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In complex industrial processes (CIPs), due to technical and economic limitations, key performance indicators (KPIs), especially the chemical content-related KPIs, are often difficult to measure in real time, which hinders the propagation of advanced process control technologies. This paper presents a soft sensor-based online KPI inference scheme by a state transition algorithm (STA)-optimized adaptive pre-sparse neuro-fuzzy inference system model, called STA-APSNFIS. It introduces a pre-sparse neural network to the traditional adaptive neuro-fuzzy inference system (ANFIS) model to establish an adaptive pre-sparse neuro-fuzzy inference system (APSNFIS) model to alleviate the adverse effects of data redundancy and noise interference in the detectable process monitoring data, which can effectively reduce the complexity of neuro-fuzzy inference system (NFIS) and speed up its convergence. Successively, to avoid being trapped at a local optimum, the STA-based optimization algorithm is adopted to replace the traditional gradient-based optimization approach to achieve an optimal APSNFIS model. Extensive validation and comparative experiments on nonlinear numeric simulation systems, benchmark Tenessee Eastman (TE) process and a real industrial bauxite flotation process demonstrated that the proposed STA-APSNFIS performed favorably against traditional ANFIS model as well as its variants, e.g., PSO-ANFIS, GA-ANFIS, and some other soft sensor-based KPI inference models.

STA-APSNFIS: STA-Optimized Adaptive Pre-Sparse Neuro-Fuzzy Inference System for Online Soft Sensor Modeling