Experimental Response Surface Research Articles

Optimum carbonization of Kevlar fabric for electromagnetic interference shielding applications

The study involved single-stage carbonization and physical activation of Kevlar woven fabric to convert into activated carbon fabric. The carbonization process was optimised for high carbon yield and low electrical resistivity of activated carbon fabric using Box-Behnken experimental design and response surface methodology. The three process parameters namely charcoal amount, gas flow rate, and carbonization temperature were selected. The empirical equations obtained through response surface methodology for carbon yield and electrical resistivity were found in good agreement with the experimental values. An optimum amount of charcoal, optimum nitrogen flowrate, and low carbonization temperature was found suitable for higher carbon yield. On the other hand, high charcoal amount, high carbonization temperature, and optimum nitrogen flow rate resulted in low electrical resistivity of activated carbon fabric. Later, the activated carbon fabrics were prepared under the optimum carbonization conditions to get high carbon yield and low electrical resistivity. The optimized sample for electrical resistivity showed higher electromagnetic interference (EMI) shielding properties at lower as well as higher frequencies due to its highly porous morphology and electrical conductivity.

Highly sensitive and selective electrochemical sensor for simultaneous determination of gallic acid, theophylline and caffeine using poly(l-proline) decorated carbon nanotubes in biological and food samples

In this work, a novel, simple and reproducible poly(l-proline)/functionalized multi-walled carbon nanotube composite on glassy carbon electrode (poly(PRO)-MWCNTs/GCE) was developed as an electrochemical sensor for the simultaneous determination of gallic acid (GA), theophylline (TP) and caffeine (CAF) by differential pulse voltammetry (DPV).The sensing platform was optimized by experimental design and response surface methodology, using various factors affecting polymerization and detection, such as electropolymerization time and potential, and pH, respectively. As a result, the dispersion conditions were the mixing of 1.78 mg MWCNTs with 1.00 mL l-proline solution to 4.14 mg mL−1 (in SDBS 0.5%), followed by 21 min of sonication with electropolymerization by 16 cyclic scans. In addition, the final analysis was performed at a pH of 3.00 and prior accumulation at 0.350 V for 40 s.The electrochemical behavior of GA, TP and CAF on the optimized sensor was investigated. As a result, the electrode preserves and synergistically combines the properties of each modifier. This new electrochemical sensor showed superior electrocatalytic properties for the oxidation of GA, TP and CAF, which significantly improved the sensitivity of the three compounds.Under the optimized experimental conditions, the detection limits achieved by S/N were 0.03, 0.04 and 0.11 μmol L−1 for GA, TP and CAF, respectively. The analysis of real samples was successfully performed in human breast milk, tea, infusion of yerba mate, coffee, Coca-Cola zero and energy drink, showing good recoveries, ranged between 87 and 108%. The proposed sensor also showed good selectivity, repeatability and reproducibility, indicating feasibility and reliability.This is the first time that the l-proline monomer is used as a dispersant for MWCNTs and as a precursor for the in-situ polymerization of the proline polymer. Previously, the electropolymerizations were carried out with the monomer in solution rather than as an exfoliant of MWCNTs, where the polymer is electrosynthesized between MWCNTs rather than on them. In this way, the large specific surface area and strong adsorption ability of the nanomaterial are enhanced, and the ability to promote electron transfer reaction is increased, which provides enough effective reaction sites.

