HARPPP: Autonomous Geometric Design Optimisation of Stirred Tank Reactor Impellers and Baffles
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arXiv
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| Format: | Preprint |
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2025
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| author | Nicusan, A. Leonard Gobby, Darren Windows-Yule, Kit |
| author_facet | Nicusan, A. Leonard Gobby, Darren Windows-Yule, Kit |
| contents | Designing and optimising the geometry of industrial process equipment remains slow and still largely ad hoc: engineers make small tweaks to one standard shape at a time, build prototypes, and hope for gains. We introduce HARPPP, an autonomous design loop that couples a compact, programmable geometry model to power-controlled CFD and evolutionary search. The geometry model is a single mathematical description that reproduces every standard impeller as a special case while spanning an unlimited set of manufacturable shapes. Working with Johnson Matthey on an industrial vessel, HARPPP explored a 23-parameter impeller-baffle space at constant power (3024 W), executing 3,000 simulation cycles in 15 days. The search uncovered multiple design families that outperform a Rushton/4-baffle baseline in both mixing intensity and uniformity, including twisted-plate impellers and pitched/curved baffles (intensity +18 to +78 percent; uniformity CoV -16 to -64 percent). A clear intensity-uniformity Pareto frontier emerged, enabling application-specific choices. Because HARPPP treats the simulator as the objective, it generalises to other equipment wherever credible physics models exist. |
| format | Preprint |
| id |
arxiv_https___arxiv_org_abs_2510_19004 |
| institution | arXiv |
| publishDate | 2025 |
| record_format | arxiv |
| spellingShingle | HARPPP: Autonomous Geometric Design Optimisation of Stirred Tank Reactor Impellers and Baffles Nicusan, A. Leonard Gobby, Darren Windows-Yule, Kit Fluid Dynamics Computational Physics 65M08, 65N08, 76D05, 76M12, 65K05, 90C59, 90C30, 65Y05, 68W10, 68U07 I.6.3; I.6.5; J.2; G.1.6; I.2.8; D.1.3 Designing and optimising the geometry of industrial process equipment remains slow and still largely ad hoc: engineers make small tweaks to one standard shape at a time, build prototypes, and hope for gains. We introduce HARPPP, an autonomous design loop that couples a compact, programmable geometry model to power-controlled CFD and evolutionary search. The geometry model is a single mathematical description that reproduces every standard impeller as a special case while spanning an unlimited set of manufacturable shapes. Working with Johnson Matthey on an industrial vessel, HARPPP explored a 23-parameter impeller-baffle space at constant power (3024 W), executing 3,000 simulation cycles in 15 days. The search uncovered multiple design families that outperform a Rushton/4-baffle baseline in both mixing intensity and uniformity, including twisted-plate impellers and pitched/curved baffles (intensity +18 to +78 percent; uniformity CoV -16 to -64 percent). A clear intensity-uniformity Pareto frontier emerged, enabling application-specific choices. Because HARPPP treats the simulator as the objective, it generalises to other equipment wherever credible physics models exist. |
| title | HARPPP: Autonomous Geometric Design Optimisation of Stirred Tank Reactor Impellers and Baffles |
| topic | Fluid Dynamics Computational Physics 65M08, 65N08, 76D05, 76M12, 65K05, 90C59, 90C30, 65Y05, 68W10, 68U07 I.6.3; I.6.5; J.2; G.1.6; I.2.8; D.1.3 |
| url | https://arxiv.org/abs/2510.19004 |