Data-driven Bi-level Optimization of Thermal Power Systems with embedded Artificial Neural Networks

Industrial thermal power systems have coupled performance variables with hierarchical order of importance, making their simultaneous optimization computationally challenging or infeasible. This barrier limits the integrated and computationally scaleable operation optimization of industrial thermal power systems. To address this issue for large-scale engineering systems, we present a fully machine learning-powered bi-level optimization framework for data-driven optimization of industrial thermal power systems. The objective functions of upper and lower levels are approximated by artificial neural network (ANN) models and the lower-level problem is analytically embedded through Karush-Kuhn-Tucker (KKT) optimality conditions. The reformulated single level optimization framework integrating ANN models and KKT constraints (ANN-KKT) is validated on benchmark problems and on real-world power generation operation of 660 MW coal power plant and 395 MW gas turbine system. The results reveal a comparable solutions obtained from the proposed ANN-KKT framework to the bi-level solutions of the benchmark problems. Marginal computational time requirement (0.22 to 0.88 s) to compute optimal solutions yields 583 MW (coal) and 402 MW (gas turbine) of power output at optimal turbine heat rate of 7337 kJ/kWh and 7542 kJ/kWh, respectively. In addition, the method expands to delineate a feasible and robust operating envelope that accounts for uncertainty in operating variables while maximizing thermal efficiency in various scenarios. These results demonstrate that ANN-KKT offers a scalable and computationally efficient route for hierarchical, data-driven optimization of industrial thermal power systems, achieving energy-efficient operations of large-scale engineering systems and contributing to industry 5.0.

From drift to adaptation to the failed ml model: Transfer Learning in Industrial MLOps

Model adaptation to production environment is critical for reliable Machine Learning Operations (MLOps), less attention is paid to developing systematic framework for updating the ML models when they fail under data drift. This paper compares the transfer learning enabled model update strategies including ensemble transfer learning (ETL), all-layers transfer learning (ALTL), and last-layer transfer learning (LLTL) for updating the failed feedforward artificial neural network (ANN) model. The flue gas differential pressure across the air preheater unit installed in a 660 MW thermal power plant is analyzed as a case study since it mimics the batch processes due to load cycling in the power plant. Updating the failed ANN model by three transfer learning techniques reveals that ETL provides relatively higher predictive accuracy for the batch size of 5 days than those of LLTL and ALTL. However, ALTL is found to be suitable for effective update of the model trained on large batch size (8 days). A mixed trend is observed for computational requirement (hyperparameter tuning and model training) of model update techniques for different batch sizes. These fundamental and empiric insights obtained from the batch process-based industrial case study can assist the MLOps practitioners in adapting the failed models to data drifts for the accurate monitoring of industrial processes.

Neural Network-enabled Domain-consistent Robust Optimisation for Global CO$_2$ Reduction Potential of Gas Power Plants

We introduce a neural network-driven robust optimisation framework that integrates data-driven domain as a constraint into the nonlinear programming technique, addressing the overlooked issue of domain-inconsistent solutions arising from the interaction of parametrised neural network models with optimisation solvers. Applied to a 1180 MW capacity combined cycle gas power plant, our framework delivers domain-consistent robust optimal solutions that achieve a verified 0.76 percentage point mean improvement in energy efficiency. For the first time, scaling this efficiency gain to the global fleet of gas power plants, we estimate an annual 26 Mt reduction potential in CO$_2$ (with 10.6 Mt in Asia, 9.0 Mt in the Americas, and 4.5 Mt in Europe). These results underscore the synergetic role of machine learning in delivering near-term, scalable decarbonisation pathways for global climate action.