Research on a new-designed Venturi ejector and dazomet particle motion characteristics for dilute-phase pneumatic conveying systems based on CFD-DEM

To disperse dazomet, a commonly used soil fumigant for soil disinfection, over large soil surfaces, dilute-phase pneumatic conveying can be utilized. Currently, most research has focused on pneumatic conveying systems for large particles, such as coal conveying or pneumatic seeding However, there has been almost no research on the dilute-phase pneumatic conveying of dazomet particles. Therefore, a coupled simulation model based on computational fluid dynamics and discrete element method (CFD-DEM) was established to study the effect of the structural parameters of the Venturi ejector on the motion of particles and airflow fields variation characteristics for the pneumatic conveying system of dazomet particles. Based on the Box–Behnken experimental design method, a 3-factor and 3-level response surface simulation experiment was carried out by selecting the contraction angle, throat diameter, and diffusion angle of the Venturi ejector as factors. The suction-flow ratio, average velocity of particles, average coordinates of particles in the vertical direction, and corresponding standard deviation at the outlet of the pipeline were chosen as response indexes. Multiple linear regression models were established between each factor and response index. The simulation results showed that the impact of factors on the 4 response indexes from strong to weak were throat diameter, contraction angle, and diffusion angle. With decreasing throat diameter, the suction flow ratio and average velocity of the particles increased. The average coordinates of the particles in the vertical direction decreased, while the standard deviation increased, indicating that the pneumatic conveying performance of the system increased. The optimal structural parameters for the contraction angle, throat diameter, and diffusion angle were 34.5°, 15 mm, and 12.0°, respectively. The experimental results demonstrated that the application precisions of the optimised Venturi ejector were 99.23%, 98.46%, and 98.56% at application rates of 15, 20, and 25 g/s, respectively. The results provide a theoretical reference for the structural optimisation of the Venturi ejector and operational performance evaluation of the pneumatic conveying system for dazomet particles.

Experimental analysis and response surface optimization of the influence of Zn/Al mass ratio on the creep resistance and tensile properties of As-cast Mg-Zn-Al alloy

Mg-Zn-Al (ZA) alloys are intended to exhibit creep resistance and high temperature mechanical capabilities due to appropriate Zn/Al mass ratio control. The effect of altering Al concentration (1, 2, 3, 4, 5, 6) on the tensile and creep resistance properties of Mg-9Zn-xAl alloy was determined experimentally and quantitatively optimized using response surface method (RSM). It was observed that 2 wt% Al improves both room and elevated temperature tensile strength, and ductility of the considered ZA alloy. The creep rate sharply increased when the mass fraction of aluminum rose above 4 wt%. For the purpose of forecasting the tensile and creep properties of the ZA alloy at any given aluminum mass percentage, quartic models were generated, with all model terms significant. Strong room and high-temperature tensile strength, %elongation, and creep resistance were all reached in the low Al-containing ZA alloys, with 1.597 wt% anticipated ideal Al mass concentration, according to RSM optimization.

Effects of WEDM and AWJ cutting methods on induction motor efficiency and total magnetic losses: Experimental design and response surface methodology

In this study, the effect of cutting electrical steel laminations using abrasive water jet (AWJ) and wire electrical discharge machining (WEDM) techniques on 5.5 kW induction motor efficiency (MEfficiency) and total magnetic losses (TLosses) was investigated. After the stator and rotor packages were formed, winding, varnishing and mechanical assembly processes were carried out and the motors were prepared for MEfficiency and TLosses tests according to the IEC 60034-2-1-1A standard. Tests were performed using different frequencies (f) and motor loading rates (MLoad). While burr formation was observed with the effect of plastic deformation on the cutting edge of electrical steels with AWJ, recast layer formation was observed with the effect of heat in WEDM. MEfficiency decreased while TLosses increased due to increasing f and MLoad in both cutting methods. Maximum MEfficiency and minimum TLosses values were measured in WEDM, it was determined that optimum results using Response Surface Methodology (RSM) were measured at f of 50 Hz and MLoad of 100% values in both cutting methods. The statistical effects of f and MLoad on MEfficiency and TLosses were revealed with ANOVA (Analysis of variance). In addition, mathematical models were developed for the prediction of MEfficiency and TLosses.

