22nd IEEE International Symposium on Intelligent Control

Part of IEEE Multi-conference on Systems and Control

Singapore, 1-3 October 2007

TuB07.5

Constructing the Model of Propylene Distillation Based on Neural

Networks
Jingui Lu, Ning Fang, Jinguo Lin, Fengxin Chen and Guanghui Chen

AbstractThe model of propylene distillation helps improve

the quality of propylene products. This paper proposes a
methodology of constructing the model of propylene distillation
based on the neural network technique. The strategy of
adjusting the neural network-based model of propylene
distillation with rough sets is proposed. A numerical example of
the neural network-based model for actual propylene
distillation is provided. A comparison is made between the
predicted results from the model and the actual results, which
validates the effectiveness of the model of propylene distillation.

I. INTRODUCTION

ropylene is needed to produce synthetic resin and rubber

and to synthesize the process of polymers. In the chemical
industry, propylene plays an important role in providing
production materials. For the purpose of transportation and
storage, it is necessary to use the operation of distillation to
separate pure propylene from the mixture of chemical
products. The distillation operation is important in the
process of producing the propylene [1]. Because the model of
propylene distillation can be applied to analyze the
production process of propylene with computer simulation,
constructing the model of propylene distillation helps
improve the quality of propylene products.
Research work in the modeling of propylene distillation
has been performed in recent decades. A non-equilibrium
optimization model of METSH equations was proposed in the
computer simulation of propylene distillation [2]. The
optimization model, which aims to minimize the cost of the
distillation tower, was developed based on the
non-equilibrium model, and the optimized data was helpful
for the production process of propylene distillation [2]. The
real-world data of propylene distillation of rectification trays
of a gas fractionation plant was compared with theoretical
predictions, and valuable suggestions were made for
Manuscript received January 6, 2006. This work was supported in part by
the National Natural Foundation of Science, P. R. China, under Grant No.
50675097, and the Department of Science & Technology of Jiangsu Province,
P. R. China, under Grant No. BK2006519
Jingui Lu is with Nanjing University of Technology, Nanjing 210009,
Jiangsu Province, P. R. China (Corresponding Author, Telephone:
86-25-83242113; Fax: 86-25-83587363; e-mail: lujg@ njut.edu.cn)
Ning Fang is with College of Engineering, Utah State University, Logan,
Utah 84322, U.S.A. (e-mail: nfang@engineering.usu.edu).
Jinguo Lin is with Nanjing University of Technology, Nanjing 210009,
Jiangsu Province, P. R. China (e-mail: zdhljg@163.com).
Fengxin Chen is with Nanjing University of Technology, Nanjing 210009,
Jiangsu Province, P. R. China (e-mail: chenfx_njgd@163.com).
Guanghui Chen is with Nanjing University of Technology, Nanjing
210009, Jiangsu Province, P. R. China (e-mail: chenghgh@163.com).

1-4244-0441-X/07/$20.00 2007 IEEE.

rectification trays to improve the efficiency of propylene

distillation [3]. Computer simulation was performed based on
a model of propylene distillation using computer software
package ASPEN PLUS in [4][5][6][7]. The production
process of propylene distillation was analyzed using
computer simulation, and the optimal operation parameters
were suggested for the tower tray [4]. ASPEN PLUS was also
employed to simulate the distillation process of propylene,
and the high purity of propylene was obtained by optimizing
the operation conditions [5]. A model of separating propylene
from propane was further introduced with ASPEN PLUS for
propylene distillation, and computer simulation of the
production process of propylene distillation was performed
[6]. The computer simulated results provide an important
basis for adjusting the feed inlet and the flow rate at the
bottom of tray for practical applications [6].
Neural network attracts the attention of researchers in a
wide variety of engineering fields in recent decades. Neural
network consists of many elements that have a nonlinear
relationship between input and output vectors. Compared
with other modeling technologies [8], neural network has a
main advantage: non-linear character. Neural network has
been successfully applied in constructing various models of
real-world problems such as the approximation model that
relates stresses and design variables of mechanical structures
[9]. Neural network has also been applied to construct the
model of catalyst distillation system of dimethyl carbonate,
and an optimization method of genetic algorithm was used to
search for optimal operation parameters based on the neural
network technique [10]. The ever-increasing applications of
neural network have also demonstrated its powerful mapping
ability for various problems [11].
The present paper deals with the construction of the model
of propylene distillation. Neural network, which has
non-linear character of mapping, is applied to generate the
model of the process of propylene distillation, using the
actual data from real-world production processes. Because
the purity of propylene is an important factor for propylene
distillation, the neural network-based model of the propylene
purity of distillation is taken into consideration in this paper.
In addition, because the production process of propylene
distillation is dynamic, a strategy of adjusting the neural
network-based model with rough sets is proposed.
The present paper consists of this Introduction section and
other three sections. The method of constructing the model of
propylene purity of distillation based on the neural network
technique is presented in Section 2. The strategy of adjusting

