chemical plant operators

Abstract: Optimizing industrial process flowsheets is often computationally prohibitive due to the high cost of rigorous simulations and the curse of dimensionality inherent in complex design spaces. To address these challenges, we present a reduced-space multi-fidelity Bayesian optimization (RS-MFBO) framework designed for high-dimensional, expensive black-box functions. The approach integrates Global Sensitivity Analysis (GSA) for dimensionality reduction with a fidelity-augmented Gaussian process that captures correlations between low-cost approximations and expensive high-fidelity evaluations. A cost-aware acquisition strategy, augmented with cooldown and promotion mechanisms, adaptively guides the allocation of samples across fidelities. The framework is validated on two distinct industrial process simulators: a plasmid DNA bioprocess in SuperPro Designer and a green fuel synthesis plant in Aspen HYSYS. Results across diverse economic and physical objectives demonstrate that the proposed method substantially reduces the number of high-fidelity simulator evaluations while maintaining competitive optimization performance compared to single-fidelity baselines. These results highlight RS-MFBO as a scalable, simulator-agnostic approach for cost-constrained black-box optimization.

Abstract: Void fraction, which quantifies the proportion of the fluid flow volume occupied by the gas phase, is a key parameter in the characterization of gas-liquid two-phase flow. Existing estimation methods either rely on flow assumptions that do not generalize across different fluids or on intrusive sensing that disturbs the flow behavior. We propose VFNet, a dual-branch spatio-temporal neural network for void-fraction prediction from synchronized multi-view videos of two-phase flow. A local branch extracts features from confined spatial regions and fuses the synchronized dual views, while a spatio-temporal branch captures the global evolution of the flow across space and time to refine a coarse geometric estimate. Trained on simulated computational fluid dynamics (CFD) data with known ground-truth void fractions and evaluated against both learning-based and traditional baselines, VFNet achieves the best performance across a broad range of metrics and also improves downstream flow-pattern classification on real two-phase flow data.