A novel convolutional autoencoder and neural ODE (CAE-NODE) framework is proposed for a reduced-order model (ROM) applied to transient 2D counterflow flames, as an extension of AE-NODE methods in homogeneous reactive systems to spatially resolved flows. The multidimensional thermochemical fields (256 x 256 grid, 21 variables) obtained from direct numerical simulations (DNS) are used in training the CAE, where convolutional layers learned the underlying spatial correlations, allowing the CAE to construct an unsupervised 3D latent manifold that is physically meaningful, smooth, and continuous in time. This results in a compression ratio of over 400,000 times. The NODE then subsequently learns the continuous-time dynamics on the latent manifold, enabling the prediction of the full temporal evolution of the flames by integrating forward in time from an initial condition. The results demonstrate that the CAE-NODE can accurately capture the entire transient process, including ignition, flame propagation, and the gradual transition to a non-premixed condition, with excellent agreement with the DNS, while adhering to conservation principles at virtually no computational cost compared to the reference DNS. Predictions remain accurate at strain rates outside the training range. Moreover, despite being unsupervised, the learned latent manifold is highly correlated with the flame-state descriptors such as the progress variable, mixture fraction, and the scalar dissipation rate. This study, for the first time, highlights the potential of CAE-NODE for surrogate modeling of unsteady dynamics of multi-dimensional reacting flows.
Turbulent combustion simulations are crucial for many scientific and engineering systems. However, the high cost to fully resolve the complex multiscale and multiphysics behavior makes direct simulation typically infeasible. The equivalent reactor network (ERN) approach attempts to improve computational efficiency by replacing a multidimensional turbulent simulation with a series of much cheaper 0-D and 1-D chemical reactors, providing a surrogate model that retains detailed chemistry at the cost of simplified flow physics. However, their development remains a challenge, often requiring either expert analysis, or automated approaches that sacrifice accuracy. In this work, we develop an automated machine-learning-assisted framework for constructing ERNs of the Sandia-D turbulent methane/air flame. Principal component analysis is first used to reduce high-dimensional thermochemical computational fluid dynamics (CFD) data to a low-dimensional latent space, where k-means clustering identifies physically interpretable flame regions used to initialize a reactor-network graph. This initialization is then refined using finite-difference gradient descent wrapped around non-differentiable Cantera reactor simulations. Across 30 RANS simulations spanning a range of pilot temperatures and inlet methane compositions, the optimized 7-reactor ERN achieves a maximum-temperature R2 score of 0.7945 while preserving a ∼6000× speedup over the CFD solver. Outlet CO prediction remains more challenging, with a final R2 score of −0.4183, but improves substantially from the unoptimized clustering initialization. These results show that unsupervised thermochemical feature extraction can provide effective physics-informed initializations for ERN construction, while gradient-based refinement can significantly improve predictive accuracy without manual reactor-network design.
Real-time thermal-hydraulic simulation is essential for digital twin (DT) technology that supports the safe and efficient operation of small modular reactors (SMRs). Computational fluid dynamics (CFD) provides high-fidelity flow analysis, but its computational cost prevents direct use in DT applications. AI-based surrogate modeling has been actively investigated to address this limitation, yet neural operator--based surrogates for CFD-level transient analysis of SMR-specific geometries have not been reported. This study presents an integrated framework that combines a reduced-order model (ROM) with neural operators, applied to the helical coil steam generator (HCSG) of the System-integrated Modular Advanced Reactor (SMART). Two ROM strategies tailored to each CFD data type were compared, an MLP-based autoencoder (AE) for unstructured mesh data and a convolutional autoencoder (CAE) for structured mesh data, and each was coupled with the deep operator network (DeepONet) to construct the latent DeepONet (L-DeepONet). The Fourier neural operator (FNO) was additionally adopted for comparison. A multi-scale technique was incorporated into both frameworks to mitigate spectral bias and improve the prediction of Kármán vortex streets developing inside the HCSG. The multi-scale L-DeepONet captured the instantaneous periodic vortex dynamics in both velocity and pressure fields, while the FNO and its multi-scale variant predicted the time-averaged mean flow and provided reliable pressure drop estimates. These complementary characteristics provide a practical model-selection guideline that links each architecture to specific DT objectives based on CFD data type and the required level of flow resolution.
We present a physics-constrained machine learning framework for accelerating the direct numerical simulation (DNS) of turbulent reacting flows. The model replaces the direct evaluation of detailed chemical source terms with a surrogate that predicts reaction rates from a reduced thermochemical state. To improve physical consistency, the second law of thermodynamics is incorporated as a training constraint by enforcing non-negative entropy generation, which restricts the evolution of the thermochemical state to physically admissible directions and improves stability during time integration. The approach is demonstrated on DNS of a two-dimensional planar lean premixed methane-air flame interacting with a turbulent flow field. The model reproduces detailed-chemistry results with high fidelity while achieving more than an order-of-magnitude reduction in computational cost. Furthermore, a residual-based synthetic data augmentation strategy enables parametric exploration by constructing new training data from the original dataset, allowing accurate simulation at new inlet conditions without additional detailed-chemistry CFD runs. These results demonstrate that thermodynamically constrained machine learning can provide reliable and computationally efficient surrogates for detailed chemistry in high-fidelity combustion simulations.