an accurate enough model. An index,

the predicted fitness of objective function at a sample point is defined as the information

energy. An index of information content of sampling point was defined as the

information entropy. New samples were generated based on Monte Carlo importance

sampling of the free energy, with “temperature” which is related to the number of

previously sampled points being a balancing parameter. Tang et al117 and Chi et al118

also used an evolutionary meta-model optimization in which the prediction uncertainty

of the GPR was used in addition to the prediction mean to determine the future sampling

points. An alternative method of preventing premature convergence is to use an

index that took care of the uncertainty of the prediction, known as expected

improvement (EI)119. EI recognizes that the predicted improvement is a random variable,

because the meta-model gives prediction mean and variance. Therefore, the predicted

improvement should be integrated with its probability density function to attain its

expected value, i.e. EI, which should be the objective function to be optimized.

3.3 MODEL MIGRATION

In many engineering applications, simulations were often called upon to solve

problems with some degree of similarity. For example, CFD simulations were

carried out and a “old” meta-model has been constructed for a given equipment with a

set of geometrical design parameters with a fluid of given rheological properties. It

would most desirable if we can construct “new” meta-model for another piece of
equipment that is similar in structure but with slightly different geometries and/or

another fluid with different rheological properties, using the given “old” meta-model

plus only a few simulation data . Another typical problem of in chemical engineering

is scale-up of reactor. It is well known that optimal operating condition found for a

reaction out in a lab size reactor may not work when a reactor is scaled to larger

dimensions. Although kinetics and thermodynamics will not change as the equipment

is scaled up. Mixing and heat transfer changes with dimension. CFD simulation

were often used to solve scale-up problems, but CFD coupled with reaction is

notoriously difficult to execute. Hence development of meta-models for design and

optimization is necessary.

Gao and coworkers120,121,122,123 recognized the problem of how to efficiently

modify an existing meta-process model to fit a different yet similar process. The

existing model is denoted as the “base model”, while the model to be developed for the

new process is called as the “new model”. At least one of the following two objectives

are expected to be achieved.

(1) To attain similar prediction accuracy, fewer data are required for migrating from the

base model to the new model than for developing an entirely new model without

the migration step.

(2) The migrated new model is more accurate than the model developed without the

aid of migration if nearly equal number of experimental data are used in model

training.
124
Motivated by the standardization step in calibration model transfer , the migration

can be conducted by a parametric scale and bias correction (SBC) of the base

model120,123:

𝒚(𝒙) = 𝑑𝑖𝑎𝑔 [𝑠𝑦,1 ⋯ 𝑠𝑦,𝐾𝑦 ] 𝒇𝑜 (𝑑𝑖𝑎𝑔[𝑠𝑥,1 ⋯ 𝑠𝑥,𝐾𝑥 ]𝒙 + 𝒃𝒙 ) + 𝒃𝑦


where 𝒇𝑜 denotes the base model; 𝑠𝑦,1 ⋯ 𝑠𝑦,𝐾𝑦 and 𝑠𝑥,1 ⋯ 𝑠𝑥,𝐾𝑥 are scaling

parameters of different dimensions of the output and input space; 𝒃𝑦 and 𝒃𝒙 are bias

vectors in the output and input space respectively. Data of the new process are used

to determine the scale and bias transformation parameters. The SBC, being linear

transformations in output and input space, is an arbitrary similarity condition that may

not have sufficient flexibility to model the new process of interest. To overcome this

limitation, Yan et al.125 proposed a Bayesian migration method to update the scale-bias

functions given experimental data from the new process. Their method is named as

functional SBC, which is based on a GPR model framework. The input-output relation

of the functional SBC is given by

𝒚(𝒙) = 𝒔(𝑥)𝒇𝑜 (𝒙) + 𝜹(𝒙)

with 𝒔(𝑥) being a linear scaling function

𝒔(𝒙) = 𝒔𝑦𝑜 + 𝑑𝑖𝑎𝑔 [𝑠1 ⋯ 𝑠𝐾𝑦 ] 𝒙

and bias correction 𝜹(𝒙) is chosen to be a Gaussian process with zero-mean. The

underlying assumption that if the new process is similar to the old process, 𝜹(𝒙) would

be quite close to zero and its determination would require much less data points.