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the neural network-based model with rough sets is discussed

in Section 3. A numerical example of the model of neural
network for actual propylene distillation is provided, and the
comparison between the predicted results and the actual
results is made in Section 4.
II. CONSTRUCTING THE MODEL OF PROPYLENE DISTILLATION
BASED ON NEURAL NETWORK

Distillation tower is important in the production process of

propylene distillation. Liquid hydrocarbon is distilled into
propylene with distillation tower after previous operations,
such as the removal of impurity. After heated to a predefined
temperature, hydrocarbon is feed to distillation tower for
crude propylene. The chemical products of crude propylene
and propane are separated from the mixture as a result of the
heat and mass transfer of multilayer trays in the distillation
tower for crude propylene. In distillation tower for pure
propylene, pure propylene and propane are finally obtained
after heat and mass transfer. In addition, cooled liquids at the
bottom of tower, acting as reflux liquids, are pumped up the
top of the tower.
Although propylene distillation is a physical process, the
distillation process is complex. Many factors, such as the
ingredient, the feed amount, structures of distillation towers
for crude and pure propylene, can make a substantial
influence in the efficiency and quality of propylene
distillation. Numerous operation parameters, such as the
reflux rate at the bottom of tower, the percentage of propylene,
the operation pressure, the operation temperature, determine
the purity of propylene and propane. It is therefore difficult to
construct the model of propylene distillation using the
distillation theory that involves numerous assumptions and
simplifications. With the powerful ability of non-linear
mapping, neural network can be used to construct the model
by training various patterns involved in the distillation
process. Neural network provides a powerful modelling tool
for the chemical production process. Based on the real-world
actual data from propylene distillation, neural network is
applied to construct the model of propylene distillation
process in this paper.
Because the structures of distillation towers for crude and
pure propylene are determined before constructing the neural
network-based model of propylene distillation, the structural
parameters of distillation towers are not considered in the
model. The operation parameters, such as the reflux rate at the
bottom of tower, have more significant effects on the purity
of propylene and propane. Thus, six parameters that include
the feed amount, the position of propylene at the bottom of
tower, reflux rates of crude and pure propylene, the operation
pressure, the operation temperature, are employed as inputs
when dealing with the patterns of the propylene distillation
process. The purity of crude and pure propylene and propane
are employed as outputs for the patterns of the propylene
distillation process. A back-propagation algorithm is applied
to train the patterns to construct the model of neural network

of propylene distillation.
The structure of neural network is first determined for
constructing the model of propylene distillation. Then, the
patterns are selected for the production process of propylene
distillation. A learning algorithm is finally chosen to generate
the weights of the neural network-based model. The
following steps are preformed to construct the model of
propylene distillation based on the neural network technique.
A. Determine the structure of neural network
A three-layer neural network including input and output
layers is chosen as the architecture of the model of propylene
distillation. The feed amount x1, the operation pressure
x2 ,the operation temperature x3, the position of propylene at
the bottom of tower x4, and reflux rates of crude and pure
propylene x5 and x6 are chosen as inputs. The purity of crude
propylene y1 , the purity of pure propylene y2, and the purity
of propane y3 are chosen as outputs. The structure of neural
network for propylene distillation is shown in Fig. 1. The
number of neurons in input and output layers can be easily
determined as given before. The number of neurons in the
hidden layer is determined empirically.

Fig. 1. The structure of neural network for propylene distillation

B. Select patterns
The various patterns that represent the actual production
process of propylene distillation are selected. For practical
applications, a large amount of data is involved in the process
of propylene distillation in the distributed control system. The
feed amount x1, the operation pressure x2, the operation
temperature x3, the position of propylene at the bottom of
tower x4, and reflux rates of crude and pure propylene x5 and
x6 are employed as input vectors for the patterns. The purity
of crude propylene y1 , the purity of pure propylene y2, and the
purity of propane y3 are used as output vectors for the patterns.
The patterns are obtained based on the actual production
process of propylene distillation.
The activation function of the three-layer neural network
used in this paper is the sigmoid function. Its outputs are in
the interval of [0, 1]; thus, the outputs in the patterns to be
trained are normalized before the training procedure.