Study on the Relationship between Process Parameters and theFormation of GTAW Additive Manufacturing of TC4 Titanium Alloy Using the Response Surface Method

The geometric parameters of the deposited layer include the width, height, and penetration depth of the deposited layer. The welding current, wire feeding speed, and torch travel speed during the additive manufacturing process of TC4 titanium alloy have the greatest impact on the geometric parameters of the deposited layer. In order to study how the deposition layer width, deposition layer height, and penetration depth are affected by the welding current, wire feeding speed, and torch travel speed, this article uses Design Expert 8.0.6 software for Box−Behnken design response surface experiments. During the experimental design, the welding current, wire feeding speed, and torch travel speed are used as input variables. The deposition layer width, deposition layer height, and penetration depth are selected as the responses. We designed 17 response surface experiments that were conducted using GTAW-AM. The results show that as the welding current increases, the penetration depth and width of deposition layer gradually increase, and the deposition layer height gradually decreases. As the wire feeding speed increases, the deposition layer height and penetration depth gradually increase, and the wire feeding speed has a minimal effect on the deposition layer width. As the torch travel speed increases, the penetration depth, width and height of deposition layer gradually decrease. The response surface method experimental design can also optimize the matching of three process parameters: welding current, wire feeding speed, and torch travel speed, thereby obtaining the optimal matching range of process parameters. Within the optimized matching range of process parameters, a welding current of 90 A, a wire feeding speed of 900 mm/min, and a torch travel speed of 200.18 mm/min were selected to prepare TC4 titanium alloy thin-walled part. The microstructure of the top, middle and bottom are all basketweave structure. The α phase gradually becomes coarse from the top to the bottom. The microhardness of the top, middle, and bottom of the thin-walled parts is 362.7 HV, 352.7 HV, and 340.5 HV, respectively. The horizontal tensile strength is 926.1 MPa, with an elongation of 12.22%, and the vertical tensile strength is 938.1 MPa, with an elongation of 14.41%.

Statistical optimization of process variables for agarase production using Microbacterium sp. SS5 strain from non-marine sources

Agar oligosaccharides are thought to be valuable biomolecules with high bioactivity potential, along with a wide range of applications and advantages. The current study aimed to optimize the culture parameters required to produce agarase enzyme and agar oligosaccharides from industrial waste agar. Microbacterium spp. strain SS5 was isolated from a non-marine source and could synthesize oligo derivatives for use in a variety of industries ranging from food to pharmaceuticals. In addition, the strain and culture conditions were optimized to maximize extracellular agarase production. The bacterium grew best at pH 5.0 − 9.0, with an optimal pH of 7.5 − 8.0; temperatures ranging from 25 to 45 °C, with an optimal of 35 °C; and carbon and nitrogen concentrations of 0.5% each. Plackett-Burman experimental design and response surface methods were used to optimize various process parameters for agarase production by Microbacterium spp. strain SS5. Using the Plackett-Burman experimental design, eleven process factors were screened, and agar, beef extract, CaCl2, and beginning pH were found as the most significant independent variables affecting agarase production with confidence levels above 90%. To determine the optimal concentrations of the identified process factors on agarase production, the Box- Behnken design was used. Agarase production by Microbacterium spp. strain SS5 after optimization was 0.272 U/mL, which was determined to be greater than the result obtained from the basal medium (0.132 U/mL) before screening using Plackett-Burman and BBD with a fold increase of 2.06.

Performance enhancement of up-flow anaerobic sludge blanket reactor for psychrophilic temperature during the dry season: Kality wastewater treatment plant

