Industrial processes generate complex data that challenge fault detection systems, often yielding opaque or underwhelming results despite advanced machine learning techniques. This study tackles such difficulties using the Tennessee Eastman Process, a well-established benchmark known for its intricate dynamics, to develop an innovative fault detection framework. Initial attempts with standard models revealed limitations in both performance and interpretability, prompting a shift toward a more tractable approach. By employing SHAP (SHapley Additive exPlanations), we transform the problem into a more manageable and transparent form, pinpointing the most critical process features driving fault predictions. This reduction in complexity unlocks the ability to apply causal analysis through Directed Acyclic Graphs, generated by multiple algorithms, to uncover the underlying mechanisms of fault propagation. The resulting causal structures align strikingly with SHAP findings, consistently highlighting key process elements-like cooling and separation systems-as pivotal to fault development. Together, these methods not only enhance detection accuracy but also provide operators with clear, actionable insights into fault origins, a synergy that, to our knowledge, has not been previously explored in this context. This dual approach bridges predictive power with causal understanding, offering a robust tool for monitoring complex manufacturing environments and paving the way for smarter, more interpretable fault detection in industrial systems.

Found Energy, a startup in Boston, aims to harness the energy in scraps of aluminum metal to power industrial processes without fossil fuels. Since 2022, the company has worked to develop ways to rapidly release energy from aluminum on a small scale. Now it's just switched on a much larger version of its aluminum-powered engine, which it claims is the largest aluminum-water reactor ever built. Early next year, it will be installed to supply heat and hydrogen to a tool manufacturing facility in the southeastern US, using the aluminum waste produced by the plant itself as fuel. If everything works as planned, this technology, which uses a catalyst to unlock the energy stored within aluminum metal, could transform a growing share of aluminum scrap into a zero-carbon fuel. Rondo Energy just turned on what it says is the world's largest thermal battery, an energy storage system that can take in electricity and provide a consistent source of heat.

We got a sneak peek inside Found Energy's lab, just as it gears up to supply heat and hydrogen to its first customer. The crushed-up soda can disappears in a cloud of steam and--though it's not visible--hydrogen gas. "I can just keep this reaction going by adding more water," says Peter Godart, squirting some into the steaming beaker. "This is room-temperature water, and it's immediately boiling. Doing this on your stove would be slower than this." Godart is the founder and CEO of Found Energy, a startup in Boston that aims to harness the energy in scraps of aluminum metal to power industrial processes without fossil fuels.

An application of machine learning to the industrial processes stabilization is an open problem which promises a huge potential benefit to the such critical industries as metals and energy development if solved. Classical optimization methods, such as finite-horizon markov decision processes [1], non-linear programming reformulation of control [2] and point-wise optimization [3] are frequently employed in order to achieve better stability of time series process, successfully improving production quality, minimizing expenses and manufacturing devices deficiency with near-future planing or real-time optimization. Machine learning, known for its prominent results in solution of enterprise problems [4], became widely applied to the time series prediction and generation after recent advances in such fields as natural language processing, due to the similarity aforementioned tasks in their time dependent recurrent nature [5]. Thus, contemporary time series modeling is performed with long short-term memory (LSTM) models [6] and Transformers [7], incorporating different attention strategies. Currently, state-of-the-art approaches to ML-driven optimization include an application of reinforcement learning, but for time series problems, the usual focus stays on approximation of the industrial process as a dynamic system on the basis of recurrent neural network (RNN), with such methods as recurrent stabilization control [8, 9].

Soft sensing of hard-to-measure variables is often crucial in industrial processes. Current practices rely heavily on conventional modeling techniques that show success in improving accuracy. However, they overlook the non-linear nature, dynamics characteristics, and non-Euclidean dependencies between complex process variables. To tackle these challenges, we present a framework known as a Knowledge discovery graph Attention Network for effective Soft sensing (KANS). Unlike the existing deep learning soft sensor models, KANS can discover the intrinsic correlations and irregular relationships between the multivariate industrial processes without a predefined topology. First, an unsupervised graph structure learning method is introduced, incorporating the cosine similarity between different sensor embedding to capture the correlations between sensors. Next, we present a graph attention-based representation learning that can compute the multivariate data parallelly to enhance the model in learning complex sensor nodes and edges. To fully explore KANS, knowledge discovery analysis has also been conducted to demonstrate the interpretability of the model. Experimental results demonstrate that KANS significantly outperforms all the baselines and state-of-the-art methods in soft sensing performance. Furthermore, the analysis shows that KANS can find sensors closely related to different process variables without domain knowledge, significantly improving soft sensing accuracy.

