Froth color can be referred to as a direct and instant indicator to the key flotation production index, for example, concentrate grade. However, it is intractable to measure the froth color robustly due to the adverse interference of time-varying and uncontrollable multisource illuminations in the flotation process monitoring. In this article, we proposed an illumination-invariant froth color measuring method by solving a structure-preserved image-to-image color translation task via an introduced Wasserstein distance-based structure-preserving CycleGAN, called WDSPCGAN. WDSPCGAN is comprised of two generative adversarial networks (GANs), which have their own discriminators but share two generators, using an improved U-net-like full convolution network to conduct the spatial structure-preserved color translation. By an adversarial game training of the two GANs, WDSPCGAN can map the color domain of froth images under any illumination to that of the referencing illumination, while maintaining the structure and texture invariance. The proposed method is validated on two public benchmark color constancy datasets and applied to an industrial bauxite flotation process. The experimental results show that WDSPCGAN can achieve illumination-invariant color features of froth images under various unknown lighting conditions while keeping their structures and textures unchanged. In addition, WDSPCGAN can be updated online to ensure its adaptability to any operational conditions. Hence, it has the potential for being popularized to the online monitoring of the flotation concentrate grade.

This paper proposes an online BSD monitoring scheme by incorporating a multiscale deblurring full convolutional network (MsD) and a multistage jumping feature-fused full convolutional network (MsJ), having the potential of online identification of the health state of flotation process operations. MsD can restore blurry froth images from any complex foggy and motion-blurred scene due to air-water fogs, camera vibrations and high-speed froth flows. MsJ is proposed to accurately segment various froth images with fully-occupied and closely-adhesive fragile bubbles, involving multiple residual groups and multiple jumping feature layers to delineate bubbles of various sizes adaptively. The Weibull distribution behavior of the left-skewed BSD is demonstrated by the sequential fragmentation theory, whose parameters can be used to identify the flotation state. Extensive comparative experiments on a real copper-mine flotation process demonstrate that the proposed method performs favorably against the state-of-the-art froth image segmentation approaches and the Weibull distribution model can effectively characterize the underlying left-skewed BSD behavior, which is an effective indicator for the online flotation state identification or health evaluation.

This article proposes a robust end-to-end deep learning-induced fault recognition scheme by stacking multiple sparse-denoising autoencoders with a Softmax classifier, called stacked spare-denoising autoencoder (SSDAE)-Softmax, for the fault identification of complex industrial processes (CIPs). Specifically, sparse denoising autoencoder (SDAE) is established by integrating a sparse AE (SAE) with a denoising AE (DAE) for the low-dimensional but intrinsic feature representation of the CIP monitoring data (CIPMD) with possible noise contamination. SSDAE-Softmax is established by stacking multiple SDAEs with a layerwise pretraining procedure, and a Softmax classifier with a global fine-tuning strategy. Furthermore, SSDAE-Softmax hyperparameters are optimized by a relatively new global optimization algorithm, referred to as the state transition algorithm (STA). Benefiting from the deep learning-based feature representation scheme with the STA-based hyperparameter optimization, the underlying intrinsic characteristics of CIPMD can be learned automatically and adaptively for accurate fault identification. A numeric simulation system, the benchmark Tennessee Eastman process (TEP), and a real industrial process, that is, the continuous casting process (CCP) from a top steel plant of China, are used to validate the performance of the proposed method. Experimental results show that the proposed SSDAE-Softmax model can effectively identify various process faults, and has stronger robustness and adaptability against the noise interference in CIPMD for the process monitoring of CIPs.

Due to technical or economic limitations, timely measuring quality-relevant key performance indicators (KPIs) of complex industrial processes (CIPs), especially the chemical composition-related indexes, is intractable. Process monitoring image sequences (PMISs) usually involve significant information about the operation states and KPIs. Thus, soft sensor-based online KPI inference by incorporating process monitoring variables (TPMVs) and PMISs is more promising. However, the extremely inconsistent sampling rates with different expression forms and concerning aspects between PMISs and TPMVs lead to a great challenge in the soft sensor modeling by combining PMISs and TPMVs. In this article, a self-attention dual-channel deep network (SADCDN)-based soft sensor model for the end-to-end online KPI detection/prediction is proposed. Specifically, one channel adopts the gated recurrent unit (GRU) network to extract intrinsic time-series features in TPMVs, and simultaneously the other channel introduces a novel frame-dilated convolution fusion neural network (FDCFNN) to extract intrinsic spatiotemporal features from PMISs to address the sampling inconsistence between PMISs and TPMVs. Successively, dual-channel network features with different concerning aspects are weighted and fused based on an introduced self-attention mechanism to bridge the gap of sampling rates and concerning aspects between PMISs and TPMVs for the soft sensor modeling. Practical application results on two real industrial processes, the bauxite flotation process and the sintering process of a cement rotary kiln, have demonstrated the effectiveness and superiority of the proposed dual-channel model, laying a foundation for the process optimization of CIPs.

This paper presents a simple yet powerful online flotation process working condition (FPWC) discrimination approach based on the sparse representation of froth images. It learns a local Gabor pattern-based discriminative dictionary with a linear classification model simultaneously for the FPWC identification by solving a sparsity-constrained optimization problem. The proposed method tends to achieve similar and distinct sparse codes of froth images for the same and different FPWCs, respectively, facilitating the accurate FPWC identification. To ensure the adaptability of the FPWC discrimination model, an incremental learning-based online model updating procedure is further derived to monitor the dynamically changing characteristics of FPWCs based on an introduced sparsity discrimination index. The proposed method was validated on an industrial preferential lead-flotation sub-circuit process. The prototype monitoring system with extensive confirmatory and comparative experiments shows the effectiveness and superiority of the proposed method, which lays a foundation for the optimal control of industrial flotation processes.