The main purpose of wastewater treatment plant (WWTP) is to reduce organic and inorganic pollutants to meet standards. But WWTPs employing up flow anaerobic sludge blanket (UASB) reactors under psychrophilic temperature are currently removing about 55% chemical oxygen demand (COD) and 70% total dissolved solids (TSS). The research was done to increase the treatment efficiencies of UASB reactor working under psychrophilic conditions through optimization of operational parameters like temperature, organic loading rate (OLR), pH and hydraulic retention time (HRT). Experimentation was carried out in a 0.0486 m3 square-shaped pilot-scale UASB reactor. Experimental design response surface method (RSM) for performance enhancement and optimization of UASB reactor operational parameters through five levels of central composite design (CCD) was used. The optimized operational parameters obtained from CCD-RSM were as follows: temperature of 21.58 °C, OLR of 2.99 kg COD/m3.d, HRT of 4.37hrs and pH of 6.3. Using optimized parameters, tests yielded efficiencies of 92.70%, 99.06%, and 94.50% for COD, TSS, and volatile suspended solid (VSS) respectively. The outlet concentrations of alkalinity, and volatile fatty acids (VFA), were found to be lower than the inlet concentrations. The alkalinity in the system accepts the hydrogen ion released by acids and the system is taken over by methanogensis to maintain the pH. The outlet concentration of sulfate ion was found to be increasing due to inhabitation of sulfur-reducing bacteria by an anaerobic condition of VFA and alkalinity at a pH less than 7.8.This process favors the production of CH4 than H2S gas. In general, there was a high likelihood of improving the performance of UASB reactor operating at psychrophilic temperature by optimizing operational parameters.

Enhancing eco-concrete performance through synergistic integration of sugarcane, metakaolin, and crumb rubber: Experimental investigation and response surface optimization

Sustainable construction has gained paramount importance due to the consideration of the devastating effects of construction activities on the environment. Researchers are exploring innovative approaches to mitigate the carbon footprint and enhance the durability of concrete. In order to regulate the demand and cost of concrete constituents, such as cement and sand, there is a need to invent alternative materials and utilize various industrial and agricultural wastes instead of concrete ingredients, either partially or completely. The experimental investigation and optimization of eco-concrete composites by integrating sugarcane bagasse ash (SCBA), metakaolin (MK), and crumb rubber (CR) are cutting-edge research areas that aim to develop environmentally friendly and high-performance concrete materials. The present research work has attempted to utilize SCBA up to 15% by weight of cement with an increment of 5%, MK as a fractional exchange of cement up to 15% with 5% intervals, and CR was utilized as fractional volumetric substitution of sand from 0% to 15% in concrete. Different sets of combinations were evaluated to identify effects on density, workability, compressive strength, split tensile strength, flexural strength, and microstructural properties. This study has obtained satisfactory results when compared to the control concrete for 10% substitution of cement with MK and 10% substitution of cement with SCBA, along with a 10% replacement of fine aggregate (i.e., sand) with CR. The results were analyzed and optimized using Response Surface Methodology (RSM), which illuminated a strong correlation between experimental findings and RSM models, with an R squared (R2) value of 0.9580. The experimental findings and RSM models showed a significant correlation. The increment in the substitution of sand with CR resulted in a decline in strength, and it can be controlled by adopting different effective pretreatment techniques for CR.

Optimization of an Acid-Catalyzed Direct Extraction-Methylation Method of Lipid Residues in Archaeological Vessels by Experimental Design and Response Surface Methodology

Optimization of an Acid-Catalyzed Direct Extraction-Methylation Method of Lipid Residues in Archaeological Vessels by Experimental Design and Response Surface Methodology

Development of an RSM-based predictive model for evaluation of corrosion efficiency of ATMP in one molar HCl for carbon steel samples

The corrosion control of carbon steel was investigated using ATMP (amino-trimethylene-phosphonic acid) by experimental weight loss and response surface methods. For this purpose, the simultaneous effect of the important parameters, including inhibitor concentration, temperature, and exposure time on the inhibition efficiency (IE) of ATMP was evaluated. A new RSM-based model was developed to predict ATMP effectiveness. The results obtained from Fit-statistics (R2 = 0.9946, Adj-R2 = 0.9916, and Pred-R2 = 0.9750), adequate precision (A.p = 63.1026), diagnostics plots, and PPE (Percentage-Prediction-Error) for non-designed experiments strongly confirmed the adequacy, accuracy, and validation of the developed IE-model. The results indicated that the parameters at the low levels of ATMP concentrations had the least interaction effect on the inhibition efficiency (IE< 35%). The addition of inhibitor concentration up to 150 ppm near the low level of temperature (30–40 °C) and high level of exposure time (85–105 h) had the most interaction effect between parameters and significantly enhanced the inhibition efficiency. Furthermore, numerical optimization was performed to maximize IE while minimizing the concentration of inhibitor. The optimization provided showed an inhibition performance of 80.434% at 126 ppm, 31 °C, and 26.4 h.

