Indra Jungjohann

Jennifer Werner, Justus Arweiler, Indra Jungjohann et al.

Anomaly detection (AD) in chemical processes based on deep learning offers significant opportunities but requires large, diverse, and well-annotated training datasets that are rarely available from industrial operations. In a recent work, we introduced a large, fully annotated experimental dataset for batch distillation under normal and anomalous operating conditions. In the present study, we augment this dataset with a corresponding simulation dataset, creating a novel hybrid dataset. The simulation data is generated in an automated workflow with a novel Python-based process simulator that employs a tailored index-reduction strategy for the underlying differential-algebraic equations. Leveraging the rich metadata and structured anomaly annotations of the experimental database, experimental records are automatically translated into simulation scenarios. After calibration to a single reference experiment, the dynamics of the other experiments are well predicted. This enabled the fully automated, consistent generation of time-series data for a large number of experimental runs, covering both normal operation and a wide range of actuator- and control-related anomalies. The resulting hybrid dataset is released openly. From a process simulation perspective, this work demonstrates the automated, consistent simulation of large-scale experimental campaigns, using batch distillation as an example. From a data-driven AD perspective, the hybrid dataset provides a unique basis for simulation-to-experiment style transfer, the generation of pseudo-experimental data, and future research on deep AD methods in chemical process monitoring.

Justus Arweiler, Indra Jungjohann, Aparna Muraleedharan et al.

Machine learning (ML) holds great potential to advance anomaly detection (AD) in chemical processes. However, the development of ML-based methods is hindered by the lack of openly available experimental data. To address this gap, we have set up a laboratory-scale batch distillation plant and operated it to generate an extensive experimental database, covering fault-free experiments and experiments in which anomalies were intentionally induced, for training advanced ML-based AD methods. In total, 119 experiments were conducted across a wide range of operating conditions and mixtures. Most experiments containing anomalies were paired with a corresponding fault-free one. The database that we provide here includes time-series data from numerous sensors and actuators, along with estimates of measurement uncertainty. In addition, unconventional data sources -- such as concentration profiles obtained via online benchtop NMR spectroscopy and video and audio recordings -- are provided. Extensive metadata and expert annotations of all experiments are included. The anomaly annotations are based on an ontology developed in this work. The data are organized in a structured database and made freely available via doi.org/10.5281/zenodo.17395544. This new database paves the way for the development of advanced ML-based AD methods. As it includes information on the causes of anomalies, it further enables the development of interpretable and explainable ML approaches, as well as methods for anomaly mitigation.

Dennis Wagner, Arjun Nair, Billy Joe Franks et al.

Undetected anomalies in time series can trigger catastrophic failures in safety-critical systems, such as chemical plant explosions or power grid outages. Although many detection methods have been proposed, their performance remains unclear because current metrics capture only narrow aspects of the task and often yield misleading results. We address this issue by introducing verifiable properties that formalize essential requirements for evaluating time-series anomaly detection. These properties enable a theoretical framework that supports principled evaluations and reliable comparisons. Analyzing 37 widely used metrics, we show that most satisfy only a few properties, and none satisfy all, explaining persistent inconsistencies in prior results. To close this gap, we propose LARM, a flexible metric that provably satisfies all properties, and extend it to ALARM, an advanced variant meeting stricter requirements.