Summary of Research Project Results Under the JSPS FY2000
"Research for the future Program"



1.Research Institution Kyoto University
 
2.University-Industry Cooperative Research Committee 143rd Committee on Process Systems Engineering
 
3.Term of Project FY1996〜FY2000
 
4.Project Number 96R14301
 
5.Title of Project Intelligent Support System for Design, Operation, and Maintenance of Next Generation Chemical Plants

6.Projetct Leader
Name Institution,Department Title of Position
Hashimoto, Iori Kyoto University, Dept. of Chemical Engineering Professor

7.Core Members

Names Institution,Department Title of Position
Nishitani, Hirokazu Nara Inst. Sci. Tech., Grad. Sch. of Information Sciemce Professor
Hasebe, Shinji Kyoto University, Dept. of Chemical Engineering Assoc. Prof.
Matsuyama, Hisayoshi Kyushu University, Dept. of Chemical Engineering Professor

8.Cooperating Researchers

Names Institution,Department Title of Position
Itoh, Toshiaki Mitsubishi Chemical Corp., Yokohama Research Center Vice Director
Sadotomo, Hideo Mitsui Chemicals, Inc., System Dept. General Manager
Suzuki, Go Toyo Engineering Corp., Process Dept. Technical Advisor

9.Summary of Research Results

The purpose of this research project is to develop intelligent, computer-aided support systems for researchers and engineers who must deal with many difficult problems related to the next generation chemical processes. The research members selected from 7 national universities and 5 companies cooperated in developing efficient computer systems for the following six themes: i) Life-cycle assessment system needed for making future chemical processes cleaner production systems, ii) Batch distillation systems with minimum energy consumption, iii) Autonomous distributed scheduling systems, iv) Intelligent control systems for the assurance of high quality products, v) Intelligent systems for plant surveillance and diagnosis of abnormal plant situations, and vi) Intelligent support systems for training and educating plant operators. The following main research results were obtained for each theme mentioned above. Multi-effect batch distillation system named MEBAD was proposed. Its excellent characteristics in energy consumption and separation performance were theoretically analyzed and experimentally examined using the pilot plant newly constructed at Kyoto university (theme ii, one patent application has been filed). An autonomous distributed scheduling system for just in time production was developed (theme iii). New processing methods for micro cellular plastics were developed using super critical fluid (theme iv, 3 patent applications have been filed). Concerning the composition control of multi-components distillation columns, combination of predictive estimation control and cascade control scheme was proposed and its excellent control performance was demonstrated by many simulation calculations (theme iv). New effective system was developed for diagnosing malfunction of flow meters (theme v). New guiding principles were clarified for designing human-machine interfaces of plant operation systems (theme vi). Ninety-five technical papers related to themes ii) - vi) were published and four patent applications have been filed. Eight prototype systems were developed as computer-aided intelligent support systems.

10.Key Words

(1)Process Systems Engineering、(2)Intelligent Support System、(3)Energy Conservation
(4)Autonomous Decentralized System、(5)Process Control、(6)Scheduling
(7)Fault Detection and Diagnosis、(8)Human Interface、(9)Polymer Processing

11.References

[Reference Articles]
Author Title of Article
Kazuhiro Takeda Fault Diagnosis Using Condition for Cause-Effect Relationship among State Variables
Journal Volume Year Pages Concerned
Kagaku Kogaku Ronbunshu 22 1996 1009-1017

Author Title of Article
Teiji Kitajima Autonomous Decentralized Scheduling System for Multi-stage Parallel - Unit Production Processes
Journal Volume Year Pages Concerned
Kagaku Kogaku Ronbunshu 22 1996 1031-1038

Author Title of Article
Shinji Hasebe Automatic Adjustment of Crossover Method in the Scheduling using Genetic Algorithm
Journal Volume Year Pages Concerned
Kagaku Kogaku Ronbunshu 22 1996 1039-1045

Author Title of Article
Susumu Hashizume Control of Discrete Events Using Condition/Event Net Modules
Journal Volume Year Pages Concerned
Kagaku Kogaku Ronbunshu 22 1996 1070-1078

Author Title of Article
Yoshifumi Tsuge Development of a System for Screening Potential Entrainers in Azeotropic Distillation Processes
Journal Volume Year Pages Concerned
Kagaku Kogaku Ronbunshu 22 1996 1138-1146

Author Title of Article
Yutaka Matsutani A Method of Finding a Set of Solutions of Condition/Event Net Construction Problem Using no Auxiliary Events
Journal Volume Year Pages Concerned
Transactions of the Society of Instrument and Control Engineers 32 1996 1454-1460