Solvent-Free Determination of Selected Polycyclic Aromatic Hydrocarbons in Plant Material Used for Food Supplements Preparation: Optimization of a Solid Phase Microextraction Method.

The exploitation of waste and by-products in various applications is becoming a cornerstone of the circular economy. A range of biomasses can be employed to produce food supplements. An example is a particular extract obtained from plant buds (rich in bioactive molecules), which can be easily retrieved from cities' pruning. In order to safely use this material, its possible contamination by organic pollutants needs to be estimated. A green and simple method to detect priority polycyclic aromatic hydrocarbons (PAHs) in bud samples by head space solid phase microextraction coupled to GC-MS was developed. This strategy, optimized through experimental design and response surface methodology, requires a minimal sample pre-treatment and negligible solvent consumption. The final method was found to be accurate and sensitive for PAHs with mass up to 228 Da. For these analytes, satisfactory figures of merit were achieved, with detection limits in the range 1-4 ng g-1, good inter-day precision (relative standard deviation in the range 4-11%), and satisfactory accuracy (88-105%), along with specificity guaranteed by the selected ion monitoring detection. The method was applied to bud samples coming from differently polluted areas, thus helping in estimating the safety of their use for the production of food supplements.

Optimizing the First Step of the Biocatalytic Process for Green Leaf Volatiles Production: Lipase-Catalyzed Hydrolysis of Three Vegetable Oils.

Green leaf volatiles (GLVs), including short chain volatile aldehydes, are widely used in the flavor and food industries because of their fresh aroma. To meet the growing demand for natural GLVs with high added value, the use of biocatalytic processes appears as a relevant application. In such processes, vegetable oils are bioconverted into GLVs. First, the triacylglycerols of the oils are hydrolyzed by a lipase. Then, the free polyunsaturated fatty acids are converted by a lipoxygenase. Finally, volatile C6 or C9 aldehydes and 9- or 12-oxoacids are produced with a hydroperoxide lyase. Optimization of each biocatalytic step must be achieved to consider a scale-up. In this study, three oils (sunflower, hempseed, and linseed oils) and three lipases (Candida rugosa, Pseudomonas fluorescens, and Rhizomucor miehei lipases) have been tested to optimize the first step of the process. The experimental design and response surface methodology (RSM) were used to determine the optimal hydrolysis conditions for each oil. Five factors were considered, i.e., pH, temperature, reaction duration, enzyme load, and oil/aqueous ratio of the reaction mixture. Candida rugosa lipase was selected as the most efficient enzyme to achieve conversion of 96 ± 1.7%, 97.2 ± 3.8%, and 91.8 ± 3.2%, respectively, for sunflower, hempseed, and linseed oils under the defined optimized reaction conditions.

Optimization of Mixed-Based Biochar Preparation Process and Adsorption Performance of Lead and Cadmium

