Automatic measurement of slug flow processes from in‐line videos

Slug flow processes draw much attention in chemical and pharmaceutical manufacturing thanks to their ability to eliminate downtime costs and batch‐to‐batch variation. Using in‐line video can monitor the current process status and improve the stability of the slug flow. However, there are no effective image processing methods aiming at such videos from chemical experiments due to limited training sample size and the variety of experimental settings. The paper proposes a training‐free method to automatically detect and measure the slugs from in‐line videos. Multiple image features are fused to identify the slug shapes under various lighting conditions, a six‐point model is fitted to achieve better volume estimation, and a consistency score is estimated to quantify the detection uncertainty. The proposed algorithm achieves similar results to manual labeling for various types of slug flow processes, improving the accuracy of slug column estimation by a large margin compared to the existing automatic methods. Finally, using it to monitor the slug flow process's stability and the change of the slug volume in an injection point are demonstrated. The method not only shows that handcrafted image features have the capability for detection and segmentation from chemical experiment images but also paves the road for a training‐based algorithm for the task. In this paper, we propose a training‐free machine vision method to automatically detect and measure the slugs using inline videos for slug flow processes , which draws much attention in chemical and pharmaceutical manufacturing. By fusing multiple features and considering location/shape priors, the proposed method handles various experiment settings and outperforms the existing algorithms by a large margin. We also provide a consistency score to quantify detection uncertainty.