Journal of Quality Engineering and Production Optimization

Journal of Quality Engineering and Production Optimization

Optimization of Feedstock Blending in High-Density Polyethylene Production Using an Improved Genetic Algorithm Based on Reinforcement Learning and Machine Learning Models

Document Type : Research Paper

Authors
Department of Industrial Engineering, QA.C., Islamic Azad University, Qazvin, Iran
Abstract
The polyethylene industry faces persistent challenges in optimizing feedstock and energy consumption due to the highly nonlinear, non-closed-form behavior of polymerization reactors, which renders classical gradient-based methods ineffective and trial-and-error approaches costly. Although machine learning and metaheuristic algorithms have been explored, existing solutions suffer from three major limitations: inability to generate novel feedstock blends beyond training data, lack of dynamic parameter adaptation, and absence of closed-loop feedback between prediction and optimization. To address these gaps, this study proposes a hybrid framework that synergistically integrates a Genetic Algorithm (GA), a Reinforcement Learning (RL) agent, and a Gradient Boosting Machine (GBM). In this framework, the GA generates candidate feedstock combinations, the GBM—trained on 360 daily industrial records—predicts polyethylene and wax yields with 99.9% accuracy, and a Q-learning-based RL agent dynamically tunes three critical GA parameters based on real-time performance feedback, ensuring adaptive exploration and preventing premature convergence. Applied to actual data from a high-density polyethylene (HDPE) plant, the proposed framework increased average daily polyethylene output from 950 to 1,018 tons (a 7.16% improvement) and reduced daily wax generation from 12 to 7 tons (a 41.66% reduction). Statistical analysis across 30 independent runs, verified by the Wilcoxon signed-rank test (p < 0.05), confirms that these improvements are significant and consistently outperform five well-known metaheuristic algorithms (GA, PSO, GWO, DE, and ABC). The proposed RL-GA-GBM framework provides a robust, generalizable, and computationally efficient decision-support tool for petrochemical process optimization, effectively bridging the gap between theoretical research and industrial deployment.
Keywords


Articles in Press, Accepted Manuscript
Available Online from 15 July 2026