Irreversible pollution by heavy metals such as lead (Pb) and cadmium (Cd) adversely affects the ecological environment and human health. Due to its high adsorption, microporosity, and specific surface area, biochar possesses excellent potential for use in heavy metal pollution remediation. The preparation of mixed-based biochar from sludge and cotton stalk can solve the problems inherent to pure sludge biochar, such as undeveloped pore structure and a small specific surface area, while resourcefully utilizing both waste biomass types. This study investigated the adsorption capacity for Pb2+ and Cd2+ of mixed-based biochar prepared at different pyrolysis temperatures, different pyrolysis residence times, and different cotton stalks percentages. Response surface experiments revealed the optimum process conditions for preparing mixed-based biochar, which included a pyrolysis temperature of 638 °C, a pyrolysis residence time of 86 min, and an addition ratio of 50% for cotton stalks. The isothermal adsorption experiments revealed that the maximum adsorption capacities of mixed-based biochar for Pb2+ and Cd2+ were 111.11 and 86.21 mg/g, respectively. Our findings suggest the co-pyrolysis of sludge and cotton stalk as a green and sustainable method for safely disposing of Pb and Cd.

Comprehensive study of MWCNT and CuO/SAE50 hybrid nanofluid with experimental method and response surface methodology and introducing this nanofluid to the industry

In this study, rheological behavior of hybrid nanofluid (HNF) with MWCNT(35%)-CuO (65%) nanoparticles (NPs) in SAE50 base oil was investigated by response surface methodology (RSM) and laboratory methods. Viscosity of HNF samples with solid volume fractions of SVF = 0.0625% to 1% was measured at temperatures between (T = 25–50 °C) and shear rates in the range of SR = 666.5–7998 s−1 using a Brookfield viscometer. The behavior of HNF shows non-Newtonian behavior in terms of relation between SR and shear stress (SS) in all SVFs. The relative viscosity at T = 30 °C and SVF = 1% has the highest value and is equal to + 22%. Viscosity changes in terms of temperature show that viscosity decreases with increasing temperature. The maximum viscosity difference at T = 25 °C is equal to −13.7 (-2.97). Also, to save time and reduce economic costs and check the accuracy and correctness of experimental data, it was predicted by RSM. Modeling with a three-variable mathematical relationship including T, SVF, and SR with R2 = 0.9986 coefficient was presented. After checking the viscosity with independent variables, it was determined that T effect is greater than other parameters on viscosity. Comparison results between experimental data and the proposed data show a high agreement between the predicted values.

Oxygen vacancies mediate the degradation of refractory organics in the interflow around a simple landfill: Based on Mg-Fe3O4/PMS system

The interflow around simple landfills in villages and towns contains high-risk and trace refractory organics (TRO), which can have serious effects on the rural living environment. Here, an iron-based catalyst containing oxygen vacancies was prepared by doping with Mg, and the Mg-Fe3O4/peroxymonosulfate (PMS) advanced oxidation system was constructed to mediate the efficient degradation of the pollutants in the interflow around simple landfills. The parameters of the system were optimized to maximize the degradation of the pollutants in interflow via single-factor and response surface experiments. Electron paramagnetic resonance revealed that oxygen vacancies can effectively form in the catalyst by doping co-precipitation. The rate of chemical oxygen demand removal from the interflow was 96.01 ± 1.12% under the following conditions: 10% Mg doping, 1.03 g·L−1 catalyst dosage, and 13.47 mmol·L−1 PMS dosage. UV254 and E280 decreased from 0.403 and 0.305 cm−1 to 0.199 and 0.164 cm−1, respectively, and E300/E400 increased from 5.56 to 8.92 after the reaction. Excitation–emission matrix spectra showed that the corresponding absorption peaks of fulvic acid and tyrosine analogs were heavily attenuated. Gas chromatography–mass spectrometry analysis showed that the number of TRO decreased from 57 to 9, indicating that a large amount of TRO had been removed. A mechanistic analysis revealed that SO4·- and OH· might play a major role in the reaction process and that 1O2 plays an important role in the degradation process.

Optimization of fermentation, purification and properties of blue pigment produced from Quambalaria cyanescens QY229.