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C. Construct the model of neural network

The neural network-based model of propylene distillation

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is constructed by training various patterns. A

back-propagation algorithm is applied to train the patterns.
The training procedure includes the following five steps.
1) Read the patterns
Based on the file format, the input file of patterns is
prepared for the training procedure.
2) Initialize the weights of neural network
The weights of neural network are initialized for the
training procedure. The initial weights are given randomly.
3) Compute outputs and derivatives
The following equations (1) and (2) of a three-layer neural
network are used to calculate the inputs and outputs of
neurons in both hidden and output layers:
(1)
net jk = Wij Oik
O jk = f ( net jk )

(2)

where Wij is the weight between neuron i and neuron j in the

different layer, netjk is the input of neuron j for pattern k, and
Ojk is the output of neuron j for pattern k.
After the computation of the actual output, the derivatives
jk of error function to the input of neurons in the hidden
layer and the output layer are determined using equations (3)
and (4), respectively.

jk =

E k d k

= (Yk d k ) f ( net jk )
d k net jk

jk = f (net jk ) ( mkWmj )

(3)
(4)

where Ek is the difference between the actual and expected

output for pattern k, Yk is the actual output for pattern k, and
dk is the expected output for pattern k.
The derivatives of error function to the weight between
neurons in different layers are calculated using equation (5),
afterjk and Ojk are obtained based on equtations (1)-(4).
Ek/ Wij=jk O ik

(5)

4) Evaluate the training procedure

If the error between the actual and expected output for all
patterns are within the expected measure of error, stop the
training procedure. Otherwise, continue the training
procedure. The error between the actual and expected output
for pattern k and all patterns is determined using equations (6)
and (7).
(6)
E k = (Yk d k ) 2
E=

1 N
(Yk d k ) 2
2 k =1

III. STRATEGY OF ADJUSTING THE MODEL OF NEURAL

NETWORK FOR PROPYLENE DISTILLATION

Because the operation parameters, such as the feed amount,

the operation temperature, and the reflux rate of the propylene,
always vary, the production of propylene distillation is a
dynamic process. The model of neural network of propylene
distillation should therefore be adjusted. The fluctuation of
the production process of propylene distillation results in the
increment of the number of patterns. The strategy of adjusting
the model of neural network for propylene distillation is
proposed in this paper based on analyzing the incremental
patterns with rough sets.
If the incremental patterns of propylene distillation dont
describe the new production process, it is not necessary to
adjust the model of neural network. Otherwise, the model of
neural network of propylene distillation should be adjusted. It
is important to adjust the model proposed in this paper by
determining whether the incremental patterns describe the
new production process of propylene distillation.
Rough sets were developed by Zdzislaw Pawlak based on
analyzing the logical character of an information system [12].
It needs no extra information for rough sets to reduce the
attribute values of data. The data can be condensed by rough
sets without changing the original character of data. Rough
sets are applied to reduce the attribute values of the patterns
as well as the incremental patterns of propylene distillation.
The patterns and the incremental patterns of propylene
distillation are employed in a decision table of continuous
values. The input vectors that include the feed amount x1, the
operation pressure x2, the operation temperature x3, the
position of propylene at the bottom of tower x4, and reflux
rates of crude and pure propylene x5 and x6 of the patterns are
treated as condition attributes in the decision table. The
output vectors that include the purity of crude propylene y1,
the purity of pure propylene y2, and the purity of propane y3 of
the patterns are treated as decision attributes. The structure of
the decision table in the strategy of adjusting the model of
neural network is shown in Table I.

(7)
TABLE I THE STRUCTURE OF THE DECISION TABLE

where E is the difference between the actual and expected

output for all patterns and N is the total number of patterns.
5) Adjust the weights of neural network
In the training procedure, the weights of neural network
are adjusted using equation (8).
Wij (n+1) = W ij (n) + E/ Wij

where n is the number of iteration in the training procedure.

The adjustment of weights is continued until the expected
measure of error is obtained. The weights distributed between
neurons in the different layers describe the mapping
relationship embodied in the patterns. Hence the neural
network-based model that describes the production process of
propylene distillation can be obtained.

(8)

Items
Condition attributes:
Decision attributes:

Contents
x1, x2 , x3, x4, x5 and x6
y1 , y2 and y3

The attribute values of patterns and the incremental

patterns of propylene distillation are reduced with rough sets
in the strategy. If the incremental patterns in the decision table

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of propylene distillation are completely reduced with rough

sets, the model of neural network of propylene distillation
should not be adjusted. Otherwise, it is necessary to adjust the
model of neural network of propylene distillation. The
adjustable model of neural network can be constructed with
training patterns and incremental patterns. The procedure of
constructing the adjustable model is similar to those steps
described in Section II. If the incremental patterns in the
decision table of propylene distillation are partially reduced
with rough sets, it will then be determined whether the model
of neural network of propylene distillation should be adjusted
by using the percentage of the number of reduced patterns.
An algorithm of discriminating the matrix in rough sets is
applied to reduce the decision table in the proposed strategy.
The K-Means algorithm is adopted to make the attribute
values discrete before reducing the data. The algorithms of
discriminating the matrix and K-Means used in the proposed
strategy are described in [13].

