Development of an ANFIS-Based Intelligent Control System for Free Chlorine Removal from Industrial Wastewater Using Ion-Exchange Resin
Аннотация
The removal of residual free chlorine ions from industrial wastewater is a critical step toward achieving sustainable and environmentally compliant water reuse. Excess chlorine in sludge collector water causes corrosion of process equipment, inhibits biological treatment, and leads to toxic discharge effects. In this study, an intelligent control strategy was developed for an ion-exchange-based dechlorination process to dynamically regulate chlorine concentration in the effluent stream. A pilot-scale ion-exchange filtration unit, designed with a nominal capacity of 500 L h−1, was constructed using a strong-base anion-exchange resin to selectively adsorb chloride and free chlorine ions. A total of 200 experimental observations were obtained to characterize the nonlinear relationship between inlet flow rate and outlet chlorine concentration under varying operational conditions. Based on these experimental data, an Adaptive Neuro-Fuzzy Inference System (ANFIS) model was developed in MATLABR2025 to simulate and control the ion-exchange process. Two model-optimization techniques, Grid Partition + Hybrid and Subtractive Clustering + Hybrid, were applied. The subtractive clustering approach demonstrated faster convergence and superior accuracy, achieving RMSE = 0.147 mg L−1, MAE = 0.101 mg L−1, and R2 = 0.993, outperforming the grid-partition model (RMSE ≈ 0.29, R2 ≈ 0.97). The resulting ANFIS model was subsequently integrated into a MATLAB/Simulink-based intelligent control system for real-time regulation of chlorine concentration. A comparative dynamic simulation was performed between the proposed ANFIS controller and a conventional PID (Proportional-Differential-Integral) controller. The results revealed that the ANFIS controller achieved a faster response (rise time ≈ 28 s), lower overshoot (≈6%), and shorter settling time (≈90 s) compared to the PID controller (rise time ≈ 35 s, overshoot ≈ 18%, settling time ≈ 120 s). These improvements demonstrate the ability of the proposed model to adapt to nonlinear process behavior and to maintain stable operation under varying flow conditions.