Higher-order sensor networks are more accurate in characterizing the nonlinear dynamics of sensory time-series data in modern industrial settings by allowing multi-node connections beyond simple pairwise graph edges. In light of this, we propose a deep spatio-temporal hypergraph convolutional neural network for soft sensing (ST-HCSS). In particular, our proposed framework is able to construct and leverage a higher-order graph (hypergraph) to model the complex multi-interactions between sensor nodes in the absence of prior structural knowledge. To capture rich spatio-temporal relationships underlying sensor data, our proposed ST-HCSS incorporates stacked gated temporal and hypergraph convolution layers to effectively aggregate and update hypergraph information across time and nodes. Our results validate the superiority of ST-HCSS compared to existing state-of-the-art soft sensors, and demonstrates that the learned hypergraph feature representations aligns well with the sensor data correlations. The code is available at https://github.com/htew0001/ST-HCSS.git

In this work, we introduce MOLA: a Multi-block Orthogonal Long short-term memory Autoencoder paradigm, to conduct accurate, reliable fault detection of industrial processes. To achieve this, MOLA effectively extracts dynamic orthogonal features by introducing an orthogonality-based loss function to constrain the latent space output. This helps eliminate the redundancy in the features identified, thereby improving the overall monitoring performance. On top of this, a multi-block monitoring structure is proposed, which categorizes the process variables into multiple blocks by leveraging expert process knowledge about their associations with the overall process. Each block is associated with its specific Orthogonal Long short-term memory Autoencoder model, whose extracted dynamic orthogonal features are monitored by distance-based Hotelling's $T^2$ statistics and quantile-based cumulative sum (CUSUM) designed for multivariate data streams that are nonparametric, heterogeneous in nature. Compared to having a single model accounting for all process variables, such a multi-block structure improves the overall process monitoring performance significantly, especially for large-scale industrial processes. Finally, we propose an adaptive weight-based Bayesian fusion (W-BF) framework to aggregate all block-wise monitoring statistics into a global statistic that we monitor for faults, with the goal of improving fault detection speed by assigning weights to blocks based on the sequential order where alarms are raised. We demonstrate the efficiency and effectiveness of our MOLA framework by applying it to the Tennessee Eastman Process and comparing the performance with various benchmark methods.

Industrial Operational Technology (OT) systems are increasingly targeted by cyber-attacks due to their integration with Information Technology (IT) systems in the Industry 4.0 era. Besides intrusion detection systems, honeypots can effectively detect these attacks. However, creating realistic honeypots for brownfield systems is particularly challenging. This paper introduces a generative model-based honeypot designed to mimic industrial OPC UA communication. Utilizing a Long ShortTerm Memory (LSTM) network, the honeypot learns the characteristics of a highly dynamic mechatronic system from recorded state space trajectories. Our contributions are twofold: first, we present a proof-of concept for a honeypot based on generative machine-learning models, and second, we publish a dataset for a cyclic industrial process. The results demonstrate that a generative model-based honeypot can feasibly replicate a cyclic industrial process via OPC UA communication. In the short-term, the generative model indicates a stable and plausible trajectory generation, while deviations occur over extended periods. The proposed honeypot implementation operates efficiently on constrained hardware, requiring low computational resources. Future work will focus on improving model accuracy, interaction capabilities, and extending the dataset for broader applications.

Recurrent stochastic configuration networks (RSCNs) are a class of randomized learner models that have shown promise in modelling nonlinear dynamics. In many fields, however, the data generated by industry systems often exhibits nonstationary characteristics, leading to the built model performing well on the training data but struggling with the newly arriving data. This paper aims at developing a self-organizing version of RSCNs, termed as SORSCNs, to enhance the continuous learning ability of the network for modelling nonstationary data. SORSCNs can autonomously adjust the network parameters and reservoir structure according to the data streams acquired in real-time. The output weights are updated online using the projection algorithm, while the network structure is dynamically adjusted in the light of the recurrent stochastic configuration algorithm and an improved sensitivity analysis. Comprehensive comparisons among the echo state network (ESN), online self-learning stochastic configuration network (OSL-SCN), self-organizing modular ESN (SOMESN), RSCN, and SORSCN are carried out. Experimental results clearly demonstrate that the proposed SORSCNs outperform other models with sound generalization, indicating great potential in modelling nonlinear systems with nonstationary dynamics.

Industrial processes generate vast amounts of time series data, yet extracting meaningful relationships and insights remains challenging. This paper introduces a framework for automated knowledge graph learning from time series data, specifically tailored for industrial applications. Our framework addresses the complexities inherent in industrial datasets, transforming them into knowledge graphs that improve decision-making, process optimization, and knowledge discovery. Additionally, it employs Granger causality to identify key attributes that can inform the design of predictive models. To illustrate the practical utility of our approach, we also present a motivating use case demonstrating the benefits of our framework in a real-world industrial scenario. Further, we demonstrate how the automated conversion of time series data into knowledge graphs can identify causal influences or dependencies between important process parameters.