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arxiv: 2601.18399 · v2 · submitted 2026-01-26 · 💻 cs.LG

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Estimating Dense-Packed Zone Height in Liquid-Liquid Separation: A Physics-Informed Neural Network Approach

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Pith reviewed 2026-05-16 10:53 UTC · model grok-4.3

classification 💻 cs.LG
keywords physics-informed neural networkliquid-liquid separationdense-packed zone heightstate estimationextended Kalman filtergravity settlervolume balance
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The pith

A two-stage trained physics-informed neural network estimates dense-packed zone height in liquid-liquid separators using only flow measurements after pretraining on synthetic data.

A machine-rendered reading of the paper's core claim, the machinery that carries it, and where it could break.

The paper develops a method to estimate the height of the dense-packed zone in liquid-liquid gravity settlers, a key but hard-to-measure indicator. It pretrains a physics-informed neural network on synthetic data generated from a low-fidelity mechanistic model that uses only volume balance equations. The network is then fine-tuned with limited experimental measurements of phase heights and flow rates to match real separator behavior. The resulting model is placed inside an Extended Kalman Filter inspired state estimator that updates height predictions from flow data alone. In forward simulations and filter-based estimation tests, the two-stage PINN produces the most accurate results compared to non-pretrained PINNs and purely data-driven networks.

Core claim

By pretraining a PINN on synthetic data from volume balance equations derived from a low-fidelity model and then fine-tuning it with scarce experimental phase height and flow-rate data, the model can be deployed in an Extended Kalman Filter inspired framework to accurately estimate dense-packed zone heights using only readily available flow measurements, outperforming other models in all evaluations.

What carries the argument

The two-stage trained physics-informed neural network that enforces volume balance equations as soft constraints and is embedded in an Extended Kalman Filter inspired state estimation framework for online tracking.

If this is right

  • The PINN enables continuous height tracking without optical or direct sensors during operation.
  • Pretraining on synthetic data from the mechanistic model reduces the amount of experimental data required for deployment.
  • The two-stage PINN outperforms both non-pretrained PINNs and purely data-driven networks in phase-height estimation accuracy.
  • Ensemble training of all models provides a way to quantify uncertainty in the estimates.

Where Pith is reading between the lines

These are editorial extensions of the paper, not claims the author makes directly.

  • The same pretrain-then-fine-tune pattern could apply to other chemical engineering unit operations where full physics models are too expensive but partial balances are available.
  • Embedding the differentiable PINN in the filter opens the possibility of using the estimates for real-time process optimization or fault detection.
  • If faster computers become available, adding coalescence and sedimentation terms to the PINN loss could further reduce reliance on experimental fine-tuning.

Load-bearing premise

Volume balance equations alone, without droplet coalescence or sedimentation details, suffice for the fine-tuned PINN to capture actual separator dynamics.

What would settle it

New experiments on a separator with different operating conditions where the PINN height estimates deviate substantially from independent measurements would falsify the accuracy claim.

Figures

Figures reproduced from arXiv: 2601.18399 by Adel Mhamdi, Alexander Mitsos, Andreas Jupke, Manuel Dahmen, Mehmet Velioglu, Song Zhai.

