Development of an intelligent Digital Twin for prediction and control of the process behavior via transient flowsheet simulation using the example of fluidized bed spray granulation

生产设备的过程监测和控制沿着对新开发的持续需求，以避免不希望的过程状态和次规格生产费用，即使颗粒技术领域中的过程已经在工业中使用了几十年。该转移项目的主要目的是通过开发智能数字孪生来提高化学工程的流程效率。这将使用流化床喷雾造粒工艺的实例来证明。数字孪生模型再现物理工厂的状态并预测其未来行为，从而实现对过程的可靠控制。数字孪生的智能由基础模型定义，这些模型将通过连续的离线和在线分析方法进行全面的数据采集来获得。对模型细节的高度关注导致决策建议可以更快地实时提供，这允许预测以及过程优化步骤。这是作为一个特定于流程的知识模块开发的，它调用流程图模块，校准和合并数据。模拟结果由软传感器解释。将开发一个通信网关，负责仿真结果和数字过程图片之间的交互。流化床喷雾造粒模型将开发实验室规模的工厂在汉堡工业大学的应用统计设计的实验。将有意调整不需要的工艺条件，以确定稳定工艺操作的边界。由此产生的模型在流程模拟软件Dyssol中实现，该软件是在DFG前身项目（SPP 1679）期间开发的。通过使用该软件工具，Digital Twin的开发过程可以轻松地转移到固体工艺工程的其他过程和过程链中，并以最小的工作量为基础。根据模拟得出的未来过程状态，将行动建议实施到工厂的过程控制系统中。优化算法确定导致稳定操作的那些参数。过程控制系统的实施是在工业合作伙伴Pergande集团公司进行的。除了实验室规模的工厂的操作，转移到更大的工厂将被证明。现有辅助系统的扩展将为新工厂的分销带来竞争优势，并且是工业合作伙伴流化床技术领域的独特之处。此外，由于工厂的可用性更高，合同制造领域的效率可以提高约15%。

The process monitoring and control of production plants comes along with the ongoing demand for new developments to avoid unwanted process states and sub-specification production charges even though the processes in the field of particle technology have been used in industry for many decades. The main aim of this transfer project is increasing the efficiency of processes from chemical engineering by the development of an intelligent Digital Twin. This will be demonstrated using the example of the fluidized bed spray granulation process. The Digital Twin reproduces the state of the physical plant and predicts its future behavior, enable reliable control of the process. The intelligence of the Digital Twin is defined by the underlying models, which will be obtained by comprehensive data acquisition with continuous offline and online analysis methods. The high attention to detail of the models result in decision recommendations available faster the real-time, which allows predictions as well as process optimization steps. This is developed as a process-specific knowledge module that calls a flowsheet module, calibrates and consolidates the data. The results of the simulations are interpreted by soft sensors. A communication gateway will be developed that is responsible for the interaction between the simulation results and the digital process picture. The fluidized bed spray granulation model will be developed by experiments with a lab-scale plant at Hamburg University of Technology by application of statistical design of experiments. Unwanted process conditions will be deliberately adjusted in order to define the borders of stable process operation. The resulting model is implemented in the flowsheet simulation software Dyssol which has been developed during the DFG predecessor project (SPP 1679). By applying this software tool, the development procedure of the Digital Twin can be easily transferred to other processes and process chains of solids process engineering with minimal effort.Based on the future process states derived by the simulations, recommendations for actions will be implemented into the process control system of the plant. An optimization algorithm determines those parameters that result in a stable operation. The implementation into the process control system is conducted at the industrial partner, the company Pergande Group. Besides the operation of lab-scale plants, the transferability to larger plants will be demonstrated. The extension of current assistant systems will result in a competitive advantage for the distribution of new plants and is a unique feature in the field of fluidized bed technology for the industrial partner. In addition, it is assumed that the efficiency in the field of contract manufacturing can be increased by about 15 % due to a higher availability of the plants.