Author Title of Article
Susumu Hashizume Algorithm for Finding a Set of All Atoms Compatible with a Given Paetial Language
Journal Volume Year Pages Concerned
Transactions of the Society of Instrument and Control Engineers 32 1996 1560-1565

Author Title of Article
Hirokazu Nishitani A Preparatory Experiment for Usability-Test of Industrial Plant Operation Control System
Journal Volume Year Pages Concerned
The Journal of the Society for Industrial Plant Human Factors of Japan 1 1996 26-35

Author Title of Article
Shinji Hasebe A Flexible Simulation System for Scheduling with Various Constraints
Journal Volume Year Pages Concerned
Journal of Chemical Engineering of Japan 29 1996 323-329

Author Title of Article
Hirokazu Nishitani Human-Computer Interaction in the New Process Technology
Journal Volume Year Pages Concerned
Journal of Process Control 6 1996 111-117

Author Title of Article
Masatoshi Yoshida Controller Design for Parabolic Distributed Parameter Systems Using Finite Integral Transform Techniques
Journal Volume Year Pages Concerned
Journal of Process Control 6 1996 359-366

Author Title of Article
Susumu Hashizume Construction of Petri Nets from a Given Partial Language
Journal Volume Year Pages Concerned
IEICE Trans. Fundamentals E79-A 1996 2192-2195

Author Title of Article
Masahiro Ohshima Optimal Blending Operation at Polymer Silos
Journal Volume Year Pages Concerned
Kagaku Kogaku Ronbunshu 23 1997  

Author Title of Article
Masatoshi Yoshida Control of Temperature Distribution in Two Dimensional Heat Conduction Process
Journal Volume Year Pages Concerned
Kagaku Kogaku Ronbunshu 23 1997 491-497

Author Title of Article
Masatoshi Yoshida On-line Estimation of the Moisture Distribution in Granular Bed under Drying
Journal Volume Year Pages Concerned
Kagaku Kogaku Ronbunshu 23 1997 541-547

Author Title of Article
Masaru Noda Optimal Operation Policy for Three Types of Batch Distillation Columns Separating Binary Components
Journal Volume Year Pages Concerned
Kagaku Kogaku Ronbunshu 23 1997 934-941

Author Title of Article
Hirokazu Nishitani Evaluation Method of Human Interface in CRT Operation Using Protocol Analysis
Journal Volume Year Pages Concerned
The Journal of the Society for Industrial Plant Human Factors of Japan 2 1997 16-25

Author Title of Article
Teiji Kitajima Development of An Operator Model for Plant Operation
Journal Volume Year Pages Concerned
The Journal of the Society for Industrial Plant Human Factors of Japan 2 1997 106-115

Author Title of Article
Y. Murakami Application of Repetitive SA Method to Scheduling Problems of Chemical Processes
Journal Volume Year Pages Concerned
Computers and Chemical Engineering 21 1997 S1087-S1092

Author Title of Article
Akio Ishikawa A Practical Method for Removing ill-conditioning in Industrial Constrained Predictive Control
Journal Volume Year Pages Concerned
Computers and Chemical Engineering 21 1997 S1093-S1098

Author Title of Article
Shinji Hasebe Optimal Operation Policy for Multi-effect Batch Distillation System
Journal Volume Year Pages Concerned
Computers and Chemical Engineering 21 1997 S1221-S1226

Author Title of Article
Akio Ishikawa A Practical Method for Removing Ill-conditioning in Industrial Constrained Predictive Control
Journal Volume Year Pages Concerned
Kagaku Kogaku Ronbunshu 24 1998  

Author Title of Article
Shigeyuki Tateno Fault Diagnosis of Flowmeters in Distillation Tower Systems by Use of Component Balances
Journal Volume Year Pages Concerned
Kagaku Kogaku Ronbunshu 24 1998 266-272

Author Title of Article
Kiyoshi Naito Stabilizing Control of Crystal Size Distribution in Continuous Crystallization Processes
Journal Volume Year Pages Concerned
Kagaku Kogaku Ronbunshu 24 1998 318-323

Author Title of Article
Manabu Kano Inferential Control of Distillation Composition Using Partial Least Squares Regression
Journal Volume Year Pages Concerned
Kagaku Kogaku Ronbunshu 24 1998 425-430

Author Title of Article
Kazuhiro Takeda Decentralized Scheduling Algorithm for Manufacturing Plants Reguiring Frequent Repairs
Journal Volume Year Pages Concerned
Kagaku Kogaku Ronbunshu 24 1998 538-545

