Hierarchical framework for predictive maintenance of coking risk in fluid catalytic cracking units: A data and knowledge-driven method
Full Length Article|Updated:2026-03-26
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Hierarchical framework for predictive maintenance of coking risk in fluid catalytic cracking units: A data and knowledge-driven method
Chinese Journal of Chemical EngineeringVol. 84, Issue 8, Pages: 35-46(2025)
Affiliations:
1. State Key Laboratory of Heavy Oil Processing, China University of Petroleum (Beijing),Beijing,China,102249
2. College of Artificial Intelligence, China University of Petroleum (Beijing),Beijing,China,102249
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Published:2025
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Nan Liu, Chunmeng Zhu, Zeng Li, Yunpeng Zhao, Xiaogang Shi, Xingying Lan. Hierarchical framework for predictive maintenance of coking risk in fluid catalytic cracking units: A data and knowledge-driven method[J]. Chinese Journal of Chemical Engineering, 2025, 84(8): 35-46.
DOI:
Nan Liu, Chunmeng Zhu, Zeng Li, Yunpeng Zhao, Xiaogang Shi, Xingying Lan. Hierarchical framework for predictive maintenance of coking risk in fluid catalytic cracking units: A data and knowledge-driven method[J]. Chinese Journal of Chemical Engineering, 2025, 84(8): 35-46.DOI:
Hierarchical framework for predictive maintenance of coking risk in fluid catalytic cracking units: A data and knowledge-driven method
The fractionating tower bottom in fluid catalytic cracking Unit (FCCU) is highly susceptible to coking due to the interplay of complex external operating conditions and internal physical properties. Consequently
quantitative risk assessment (QRA) and predictive maintenance (PdM) are essential to effectively manage coking risks influenced by multiple factors. However
the inherent uncertainties of the coking process
combined with the mixed-frequency nature of distributed control systems (DCS) and laboratory information management systems (LIMS) data
present significant challenges for the application of data-driven methods and their practical implementation in industrial environments. This study proposes a hierarchical framework that integrates deep learning and fuzzy logic inference
leveraging data and domain knowledge to monitor the coking condition and inform prescriptive maintenance planning. The framework proposes the multi-layer fuzzy inference system to construct the coking risk index
utilizes multi-label methods to select the optimal feature dataset across the reactor-regenerator and fractionation system using coking risk factors as label space
and designs the parallel encoder-integrated decoder architecture to address mixed-frequency data disparities and enhance adaptation capabilities through extracting the operation state and physical properties information. Additionally
triple attention mechanisms
whether in parallel or temporal modules
adaptively aggregate input information and enhance intrinsic interpretability to support the disposal decision-making. Applied in the 2.8 million tons FCCU under long-period complex operating conditions
enabling precise coking risk management at the fractionating tower bottom.
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