Applicability of this method was recently demonstrated using sequential sampling and

Bayesian techniques126,127,128.

No physical reasoning has been given in developing SBC migration. However, it

is well known that equations in transport phenomena can be reduced into universal form

with dimensionless groups such as Reynolds number, Prandtl numbers and Nusselt

numbers. Therefore, input-output relations of CFD may be scale-transformable

through these dimensionless group. Recently Shen et al129 demonstrated the

advantages of performing experimental design using a dimensionless input space.

Such advantages should be much more evident if applied to the design of computer
CFD experiments.

The functional SBC transformation can find its root from the work of Qian et al38

where the same method was used to migrate between a model of low accuracy (LE)

experiment and a high accuracy (HE) experiment. The concept is especially important

for design of computer experiments, because complex computer codes can generate

results with different levels of mesh densities. It is always desirable that a meta-model

can be generated using more low fidelity runs and a small number of high fidelity runs.

Kennedy and O’Hagan130 first proposed using an auto regressive relation with a

Gaussian process model bias term to connect meta-model of different levels of mesh

fidelities. The problem of migrating between different levels of fidelity due to mesh

densities has been well researched by many authors131,132,133,134,135,136,137,138.

It should be pointed out the complexity of a computer code can be increased not

only increasing the mesh but increasing the physical processes being considered.

Chuang et al139 demonstrated by using a simple well-mixed CTSR model that contains

only the kinetics of the reaction as the base model, new meta-models can be readily

developed for full CFD simulations that take into account of mixing and heat transfer.

In theory, using the Gaussian process model for a bias term allows us to include

any differences between the “new” and “old” processes. It should be noted that the

migration is feasible even if new variables were added to the “new process”. The

success of migration depends on the functional similarity between the input-out

relations of “new” and “old” processes in the old input-space. In other words, as the

computational model become more complex, less and less significant variations will be

left out. The bias term approaches a zero function.

3.4 SUMMARY

In this section, various sampling method for constructing meta-models were


reviewed. The general consensus up to now is that space filling design should be the

most appropriate for building meta-models. However, when a meta-model was used

for optimization, a balance of importance sampling and space-filling needs should be

considered, especially in evolutionary procedures. Migration of meta-models is also

an important research area. Migration between different meshing densities has been

extensively studied. Dimensional analysis is the underlying assumption of scaling

transformation. The bias term in the functional scale and bias correction incorporate

enough flexibility to allow for migration between models of different complexities due

to inclusion of additional physical considerations.

4. APPLICATIONS

4.1 PROCESS DESIGN AND OPTIMIZATION

The most straightforward application of meta-modelling is process design and

optimization. Meta-model optimization has already been extensively used in design

and optimization of many different processes. A wide variety of applications include

flowsheeting10,140,141,142,143,144; boiler and combustion processes145,146,147; separation

processes such as simulated moving bed chromatography148, pressure swing

adsorption149 heated integrated column144, divided wall column150, CO2 capture

process151; reactor operation such as iron oxide reduction152, nano-particle synthesis153,

bacteria cultivation154; polymer processing155; chemical processes in semiconductor

industry156,157,158; etc. In should be pointed out that in some of these work, actual

experiments instead of higher fidelity simulations were used. Using data-driven

models as response surface model and iterative evolutionary strategy to direct

additional experiments and finding the optimum process condition can be classified in

general as “meta-model assisted optimization”.


A notable development is the use of surrogate model in superstructure optimization,

in which a surrogate model with categorical variables is required141. However, the

construction of a meta-model with categorical variables has not been thoroughly

investigated. The intuitive approach is to create samples at every possible

combination of categorical variables. However, such an approach would not work if

the number and levels of categorical variables are large. Qian and Wu159 have

discussed the use of GPR with quantitative and qualitative input as a surrogate model

for computer experiments. The covariance structure between category variables were

estimated using data sampled so that one does not have to perform experiments at every

possible combination of categorical variables. However, the parameter estimation, or

training, involved a complex semidefinite optimization problem that is difficult to solve.

