NeuralDEM -- Real-time Simulation of Industrial Particulate Flows

TL;DR

NeuralDEM is a deep learning-based surrogate model that enables real-time simulation of large-scale industrial particulate flows, significantly reducing computational costs while maintaining accuracy.

Contribution

It introduces a novel multi-branch neural operator framework that replaces traditional DEM routines for efficient, long-term, and large-scale particulate flow simulations.

Findings

Successfully modeled coupled CFD-DEM fluidized bed reactors with 160k CFD cells and 500k particles.

Achieved real-time simulation of complex particulate systems over 28 seconds of physical time.

Demonstrated scalability to industrial-sized scenarios previously infeasible for deep learning models.

Abstract

Advancements in computing power have made it possible to numerically simulate large-scale fluid-mechanical and/or particulate systems, many of which are integral to core industrial processes. Among the different numerical methods available, the discrete element method (DEM) provides one of the most accurate representations of a wide range of physical systems involving granular and discontinuous materials. Consequently, DEM has become a widely accepted approach for tackling engineering problems connected to granular flows and powder mechanics. Additionally, DEM can be integrated with grid-based computational fluid dynamics (CFD) methods, enabling the simulation of chemical processes taking place, e.g., in fluidized beds. However, DEM is computationally intensive because of the intrinsic multiscale nature of particulate systems, restricting simulation duration or number of particles. Towards this end, NeuralDEM presents an end-to-end approach to replace slow numerical DEM routines with fast, adaptable deep learning surrogates. NeuralDEM is capable of picturing long-term transport processes across different regimes using macroscopic observables without any reference to microscopic model parameters. First, NeuralDEM treats the Lagrangian discretization of DEM as an underlying continuous field, while simultaneously modeling macroscopic behavior directly as additional auxiliary fields. Second, NeuralDEM introduces multi-branch neural operators scalable to real-time modeling of industrially-sized scenarios - from slow and pseudo-steady to fast and transient. Such scenarios have previously posed insurmountable challenges for deep learning models. Notably, NeuralDEM faithfully models coupled CFD-DEM fluidized bed reactors of 160k CFD cells and 500k DEM particles for trajectories of 28s. NeuralDEM will open many new doors to advanced engineering and much faster process cycles.