Author Title of Article
Yoshihiro Murakami Scheduling Algorithm Searching Only the Feasible Production Sequences for Complex Batch Processes with Storage Tanks
Journal Volume Year Pages Concerned
Kagaku Kogaku Ronbunshu 24 1998 578-583

Author Title of Article
Ken-Ichiro Sotowa Comparison of the Method of Characteristics with a Finite Difference Scheme for Crystallization Process Simulation
Journal Volume Year Pages Concerned
Kagaku Kogaku Ronbunshu 24 1998 665-669

Author Title of Article
Yoshifumi Tsuge Failure Diagnosis of Flowmeters Based on Control Limits
Journal Volume Year Pages Concerned
J. SOPE 10 1998 78-85

Author Title of Article
Harue Ishii Design Instruction for Evaluation and Improvement of Operational Panels
Journal Volume Year Pages Concerned
The Journal of the Society for Industrial Plant Human Factors of Japan 3 1998 47-57

Author Title of Article
Taketoshi Kurooka Estimation of Plant Operator's Thinking State with Electroencephalograms
Journal Volume Year Pages Concerned
The Journal of the Society for Industrial Plant Human Factors of Japan 3 1998 100-109

Author Title of Article
Yoshiyuki Nishimura Partial Languages and Their Application to Theory of Discrete Event Systems
Journal Volume Year Pages Concerned
T. IEE Japan 118-D 1998 158-163

Author Title of Article
Yutaka Matsutani Construction of Condition/Event Nets from a Hierarchical Specification
Journal Volume Year Pages Concerned
Transactions of the Society of Instrument and Control Engineers 34 1998 836-843

Author Title of Article
Susumu Hashizume A Hierarchical Description of Partial Languages and Its Application to Condition/Event Nets Construction Problem
Journal Volume Year Pages Concerned
Transactions of the Society of Instrument and Control Engineers 34 1998 1922-1929

Author Title of Article
Kojiro Inamori Optimal Operating Region for Chemically Foamed Cable Coating Process
Journal Volume Year Pages Concerned
Seikei-Kakou 10 1998 68-75

Author Title of Article
Yue Liang Profile Control of Plastic Sheet in an Industrial Polymer Processing Process
Journal Volume Year Pages Concerned
Journal of Polymer Science and Engineering 38 1998 1740-1750

Author Title of Article
Masatoshi Yoshida Control of Axial Temperature Distribution in a Packed-Bed Reactor
Journal Volume Year Pages Concerned
Journal of Chemical Engineering of Japan 31 1998 381-390

Author Title of Article
Kiyoshi Naito Stabilizing Control of Continuous DTB Crystallizer -Influence of Undissolved Fine Crystals in External Heater-
Journal Volume Year Pages Concerned
Kagaku Kogaku Ronbunshu 25 1999 51-58

Author Title of Article
Kazuhiro Takeda Decentralized Scheduling Algorithm to Improve the Rate of Production without Increasing the Stocks of Intermediates
Journal Volume Year Pages Concerned
Kagaku Kogaku Ronbunshu 25 1999 343-348

Author Title of Article
Yoshihiro Murakami Scheduling Algorithm Using Repetitive SA Method Allocating Jobs to Desirable Production Lines
Journal Volume Year Pages Concerned
Kagaku Kogaku Ronbunshu 25 1999 648-654

Author Title of Article
Manabu Kano Process Monitoring Using Moving Principal Component Analysis
Journal Volume Year Pages Concerned
Kagaku Kogaku Ronbunshu 25 1999 998-1003

Author Title of Article
Manabu Kano Process Monitoring Based on Dissimilarity of Time Series Data
Journal Volume Year Pages Concerned
Kagaku Kogaku Ronbunshu 25 1999 1004-1009

Author Title of Article
Teiji Kitajima Performance Evaluation of the Distributed Scheduling System Using Message Passing
Journal Volume Year Pages Concerned
Transactions of the Society of Instrument and Control Engineers 35 1999 546-553

Author Title of Article
Kouichi Sakata The Characteristics of Human Operator's Behavior during Malfunctions in Simulator Training
Journal Volume Year Pages Concerned
The Journal of the Society for Industrial Plant Human Factors of Japan 4 1999 112-120

Author Title of Article
Kojiro Inamori Numerical Simulation for Polymeric Foaming (1)
Journal Volume Year Pages Concerned
Seikei-Kakou 11 1999 194-201

Author Title of Article
Kojiro Inamori Numerical Simulation for Polymeric Foaming (2)
Journal Volume Year Pages Concerned
Seikei-Kakou 11 1999 471-476

