With the rise of deep learning, there has been renewed interest within the process industries to utilize data on large-scale nonlinear sensing and control problems. We identify key statistical and machine learning techniques that have seen practical success in the process industries. To do so, we start with hybrid modeling to provide a methodological framework underlying core application areas: soft sensing, process optimization, and control. Soft sensing contains a wealth of industrial applications of statistical and machine learning methods. We quantitatively identify research trends, allowing insight into the most successful techniques in practice. We consider two distinct flavors for data-driven optimization and control: hybrid modeling in conjunction with mathematical programming techniques and reinforcement learning. Throughout these application areas, we discuss their respective industrial requirements and challenges. A common challenge is the interpretability and efficiency of purely data-driven methods. This suggests a need to carefully balance deep learning techniques with domain knowledge. As a result, we highlight ways prior knowledge may be integrated into industrial machine learning applications. The treatment of methods, problems, and applications presented here is poised to inform and inspire practitioners and researchers to develop impactful data-driven sensing, optimization, and control solutions in the process industries.

Bayesian Optimization (BO) is a data-efficient method for global black-box optimization of an expensive-to-evaluate fitness function. BO typically assumes that computation cost of BO is cheap, but experiments are time consuming or costly. In practice, this allows us to optimize ten or fewer critical parameters in up to 1,000 experiments. But experiments may be less expensive than BO methods assume: In some simulation models, we may be able to conduct multiple thousands of experiments in a few hours, and the computational burden of BO is no longer negligible compared to experimentation time. To address this challenge we introduce a new Dimension Scheduling Algorithm (DSA), which reduces the computational burden of BO for many experiments. The key idea is that DSA optimizes the fitness function only along a small set of dimensions at each iteration. This DSA strategy (1) reduces the necessary computation time, (2) finds good solutions faster than the traditional BO method, and (3) can be parallelized straightforwardly. We evaluate the DSA in the context of optimizing parameters of dynamic models of microalgae metabolism and show faster convergence than traditional BO.