Research on multi-objective optimization of bioreactor cupped impeller CFD based on improved proxy model

IF 5.1 3区工程技术 Q2 ENERGY & FUELS

Thermal Science and Engineering Progress Pub Date : 2025-03-14 DOI:10.1016/j.tsep.2025.103508

Quan Shi , Xiaoliang Xu , Huafeng Deng , Jianlin Li , Qinghai Zhang

{"title":"Research on multi-objective optimization of bioreactor cupped impeller CFD based on improved proxy model","authors":"Quan Shi , Xiaoliang Xu , Huafeng Deng , Jianlin Li , Qinghai Zhang","doi":"10.1016/j.tsep.2025.103508","DOIUrl":null,"url":null,"abstract":"<div><div>Bioreactors are widely used to liquid–liquid mixing in the chemical and biological fields. As a core component for enhancing the mixing efficiency of bioreactors, the structural optimization of the impeller is crucial. The study aims to analyze the impact of bioreactor cupped impeller structures on performance and to optimize the structure using an improved surrogate model. Firstly, a complete Computational Fluid Dynamics (CFD) and Fluid-Structure Interaction (FSI) simulation model is established, and its applicability is verified using the component transfer method (with the maximum relative error between simulation and experiment being 4.5 % and the minimum 0.01 %). Consideration of impeller structural variables(<em>X, k, i,M</em>), the influence of impeller structure on mixing and mechanical performance was explored. Secondly, sensitivity analysis is innovatively introduced to improve proxy model, solving the problem of excessive training sample size. Then, the mapping relationship between impeller structure parameters and performance was established, and the key parameters were optimized by genetic algorithm. The optimized impeller configuration ranged: <em>X</em> as one, <em>M</em> approximately between 160 mm and 165 mm, and angle <em>β</em> around 6° or 35°. Concurrently, compared with the optimal solution of the range analysis, the optimization effect of the improved surrogate model on the turbulent flow energy of the impeller is increased by 45.63 %, and the maximum equivalent stress is reduced by 48.67 %. Considering different manufacturing requirements, application scenarios, and material selections, this study also provides corresponding theoretical and practical recommendations.</div></div>","PeriodicalId":23062,"journal":{"name":"Thermal Science and Engineering Progress","volume":"61 ","pages":"Article 103508"},"PeriodicalIF":5.1000,"publicationDate":"2025-03-14","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":"0","resultStr":null,"platform":"Semanticscholar","paperid":null,"PeriodicalName":"Thermal Science and Engineering Progress","FirstCategoryId":"5","ListUrlMain":"https://www.sciencedirect.com/science/article/pii/S2451904925002987","RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":null,"EPubDate":"","PubModel":"","JCR":"Q2","JCRName":"ENERGY & FUELS","Score":null,"Total":0}

引用次数: 0

Abstract

Bioreactors are widely used to liquid–liquid mixing in the chemical and biological fields. As a core component for enhancing the mixing efficiency of bioreactors, the structural optimization of the impeller is crucial. The study aims to analyze the impact of bioreactor cupped impeller structures on performance and to optimize the structure using an improved surrogate model. Firstly, a complete Computational Fluid Dynamics (CFD) and Fluid-Structure Interaction (FSI) simulation model is established, and its applicability is verified using the component transfer method (with the maximum relative error between simulation and experiment being 4.5 % and the minimum 0.01 %). Consideration of impeller structural variables(X, k, i,M), the influence of impeller structure on mixing and mechanical performance was explored. Secondly, sensitivity analysis is innovatively introduced to improve proxy model, solving the problem of excessive training sample size. Then, the mapping relationship between impeller structure parameters and performance was established, and the key parameters were optimized by genetic algorithm. The optimized impeller configuration ranged: X as one, M approximately between 160 mm and 165 mm, and angle β around 6° or 35°. Concurrently, compared with the optimal solution of the range analysis, the optimization effect of the improved surrogate model on the turbulent flow energy of the impeller is increased by 45.63 %, and the maximum equivalent stress is reduced by 48.67 %. Considering different manufacturing requirements, application scenarios, and material selections, this study also provides corresponding theoretical and practical recommendations.

Abstract Image

查看原文本刊更多论文

求助全文

约1分钟内获得全文求助全文

来源期刊

Thermal Science and Engineering Progress Chemical Engineering-Fluid Flow and Transfer Processes

CiteScore

7.20

自引率

10.40%

发文量

327

审稿时长

41 days

期刊介绍： Thermal Science and Engineering Progress (TSEP) publishes original, high-quality research articles that span activities ranging from fundamental scientific research and discussion of the more controversial thermodynamic theories, to developments in thermal engineering that are in many instances examples of the way scientists and engineers are addressing the challenges facing a growing population – smart cities and global warming – maximising thermodynamic efficiencies and minimising all heat losses. It is intended that these will be of current relevance and interest to industry, academia and other practitioners. It is evident that many specialised journals in thermal and, to some extent, in fluid disciplines tend to focus on topics that can be classified as fundamental in nature, or are ‘applied’ and near-market. Thermal Science and Engineering Progress will bridge the gap between these two areas, allowing authors to make an easy choice, should they or a journal editor feel that their papers are ‘out of scope’ when considering other journals. The range of topics covered by Thermal Science and Engineering Progress addresses the rapid rate of development being made in thermal transfer processes as they affect traditional fields, and important growth in the topical research areas of aerospace, thermal biological and medical systems, electronics and nano-technologies, renewable energy systems, food production (including agriculture), and the need to minimise man-made thermal impacts on climate change. Review articles on appropriate topics for TSEP are encouraged, although until TSEP is fully established, these will be limited in number. Before submitting such articles, please contact one of the Editors, or a member of the Editorial Advisory Board with an outline of your proposal and your expertise in the area of your review.