Experimental design methods have been proposed160. The potential of such models,

sampling and optimization strategy in flowsheet and equipment design for chemical

engineers is enormous. Unfortunately, there seems to be no research on this subject

in the chemical engineering literature.

4.2 PROCESS CONTROL

It should be pointed out that there are numerous studies data-driven models such as

ANN161, RBFN162, SVM163, GPR164 can be used to represent nonlinear time series.

Such models have been used in soft-sensors development to predictive important

quality variables online165,166,167,168,169,170. They can of course be used in nonlinear

model predictive control (NMPC)171,172,173. However, such data-driven models cannot

be considered as meta-model discussed in this work, because they are not surrogates of

a more complex model. Moreover, they are usually obtained from online data, thus

experimental design to construct these models received much less interest to adaptive
or just-in-time strategies. Tsen et al174 proposed a hybrid approach in which first-

principle simulation data were trained together with experimental data to obtain an

ANN model for use in control. Such hybrid models175,176 were developed because of

the need of using prior first-principle knowledge to avoid unreasonable extrapolations

and the necessity to accommodate with experimental information, i.e. migration to a

more accurate and realistic model for control purposes.

Conceivably, a surrogate dynamic model for control can be generated using

complex high fidelity dynamic simulation. However, many researchers prefer to use

another technique known as the “reduced-order-model” (ROM) in which the surrogate

was developed by reducing the original differential algebraic equations (DAE) system

into lower order models by collocation or other mathematically rigorous simplification

techniques. Such methods have been developed for distillation columns177, bio-

reactors178, air separation179,180 etc. Since the reduced models is still an equation based

modles, ROMs are not meta-model as we have discussed.

Perhaps the closest form of meta-model in process control is under the banner of

“approximate dynamic programming” for optimal control181,182. The objective of

optimal control (and dynamic programming) is to minimize a certain “cost-to-go”

function, which is usually a time-discounted sum of costs of individual time points. The

major challenge under this framework is that the computation needed to evaluate the

cost-to-go is often very high, and thus on-line control is almost infeasible. Here the idea

of meta-modelling can help: a large number of simulations can be conducted off-line to

generate simulation data, and a meta-model (termed “approximate cost-to-go function”)

can be developed to approximate the relationship between state/manipulated variables

and the cost-to-go function. This approximate function is then used for on-line control,

and also subsequently improved.


4.3 MODEL CALIBRATION

The advantage of using meta-model as a surrogate of high fidelity model so that

design space can be efficiently explored for process improvement is intuitive and

straightforward. However, meta-model can also be used to improve predictions of

high fidelity model. Typically, a high fidelity model requires a set of physical

meaningful parameters 𝛝 to make predictions (see equation 1). For example, in CFD

simulations of reactors, 𝛝 may consists of transport properties such as viscosity,

thermoconductivity, diffusion coefficient, surface tension, thermodynamic properties

such as heat capacities, model parameters for vapor-liquid equilibrium calculations, as

well as kinetic parameters such as rate constants and activation energies.

Theoretically, these parameters can be measured by independent experiments. In

practice, they have to be calibrated by fitting simulation results with experimental data.

To do so the high fidelity simulations has to be carried out at different parameter settings

for each of the experiment conditions. This is of course computationally laborious

and often impossible when the number of parameters to be determined is large.

Alternatively, we can construct a meta-model that includes the parameter 𝛝 as our

input and characteristic experimental observations as our output. Meta-model can be

constructed with selected simulations at certain experiment conditions and parameter

settings. Iterative sampling can be carried to minimize a fitness-function of sum-

square-errors (SSE) of meta-model predictions of all experimental data.

