Machine-Learning-Based Reduced Order Modeling for Operational Analysis of Industrial Glass Melting Furnaces Using CFD Solutions

Yıl 2025, Cilt: 45 Sayı: 1, 56 - 68, 07.04.2025

Engin Deniz Canbaz , Mesut Gür

https://doi.org/10.47480/isibted.1512812

Öz

Computational Fluid Dynamics (CFD) models play a vital role in the design of industrial glass melting furnaces, offering insights into energy consumption, glass quality, temperature distribution, and refractory wear. However, the considerable computational expense associated with the large time and length scales involved in the glass melting process prevents practical utilization of those models in daily operation of the furnaces. This study presents a novel approach to address this challenge through the development of a machine-learning-based Reduced-Order Model (ROM) utilizing parametric data obtained from a CFD model of a glass melting tank of a furnace. Key operational parameters, namely pull rate, heat flux from combustion space, and electrical potential difference to supply electrical power, are chosen to create a CFD solution dataset, as they change the boundary conditions of the CFD model and, consequently, the field solution data. An autoencoder structure incorporating convolutional neural networks is established to learn and predict temperature and velocity field data. Then, the decoder section of the autoencoder is connected to the operational parameters through an auxiliary neural network. The performance of the reduced-order model is assessed for both interpolation and extrapolation using additional CFD solutions. Comparison between the field data generated by the ROM and the ground-truth CFD solutions indicates less than 1\% deviation, proving that the ROM’s capability to serve as an effective analysis tool for daily furnace operation. Furthermore, the ROM demonstrates significant advancements in solution time, up to third order, further enhancing its practical utility.

Anahtar Kelimeler

Glass Melting Furnaces, Computational Fluid Dynamics, Machine Learning, Reduced Order Model, Autoencoders

HAD Çözümlerini Kullanarak Endüstriyel Cam Ergitme Fırınlarının İşletme Analizi için Makine Öğrenimi Tabanlı İndirgenmiş Model Geliştirilmesi

Öz

Endüstriyel cam ergitme fırınları için enerji tüketimi, cam kalitesi, sıcaklık dağılımı ve refrakter aşınması hakkında bilgiler sunan hesaplamalı akışkanlar dinamiği (HAD) modelleri, fırınların tasarımında kritik öneme sahiptir. Ancak, cam ergitme prosesinde geniş bir aralığa sahip olan zaman ve uzunluk boyutlarına bağlı olarak ortaya çıkan yüksek hesaplama maliyeti, bu modellerin fırınların günlük operasyonlarında doğrudan kullanılmasını engellemektedir. Bu zorluğu aşabilmek için bu çalışma, bir cam ergitme fırınının cam banyosu HAD modelinden elde edilen parametrik sonuçları kullanarak, makine öğrenimi tabanlı bir indirgenmiş model geliştirilmesi yoluyla yeni bir yaklaşım sunmaktadır. HAD modelinin de sınır koşullarına etki ederek çözüm sonucunu değiştiren çekiş hızı (cam debisi), doğal gaz kaynaklı ısı akısı ve elektrik potansiyel fark, işletme parametreleri olarak seçilerek HAD çözümü bir veri seti oluşturulmuştur. HAD çıktısı sıcaklık ve hız alanı verilerini öğrenmek ve tahmin etmek için konvolüsyonel nöral ağları içeren bir otokodlayıcı yapı oluşturulmuştur. Sonrasında, otokodlayıcının boyutsal yükseltme yapan bölümü, ek bir tam bağlantılı nöral ağ aracılığıyla, işletme parametreleri olan sınır koşullarıyla ilişkilendirilmiştir. İndirgenmiş modelin performansı, ek HAD çözümleri kullanılarak hem interpolasyon hem de ekstrapolasyon için değerlendirilmiştir. İndirgenmiş model tarafından üretilen sonuçlar ile gerçek HAD çözümleri arasındaki karşılaştırma, %1'den az sapma olduğunu göstermekte ve indirgenmiş modelin günlük fırın operasyonları için etkili bir analiz aracı olarak hizmet etme kabiliyetini kanıtlamaktadır. Ayrıca, indirgenmiş model çözüm süresinde de üçüncü mertebeye kadar hızlanma sağlamaktadır. Bu hızlanma fırın işletmesi açıdan geliştirilen yaklaşımın oldukça fayda sağlayacağını göstermektedir.

Anahtar Kelimeler

Cam Ergitme Fırınları, Hesaplamalı Akışkanlar Dinamiği, Makine Öğrenimi, İndirgenmiş Model, Otokodlayıcı

Kaynakça

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