Author Title of Article
Morimasa Ogawa Quality Inferential Control for an Industrial High Density Polyethylene Process
Journal Volume Year Pages Concerned
Journal of Process Control 9 1999 51-59

Author Title of Article
Yoshihiro Murakami SA-Based Scheduling Algorithm for Increasing Probability of Selecting Promising Schedules
Journal Volume Year Pages Concerned
Journal of Chemical Engineering of Japan 32 1999 652-661

Author Title of Article
Emrod Elisante IMC Based Robust Pole Placement Procedure for Modal Control of One-Dimensional Heat Conduction Process
Journal Volume Year Pages Concerned
Journal of Chemical Engineering of Japan 32 1999 796-802

Author Title of Article
Shinji Hasebe Optimal Operation Policy for Total Reflux and Multi-effect Batch Distillation Systems
Journal Volume Year Pages Concerned
Computers and Chemical Engineering 23 1999 523-532

Author Title of Article
Masaru Noda Optimal Structure of Batch Distillation Column
Journal Volume Year Pages Concerned
Computers and Chemical Engineering 23 1999 S105-S108

Author Title of Article
Manabu Kano Selection of Inferential Models for Controlling Product Compositions in a Distillation Column
Journal Volume Year Pages Concerned
Kagaku Kogaku Ronbunshu 26 2000 94-99

Author Title of Article
Yoshifumi Tsuge Improvement of the System for Screening Potential Entrainers in Azeotropic Distillation Processes -Extension to the case that part of azeotropic data in the ternary mixture are unavailable-
Journal Volume Year Pages Concerned
Kagaku Kogaku Ronbunshu 26 2000 394-401

Author Title of Article
Susumu Hashizume Modular Synthesis of Sequential Control Systems Based on Condition/Event Nets
Journal Volume Year Pages Concerned
Kagaku Kogaku Ronbunshu 26 2000 443-449

Author Title of Article
Tatsushi Nishi Autonomous Decentralized Scheduling System for Flowshop Problems with Storage and Due-date Penalties
Journal Volume Year Pages Concerned
Kagaku Kogaku Ronbunshu 26 2000 661-668

Author Title of Article
Masashi Yamakawa Estimation of Logical Thinking State Using EEGs
Journal Volume Year Pages Concerned
Journal of Human Interface Society 2 2000 7-12

Author Title of Article
Junpei Yamamoto Analysis of Plant Operator's Behavior Using Eye Tracking System
Journal Volume Year Pages Concerned
The Journal of the Society for Industrial Plant Human Factors of Japan 5 2000 88-98

Author Title of Article
Kouichi Sakata Considerations on Simulator Training for Plant Operations during Malfunctions
Journal Volume Year Pages Concerned
The Journal of the Society for Industrial Plant Human Factors of Japan 5 2000 130-140

Author Title of Article
Emrod Elisante Application of Mu-Interaction Measures for Decentralized Temperature Control of Packed-Bed Chemical Reactor
Journal Volume Year Pages Concerned
Journal of Chemical Engineering of Japan 33 2000 120-127

Author Title of Article
Manabu Kano Comparison of Statistical Process Monitoring Methods: Application to the Eastman Challenge Problem
Journal Volume Year Pages Concerned
Computers and Chemical Engineering 24 2000 175-181

Author Title of Article
Kazuhisa Fujino Design and Verification of the SFC Program for Sequential Control
Journal Volume Year Pages Concerned
Computers and Chemical Engineering 24 2000 303-308

Author Title of Article
Tatsushi Nishi Autonomous Decentralized Scheduling System for Just-in-Time Production
Journal Volume Year Pages Concerned
Computers and Chemical Engineering 24 2000 345-351

Author Title of Article
Taketoshi Kurooka Mind State Estimation for Operator Support
Journal Volume Year Pages Concerned
Computers and Chemical Engineering 24 2000 551-556

Author Title of Article
Hirokazu Nishitani University-Industry Cooperative Study on Plant Operations
Journal Volume Year Pages Concerned
Computers and Chemical Engineering 24 2000 557-567

Author Title of Article
Yoshifumi Tsuge A fault detection and diagnosis for the continuous process with load-fluctuations using orthogonal wavelets
Journal Volume Year Pages Concerned
Computers and Chemical Engineering 24 2000 761-767

Author Title of Article
Takashi Hamamura The effects of design variables on the stabilizing control of continuous DTB crystallizers
Journal Volume Year Pages Concerned
Computers and Chemical Engineering 24 2000 917-923

Author Title of Article
Young Wang Optimal Grade Transition Control for Polymerization Reactors
Journal Volume Year Pages Concerned
Computers and Chemical Engineering 24 2000 1555-1561