Figure 1
Figure 1. Figure 1: Piping and instrumentation diagram of the experimental setup with DN 200 separator in the RWTH Aachen Fluid Process Engineering (AVT.FVT) lab. Blue, orange, and green colors mark the aqueous, organic, and dispersion phases (DPZ). Reproduced from Zhai et al. (2025). 2.2 Optical measurement of the dense-packed zone height The phase heights for both the heavy (water) phase and the DPZ are determined from two … view at source ↗
Figure 2
Figure 2. Figure 2: Detection of DPZ heights along the separator with effective length of 1 m. Images refer to detections in QIR03 (left) and QIR04 (right). In each image, four heights are detected for same widths. The distances between inlet and first height detection, width of QIR03, width between QIR03 and QIR04, and width of QIR04 is a = 21 cm, b = 36 cm, c = 10 cm, d = 33 cm, respectively. occasional missing measurements… view at source ↗
Figure 3
Figure 3. Figure 3: Pre-processed inlet volume flow rate and phase height measurements for the training trajec￾tory, measured at eight different positions at QIR03 and QIR04 (see [PITH_FULL_IMAGE:figures/full_fig_p007_3.png] view at source ↗
Figure 4
Figure 4. Figure 4: Post-processed experimental trajectories obtained from the gravity settler. The quantities hHP and hDP denote the average heavy-phase height and DPZ height, respectively, computed over the eight detection positions. Qin denotes the inlet volume flow rate, and Qbot and Qtop denote the bottom and top outlet volume flow rates, respectively [PITH_FULL_IMAGE:figures/full_fig_p009_4.png] view at source ↗
Figure 5
Figure 5. Figure 5: Mechanistic model schematic of the pilot-scale liquid–liquid separator. Adapted from Velioglu et al. (2025). The mechanistic LLS model Velioglu et al. (2025) is based on the following volume balance equations obtained after transforming the volume of a cylindrical segment to the height of each segment, similar to Backi et al. (2018): 0 = gsep(Qin(t), Qbot(t), Qtop(t)) = Qin(t) − Qbot(t) − Qtop(t), (1a) h˙ … view at source ↗
Figure 6
Figure 6. Figure 6: Relationship between PINN time t and process time τ . Reproduced from Velioglu et al. (2025). (v). (vii) A new two-stage training scheme is introduced (pretraining and fine-tuning). 4.1 Model architecture We define a PINN with learnable parameters θ that takes PINN time t ∈ [0, T], initial heights x(0) = [hDP(0), hHP(0)]⊤ and inlet volume flow (control) u = [Qin] as input and outputs the measurable set￾tle… view at source ↗
Figure 7
Figure 7. Figure 7: Network schematic of the PINN model for liquid-liquid separator. Note that the figure does not show the actual depth and width of the hidden layers. Time dependence is omitted for better readability. function. We use the sigmoid activation function for the output layer to prevent the argument of the square root in the denominator of Equations (1b) and (1c) from attaining negative values during PINN trainin… view at source ↗
Figure 8
Figure 8. Figure 8: Two-stage training strategy of PINN-based liquid-liquid separator model butions. In particular, the separator is discretized along the axial direction into 200 segments and across 50 droplet diameter classes, resulting in approximately 200 × 50 = 10,000 internal compartments. Embedding these calculations into the PINN would either require introducing a large number of additional outputs to represent the st… view at source ↗
Figure 9
Figure 9. Figure 9: Simulation results for the interpolation test trajectory. Predictions from an individual model are shown in transparent red, whereas the ensemble mean estimation is shown with a red dashed line [PITH_FULL_IMAGE:figures/full_fig_p019_9.png] view at source ↗
Figure 10
Figure 10. Figure 10: Simulation results for the extrapolation test trajectory. Predictions from an individual model are shown in transparent red, whereas the ensemble mean estimation is shown with a red dashed line [PITH_FULL_IMAGE:figures/full_fig_p020_10.png] view at source ↗
Figure 11
Figure 11. Figure 11: State estimation results for the interpolation test trajectory. Estimations from an individual model are shown in transparent red, whereas the ensemble mean estimation is shown with a red dashed line. ensemble in case of the DPZ height. In particular, after the maximum control action (an operating value unseen in the training trajectory) is applied at around process time τ = 500 s, the VNN mean estimate o… view at source ↗
Figure 12
Figure 12. Figure 12: State estimation results for the extrapolation test trajectory. Estimations from an indi￾vidual model are shown in transparent red, whereas the ensemble mean estimation is shown with a red dashed line. 0 200 400 600 800 1000 Process time ( ) [s] 2 3 4 5 6 7 D P Z h eig h t a t s e p a r a t o r e n d (h 4, 3) [c m] Experimental PINN based prediction VNN based prediction (a) Interpolation test trajectory 0… view at source ↗
Figure 13
Figure 13. Figure 13: Prediction of the DPZ height at the separator end. Experimental results are obtained from camera QIR04 at detection window h4,3. Estimates of the average DPZ from both PINN and VNN are fed into the NN that predicts the DPZ height at separator end [PITH_FULL_IMAGE:figures/full_fig_p026_13.png] view at source ↗
read the original abstract