The calibration of computer models dates back as far as 1978 (O’Hagan, 1978183),

where the Bayesian calibration approach was used. This involves fitting the posterior

distribution of best input parameter. The application of Bayesian calibration approach

to univariate computer models was demonstrated by Kennedy and O’Hagan184. Similar


application in multivariate, temporal and spatial computer models have been

demonstrated in several papers185,186,187,87, 188,189. Other calibration methods have been

mentioned in the literature different from the Bayesian approach. Some of them can be

found in the book by Kleijnen46 where calibration was referred to as simulation

optimization.

Examples of model calibration applications include: (1) energy simulation model

of buildings, using a Gaussian process regression technique with a radial basis

function kernel190, (2) water distribution systems, involving an evolutionary-based

meta-model with an innovative hybridization of Genetic Algorithm and Radial Basis

Function60 (Khu et al, 2004); an Artificial Neural Network linked to Genetic

Algorithm191,192,193 (3) mechanical and aerospace systems which utilizes Radial Basis

Function with non-dominated Sorting Genetic Algorithm (NSGA-II) (Khalfallah and

Ghenaiet, 2015).

4.4 SENSITIVITY ANALYSIS

A computer model can help us to locate the optimal operation of a process, it can

also help us to evaluate the sensitivity of the response to a certain input. Sensitivity

analysis can also be applied uncertain parameters of a model. Sensitivity can be

characterized locally by carrying out one-at-time changes to each input and examine

the effect on output. Chang et al provided an example of such approach biochemical

network194 was analyzed and simplified. Alternatively global variance based index

such as the Sobol indices195, fast amplitude sensitivity test (FAST)196,197, high

dimensional model representation (HDMR)198, polynomial chaos expansion

(PCE)199,200etc. can be calculated. Calculation of these global sensitivity indices is

of course time-consuming using the high fidelity model. However these indices can

be relatively easy using meta-models.30,40,201,202.. Applications of sensitivity analysis


(and the closely related uncertainty analysis), with or without a meta-model to chemical

engineering related problems include reaction kinetics203,204, biological system

modelling205, process design206, enhanced oil recovery simulation207, vapour cloud

dispersion90, etc.

4.5 SUMMARY

In this section, we have examined some applications of meta-modelling in the field

of chemical process system engineering. As we have seen, the most common

application is process optimization and design. However, meta-model development

with categorical variables is only in its early stage. Thus applications of meta-model

optimization to design problems involving flowsheet structure and non-linear integer

programing have been limited. While there are many applications in using data-

driven soft-sensor and reduced order models in nonlinear model predictive control,

these models are not meta-model as defined in this study. The closest form of meta-

model application is approximate dynamic programming. We have also pointed out

that meta-model can be used for model calibration and sensitivity analysis.

Application of sensitivity analysis to chemical engineering related problems, especially

analysis of kinetics reaction network has been well researched, partly because the need

of a meta model is much less due to relative ease of ODE simulations.

5. CONCLUSIONS

The objective of this review is to provide chemical process system engineers with

the statistical background that has been developed for design of computer experiment

and use of meta-models for optimization. We have introduced various forms of meta-

model representation. Interpolation model such as Kriging/GPR seems a useful model

in many cases. Methods of sampling in meta-model construction and optimization


has also been surveyed. In general we found that space filling design is the suitable

choice of initial experimental design and some form of balance between exploring

uncertain region and confirmation of optimal prediction must be struck in evolutionary

optimization. Examination of applications of chemical engineering related problems

found that most applications of meta-modelling emphasize on optimization. However,

optimization with categorical variables is still under-researched because meta-model

theory and sampling techniques for this kind of problems have not been fully

understood. With such knowledge, our ability to use complex, high fidelity, time

consuming simulation tools more efficiently in understanding process behavior,

optimize process design, and improve process control, can be enhanced.

ACKNOWLEDGEMENT

O. Kajero’s PhD is funded by the Tertiary Education Trust Fund (TETFUND), Nigeria

in collaboration with University of Lagos, Nigeria. This work was also partially

supported

by an International Exchange grant co-funded by the Taiwan Ministry of Science &

Technology (Grant number: MOST 104-2911-I-007-516) and the UK Royal Society

(Grant number: IE140859).

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