Author Title of Article
Masaru Noda On-line Optimization System of Pilot Scale Multi-Effect Batch Distillation System
Journal Volume Year Pages Concerned
Computers and Chemical Engineering 24 2000 1577-1583

Author Title of Article
Kazuhiro Takeda Decentralized Scheduling Algorithm to Improve the Rate of Production without Increase of Stocks of Intermediates
Journal Volume Year Pages Concerned
Computers and Chemical Engineering 24 2000 1619-1624

Author Title of Article
Manabu Kano Inferential control system of distillation compositions using dynamic Partial Least Squares regression
Journal Volume Year Pages Concerned
Journal of Process Control 10 2000 157-166

Author Title of Article
Masahiro Ohshima Quality Control of Polymer Production Processes
Journal Volume Year Pages Concerned
Journal of Process Control 10 2000 135-148

Author Title of Article
Ken-Ichiro Sotowa Application of the Method of Characteristics to Crystallizer Simulation and Comparison with Finite Difference for Controller
Journal Volume Year Pages Concerned
Journal of Process Control 10 2000 203-208

Author Title of Article
Shinji Hasebe Optimal Operation of a Continuous DTB Crystallizer
Journal Volume Year Pages Concerned
Journal of Process Control 10 2000 441-448

Author Title of Article
Takefumi Nagata In-line Monitoring of Polyethylene Density Using Near Infrared (NIR) Spectroscopy
Journal Volume Year Pages Concerned
Journal of Polymer Science and Engineering 40 2000 1107-1113

Author Title of Article
Takefumi Nagata On-line NIR Sensing of CO2 Concentration for Polymer Extrusion Foaming Processes
Journal Volume Year Pages Concerned
Journal of Polymer Science and Engineering 40 2000 1843-1849

Author Title of Article
Manabu Kano Application of Novel Statistical Process Control Methods to a Chemical Process
Journal Volume Year Pages Concerned
Transactions of the Society of Instrument and Control Engineers 37 2001 160-167

Author Title of Article
Susumu Hashizume Constructions of Condition/Event Nets with Periodic Behavior
Journal Volume Year Pages Concerned
Transactions of the Society of Instrument and Control Engineers 37 2001 268-270

Author Title of Article
Kenichi Yamagata Development of a Filter for Real-Time Failure Diagnosis of Instruments
Journal Volume Year Pages Concerned
Technology Reports of Kyushu University 74 2001 75-82

Author Title of Article
Masaru Noda Optimal Structure and On-line Optimal Operation of Batch Distillation Column
Journal Volume Year Pages Concerned
Computers and Chemical Engineering 25 2001 109-117

Author Title of Article
Tatsushi Nishi Machine-Oriented Decomposition of Flowshop Scheduling Problems Using Lagrangian Relaxation
Journal Volume Year Pages Concerned
Transactions of The Institute of Systems, Control and Information Engineers 14 2001 244-251

Author Title of Article
Taketoshi Kurooka Real-Time Monitoring of Plant Operator's Thinking State
Journal Volume Year Pages Concerned
Journal of Chemical Engineering of Japan     Submitted

Author Title of Article
Opat Orapimpan Development of a Learning System of Know-How and Know-Why in Field Operations
Journal Volume Year Pages Concerned
Journal of the Society for Industrial Plant Human Factors of Japan     Submitted

Author Title of Article
Manabu Kano A New Multivariate Statistical Process Monitoring Method Using Principal Component Analysis
Journal Volume Year Pages Concerned
Computers and Chemical Engineering     in print

Author Title of Article
Hiroya Seki Industrial Application of a Nonlinear Model Predictive Control to Polymerization Reactors
Journal Volume Year Pages Concerned
Control Engineering Practice   2001 in press

Author Title of Article
Takefumi Nagata In-Line Sensing of CO2 Concentration in Polymeric Extrusion Foaming Process
Journal Volume Year Pages Concerned
Seikei-Kakou 13 2001 in print

Author Title of Article
Mitsuko Takada Effects of CO2 on Crystallization Kinetics of Polypropylene
Journal Volume Year Pages Concerned
Journal of Polymer Science and Engineering   2001 accepted

Author Title of Article
Takefumi Nagata In-line NIR Sensing of CO2 Concentration in Polymeric Foaming Extrusion Process
Journal Volume Year Pages Concerned
Journal of Cellular Plastics   2001 accepted

Author Title of Article
Mitutaka Shimoda Polymeric Foaming Simulation for Extrusion processes
Journal Volume Year Pages Concerned
Journal of Cellular Plastics   2001 accepted


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