Convolutional Neural Network-Based Machine Vision for Non-Destructive Detection of Flooding in Packed Columns

In chemical processes, packed columns are frequently employed in various unit operations. However, the flow rates of gas and liquid in these columns are often constrained by the risk of flooding. To ensure the safe and efficient operation of packed columns, it is crucial to detect flooding in real time. Conventional flooding monitoring methods rely heavily on manual visual inspections or indirect information from process variables, which limit the real-time accuracy of results. To address this challenge, we proposed a convolutional neural network (CNN)-based machine vision approach for non-destructive detection of flooding in packed columns. Real-time images of the packed column were captured using a digital camera and analyzed with a CNN model, which was been trained on a dataset of recorded images to identify flooding. The proposed approach was compared with deep belief networks and an integrated approach of principal component analysis and support vector machines. The feasibility and advantages of the proposed method were demonstrated through experiments on a real packed column. The results showed that the proposed method provides a real-time pre-alarm approach for detecting flooding, enabling process engineers to quickly respond to potential flooding events.