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INFORMATION TO USERS This manuscript has been reproduced from the microfilm master. UMI films the text directly from the original or copy submitted. Thus, some thesis and dissertation copies are in typewriter face, while others may be from any type of computer printer. The quality of this reproduction is dependent upon the quality of the copy submitted. Broken or indistinct print, colored or poor quality illustrations and photographs, print bleedthrough, substandard margins, and improper alignment can adversely affect reproduction. In the unlikely event that the author did not send UMI a complete manuscript and there are missing pages, these will be noted. Also, if unauthorized copyright material had to be removed, a note will indicate the deletion. Oversize materials (e.g., maps, drawings, charts) are reproduced by sectioning the original, beginning at the upper left-hand corner and continuing from left to right in equal sections with small overlaps. Each original is also photographed in one exposure and is included in reduced form at the back of the book. Photographs included in the original manuscript have been reproduced xerographically in this copy. Higher quality 6" x 9" black and white photographic prints are available for any photographs or illustrations appearing in this copy for an additional charge. Contact UMI directly to order. UMI University Microfilms International A Bell & Howell Information Company 300 Nortfi Zeeb Road. Ann Arbor. Ml 48106-1346 USA 313/761-4700 800/521-0600 Order Number 0211129 A task analysis of chemical and biotechnological process synthesis Gandikota, Murthy Srinivas, Ph.D. The Ohio State University, 1991 UMI 300 N. Zeeb Rd. Ann Aibor, MI 48106 A TASK ANALYSIS OF CHEMICAL AND BIOTECHNOLOGICAL PROCESS SYNTHESIS DISSERTATION Presenled in PartialFulfillment of the Requirements for the Degree Doctor of Philosophy in the (Graduate School of The Ohio State University By Murthy Srinivas Gandikota, B.Tech, M.S. ***** The Ohio Stale University 1991 Disserlaion Committee: Approved By Dr. J. F. Davis Dr. T. Bylander Dr. S. T. Yang Advisor Department of Chemical Engineering Copyright By Murthy Gandikota 1991 To my parents ACKNOWLEDGEMENTS I thank all those who: financed my graduate school expenses even though my car was never insured during this time; in an argument disagreed with me and gave their justification; taught me what I thought I didn’t have to know; inspired me to seek knowledge by scaling dizzy heights and then fall freely to enjoy levitation; showed me affection and love mostly during day time affairs; rejected my advances because usually on those days 1 ended up working for my dissertation. 1 thank: anonymous posters on Usenet who shared their wisdom, free of charge, in public domain—especially the folks in comp.lang.lisp, comp.ai, and soc.culture.indian; the computer operators who usually made them all work, and then restored my files or reconstructed the hard disks when they didn’t; the High Street people who kept their places open for my visits even during unearthly hours—business is business; OSU for providing excellent recreational facilities in Larkins and Jesse Owen’s Centers—for me graduate study has been 50% inspiration in my office and 50% perspiration in these places. If 1 didn’t thank someone explicitly then please let me know, 1 will do so, when 1 write a book for commercial sale. Ill VITA August 15, 1964 ................................................................... Bom - Visakhapatnam, India July 1986 ............................................................................... B. Tech (Hons.) Department of Chemical Engineering Indian Institute of Technology Kharagpur, India December, 1988 ..................................................................M.S., Chemical Engineering Department of Chemical Engineering The Ohio State University Columbus, OH IV PUBLICATIONS AND PRESENTATIONS Gandikota, M., “Temporal Constraints on Event-Oriented Diagnosis and Corrective Action Planning of Dynamic Process Systems,” Tech Report, AI Applications Group, Department of Chemical Engineering, The Ohio State University, Columbus, OH, 1991. “A Knowledge-Based System for BioProcess Synthesis,” by M.S.Gandikota, J.F.Davis, S T. Yang and J. Marchio, paper invited for publication in ChemTech, 1991. “A Task-Oriented Framework for Biochemical Process Flowsheet Synthesis,” by M.S.Gandikota, S.T.Yang and J.F.Davis, in proceedings of AIChE Conference, Chicago, November, 1990 and American Chemical Society Conference, Washington, D C., August, 1990. “An Integrated Framework for Intelligent Computer Aided Design of Chemical Processes,” by N.Hari Narayanan, M.S.Gandilcota and J.Maroldt, in proceedings of 2nd International Conference on Industrial and