Blue pigments have broad applications in foods, cosmetics, and clothing. However, natural blue pigments are rare. At present, the majority of blue pigments for sale are chemically synthetic. Owing to the safety risks of chemical pigments, it is an urgent demand to develop novel natural blue pigments. The fermentation medium and culture conditions of blue pigment produced by Quambalaria cyanescens QY229 were optimized by Plackett-Burman (PB) experimental design and response surface methodology (RSM) for the first time. The stability, bioactivity and toxicity of the obtained blue pigment were studied after isolation and purification. The results showed that the optimal fermentation parameters were 34.61 g·L-1 of peptone concentration, 31.67°C of growing temperature, and 72.33mL of medium volume in a 250mL flask, and the yield of blue pigment reached 348.2±7.1 U·mL-1. QY229 blue pigment is stable to light, heat, pH, most metal ions and additives, and has certain antioxidant and inhibitory activity of α-glucosidase in vitro. QY229 blue pigment at concentrations of 0-1.25mg·mL-1 was nontoxic to Caenorhabditis elegans in an acute toxicity trial.

A Rapid Method for Testing Filtration Performance of Malt and the Optimization of the Method

A rapid filtration test method that predicts malt filtration efficiency has been developed in this research. This rapid filtration test method has an advantage over existing beer filtration tests, as it can be easily operated and there is no need to brew. Six kinds of malts with distinct filtration performance were selected, and the filtration performance was determined by measuring the turbidity of their clarified wort through simple simulation of mashing. The results indicate the filtering performance ranking as given: Copeland &gt; Pearl malt 1 &gt; Pearl malt 2 &gt; Synergy &gt; Planet &gt; Wheat malt. When a sample is purchased for six times of parallelization, RSD is less than 10%, and the experimental results are significantly correlated with viscosity and β-glucan content. Therefore, this method can effectively predict the filtration performance of malt. The response surface design 3 × 3 factor experiment was used to optimize the fast detection method, which increased the sample differentiation (F-value) and made it easier to judge the experimental results. Response surface experiment results show the optimal reaction conditions for enhancing differentiation, i.e., an enzyme ratio of 0.5 (α-amylase, β-glucanase, neutral protease = 1:2:1), a holding period of 38 min, and a reaction temperature of 44 °C. The F-value is 147.00.

Investigation of Operating Parameters of Diesel Engine Fueled with SiO2 Nanoparticles and Abrus precatorius Biodiesel: Experimental Approach and Response Surface Methodology

Investigation of Operating Parameters of Diesel Engine Fueled with SiO2 Nanoparticles and Abrus precatorius Biodiesel: Experimental Approach and Response Surface Methodology

EDEM and FLUENT Parameter Finding and Verification Study of Thickener Based on Genetic Neural Network

To improve the concentration performance of the concentrator in the iron ore beneficiation process for iron ore tailings, a coupled simulation analysis of the concentration process was conducted using the discrete element software EDEM (Engineering Discrete Element Method) and the finite element FLUENT software. The volume concentration at the bottom flow outlet of the concentrator was used as the evaluation index. The scraper rotation speed, feed rate, and feed concentration were considered as parameters. Response surface experiments were designed using the Box-Behnken module in Design Expert11 software, and numerical simulations were performed to obtain data. Based on the numerical simulation results, a prediction model was established using the backpropagation neural network (backpropagation neural network, BP-NN) and combined with the genetic algorithm (genetic algorithm, GA) for parameter optimization of the thickener’s concentration conditions. The results showed that with a scraper rotation speed of 9.7677 rpm, feed rate of 0.2037 m/s, and feed concentration of 6.5268%, the maximum outlet volume concentration reached approximately 62.00%. The predicted optimal working conditions were validated through physical tests and numerical simulations. The average outlet volume concentration in the physical tests was 60.712% (n = 10) (“n” is the number of experiments), with an error of only 2.077% compared to the predicted value. The middle outlet volume concentration in the numerical simulation experiments was 59.951% (n = 10), with an error of only 3.304% from the expected value. These results demonstrate the feasibility of using a genetic neural network for optimizing the EDEM–FLUENT simulation parameters of the thickener, providing valuable insights for the matching optimization of the thickener’s process parameters.