layer is chosen for the model of propylene distillation, and the

fourteen neurons are used in the numerical example. After
3200 iterations of the training procedure, the model of neural
network that describes the relationship between output
vectors and input vectors shown in Table II is constructed.
In order to validate the model of neural network of
propylene distillation, the model constructed with neural
network is used to predict the purity of crude and pure
propylene y1 and y2 and the purity of propane y3 , which is not
included in the patterns for constructing the model of neural
networks. The comparisons between the predicted results and
the actual results are shown in Figs. 2-4. In these figures, the
purity of crude or pure propylene or propane is indicated by
the vertical axis. The horizontal axis represents the time of
thirty days (one month).

IV. A NUMERICAL EXAMPLE

The practical data of propylene distillation from a chemical
company is used to provide a numerical example in this paper.
The model of neural network for the actual propylene
distillation is constructed, and the comparison is made
between the results predicted from the model of neural
network and the actual results. The partial patterns of
propylene distillation from the chemical company are shown
in Table II.
In Table II, all variables represent the same parameters as
described in Section III. The unit of x1, x5, and x6 is t/h. The
unit of x2 is MPa. The unit of x3 is C. The unit of all other
variables is %.

Fig. 2. Comparison of the purity of crude propylene

(Curves with symbols and describe actual and predicted data,
respectively)

TABLE II PARTIAL PATTERNS OF PROPYLENE DISTILLATION

No. x1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18

9.9
10.0
7.7
8.8
9.9
8.8
6.6
7.7
7.7
5.5
6.0
6.6
7.7
7.7
5.5
8.8
9.9
10.0

x2
1.8
1.8
1.8
1.8
1.8
1.8
1.8
1.8
1.8
1.8
1.8
1.8
1.8
1.8
1.8
1.8
1.8
1.8

x3
57
57
54
54
54
55
55
51
53
53
53
51
51
53
56
52
56
56

x4

x5

x6

80
80
80
80
80
80
80
80
80
80
80
80
80
80
80
80
80
80

120
120
120
120
120
120
120
120
120
120
110
110
110
110
110
110
120
126

85
85
85
85
85
85
85
85
85
85
85
85
85
85
85
85
107
107

y1

y2

93.1
92.5
94.5
90.9
94.0
91.3
93.4
95.2
93.5
97.4
93.8
94.8
94.4
94.0
94.3
91.9
92.6
90.7

99.75
99.70
99.75
99.83
99.82
99.76
99.97
99.96
99.95
99.98
99.97
99.90
99.98
99.97
99.94
99.95
99.48
98.79

Fig. 3. Comparison of the purity of pure propylene

(Curves with symbols and describe actual and predicted data,
respectively)

y3
92.9
91.3
97.3
94.6
92.5
98.7
98.4
97.9
97.2
98.3
95.8
97.2
96.9
95.5
97.2
91.8
97.0
98.9

Fig. 4. Comparison of the purity of propane

(Curves with symbols and describe actual and predicted data,
respectively)

A computer software package of neural network is

developed with C language, and is used to train the patterns of
propylene distillation in the numerical example. One hidden

Fig. 2 shows the comparison between the predicted results

and the actual results of the purity of crude propylene. Fig. 3
shows the comparison between the predicted results and the
actual results of the purity of pure propylene. Fig. 4 shows the
comparison between the predicted results and the actual
results of the purity of propane. From these figures, the
results predicted from the model of neural network are in

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good agreement with the actual results of the purity of crude

and pure propylene as well as the actual results of the purity
of propane.
V.

CONCLUSION

The model of propylene distillation is important for

improving the quality of propylene products. The neural
networks are applied to construct the model of propylene
distillation in this paper. The methodology of constructing the
model of propylene distillation based on the neural networks
is also discussed. The strategy of adjusting the neural
networks-based model of propylene distillation with rough
sets is proposed. A numerical example for the actual
propylene distillation is demonstrated. A comparison is made
between the predicted results from the model and the actual
results, which validates the effectiveness of the model of
propylene distillation.
ACKNOWLEDGMENT
Jingui Lu would like to thank Prof. Zhao and Prof. Zhang
of Nanjing University of Technology, Nanjing 210009,
Jiangsu Province, P. R. China, for their valuable suggestions
on this research work.
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