Engineering Applications of Artificial Intelligence and Expert Systems, July, 1990. “An Expert System Framework for the Preliminary Design of Process Flowsheets,” by M.S.Gandikota and J.F.Davis, in proceedings of the International Conference on Knowledge-Based Computer Systems, pg.88-104, Bombay, India, Dec. 11-13, 1989. “Building Expert Systems for Selection in Engineering Design,” by M.S.Gandikota and J.F.Davis, presented at the AIChE Annual Meeting, San Francisco, CA, Nov. 5-10, 1989. “A Knowledge-Based System Framework for Diagnosis in Process Plants,” by S.K.Shum, M.S.Gandikota, et al., in proceedings of the 7th Power Plant Dynamics, Control and Testing Symposium, pg.22.01, Knoxville, TN, May 15-17, 1989. “Rule-Based Expert Systems in Chemical Engineering,” by J.F.Davis and M.S.Gandikota, Computer Aids for Chemical Engineering (CACHE) Monograph Series, August, 1988. “An Intelligent Database for Process Plant Expert Systems,” by R.Bhatnagar, M.S.Gandikota, et al., in proceedings of the ISA Conference, pg.373-385, Houston, TX, Oct. 16-21, 1988. FIELDS OF STUDY Major Field: Chemical Engineering Studies in the application of artificial intelligence towards process synthesis problem solving in Chemical and Biotechnology domain. Advisor: Dr. James F. Davis VI TABLE OF CONTENTS DEDICATION .................................................................................................. ii /i(:#ir4()iifiJE:D(:;Eivii%hrirs................................................................. H: VITA ................................................................................................................ iv LIST OF FICLRES ......................................................................................... xüi LIST O F T A B L E S ........................................................................................... xv CHAPTER PACE I. INTRODUCTION ....................................................................................... I 1.1. MOTIVATION FOR KNOWLEDGE-BASED SYSTEMS IN PROCESS SYNTHESIS..................................................................... 2 1.2. LIMITED ROLE OF CURRENT COMPUTER-AIDED DESIGN TOOLS ................................................................................................. 3 1.3. AI IN CHEMICAL ENGINEERING.............................................. 5 1.4. PRIMARY RESEARCH FOCUS: BIOPROCESS SYNTHESIS 7 1.5. SECONDARY RESEARCH FOCUS: DEVELOPMENT OF PROCESS SYNTHESIS METHODS ............................................ 8 1.6. ORGANIZATION OF THE DISSERTATION............................... 9 II. A TASK APPROACH TO A KNOWLEDGE BASED SYSTEM FOR SELECTION AND SYNTHESIS OF BIOPROCESSES 12 2.1. INTRODUCTION ........................................................................... 12 VII 2.2. THE SELECTION PROBLEM ........................................................ 13 2.3. TASK ANALYSIS OF ROUTINE SELECTION PROBLEM ... 14 2.3.1. Preliminary Selection T ask ........................................................ 14 2.3.2. Critical Selection Task ............................................................... 15 2.4. CRITICAL SELECTION INFERENCE STRATEGY.................. 16 2.4.1. Activation Phase .......................................................................... 16 2.4.2. Consistency Checking Phase ................................................... 16 2.4.2.1. Primary Consistency Check Algorithm ......................... 18 2.4.2.2. Secondary Consistency Check Algorithm .................... 20 2.3. AN EXAMPLE OF CRITICAL SELECTION............................. 21 2.6. FAILURE HANDLING ..................................................................... 23 2.6.1. Preliminary Selection Failure Handling Algorithm 24 2.6.2. Critical Selection Failure Handling Algorithm ...................... 25 2.7. SELECTRIX: A KNOWLEDGE BASED SYSTEM SHELL FOR SELECTION .............................................................................. 25 2.8. SUMMARY .......................................................................................... 26 HI. APPLICATION OF SELECTRIX TO BIOPROCESS SYNTHESIS.......................................................................................... 27 3.1. KNOWLEDGE NECESSARY FOR BIOPROCESS SYNTHESIS 27 3.2. KNOWLEDGE ABOUT SEQUENCING OF PROCESS STEPS 29 3.3. KNOWLEDGE OF UNIT OPERATIONS...................................... 31 3.4. KNOWLEDGE OF INTERACTIONS AMONG UNIT OPERATIONS ..................................................................................... 36 3.5. REFINEMENT OF A FLOWSHEET .................... 37 3.6. KNOWLEDGE-BASED SYSTEM PROTOTYPING AND TESTING .............................................................. 37 3.7. CASE STUDY ..................................................................................... 38 3.8. COMPLEXITY