Separating liquid-liquid dispersions in gravity settlers is critical in chemical, pharmaceutical, and recycling processes. The dense-packed zone height is an important performance and safety indicator but it is often expensive and impractical to measure due to optical limitations. We propose a framework to estimate phase heights by combining a PINN model with readily available volume flow measurements, without requiring phase height measurements during deployment. To this end, a physics-informed neural network (PINN) is first pretrained on synthetic data and physics equations derived from a low-fidelity (approximate) mechanistic model to reduce the need for extensive experimental data. While the mechanistic model is used to generate synthetic training data, only volume balance equations are used in the PINN, as incorporating droplet coalescence and sedimentation submodels would be computationally prohibitive. The pretrained PINN is then fine-tuned with scarce experimental phase height and flow-rate data to capture the actual dynamics of the separator. We then deploy the differentiable PINN as a predictive model in an Extended Kalman Filter inspired state estimation framework, enabling the phase heights to be tracked and updated using flow-rate measurements only. We first test the two-stage trained PINN by forward simulation from a known initial state against the mechanistic model and a non-pretrained PINN. We then evaluate phase height estimation performance with the filter, comparing the two-stage trained PINN with a two-stage trained purely data-driven neural network. All model types are trained and evaluated using ensembles to account for model parameter uncertainty. In all evaluations, the two-stage trained PINN yields the most accurate phase-height estimates.

Editorial analysis

A structured set of objections, weighed in public.

Desk editor's note, referee report, simulated authors' rebuttal, and a circularity audit. Tearing a paper down is the easy half of reading it; the pith above is the substance, this is the friction.

Referee Report

3 major / 2 minor

Summary. The manuscript proposes a two-stage PINN framework to estimate dense-packed zone height in liquid-liquid gravity settlers. A PINN is pretrained on synthetic data generated by a low-fidelity mechanistic model subject to volume-balance physics constraints, then fine-tuned on scarce experimental phase-height and flow-rate pairs. The resulting differentiable model is embedded in an EKF-style estimator that updates height predictions from flow measurements alone. Ensemble training is used throughout. The central claim is that the two-stage PINN produces the most accurate forward-simulation and filtering results compared with the mechanistic model and a purely data-driven NN.

Significance. If the quantitative superiority is confirmed with proper metrics and out-of-distribution tests, the work would demonstrate a practical route for hybrid modeling under data scarcity: approximate physics for pretraining plus limited real observations for fine-tuning, followed by deployment inside a differentiable filter. Such an approach could reduce reliance on expensive instrumentation in chemical and recycling processes while still respecting conservation laws.

major comments (3)
  1. [Abstract and §4] Abstract and §4 (Results): the claim that the two-stage PINN 'yields the most accurate phase-height estimates' is unsupported by any reported RMSE, MAE, or coverage metrics, validation plots, or statistical tests on the ensemble members. Without these numbers it is impossible to judge whether the reported superiority is practically meaningful or merely within noise.
  2. [§3.2 and §2] §3.2 (PINN formulation) and §2 (Mechanistic model): the physics loss contains only volume-balance equations; coalescence and sedimentation submodels are omitted. Because the synthetic pretraining data are generated by the same low-fidelity model whose balances later appear in the loss, the training loop risks circularity. The manuscript must show, via an ablation that replaces the mechanistic pretraining with random initialization or a different generator, that the fine-tuning stage actually learns dynamics beyond the approximate model.
  3. [§4.2] §4.2 (EKF evaluation): the filtering experiments compare the two-stage PINN only against a two-stage data-driven NN. A direct comparison against the low-fidelity mechanistic model run inside the same EKF (with appropriate process noise) is missing; such a baseline would clarify whether the neural component adds value beyond the volume balances already present in the physics loss.
minor comments (2)
  1. [§3] Notation for the dense-packed zone height (h_d) and the light-phase height should be introduced once and used consistently; several paragraphs switch between symbols without explicit redefinition.
  2. [Figures 3–5] Figure captions for the ensemble trajectories should report the number of members and the plotted quantiles (e.g., median and 5–95 % bands) rather than generic 'mean ± std'.

Simulated Author's Rebuttal

3 responses · 0 unresolved

We thank the referee for the constructive and detailed comments. We address each major point below and will make the indicated revisions to strengthen the manuscript.

read point-by-point responses
  1. Referee: [Abstract and §4] Abstract and §4 (Results): the claim that the two-stage PINN 'yields the most accurate phase-height estimates' is unsupported by any reported RMSE, MAE, or coverage metrics, validation plots, or statistical tests on the ensemble members. Without these numbers it is impossible to judge whether the reported superiority is practically meaningful or merely within noise.

    Authors: We agree that the manuscript relies primarily on visual comparisons in the figures without tabulated numerical metrics or statistical tests on the ensembles. This omission makes it difficult to assess practical significance. In the revised version we will add a results table reporting RMSE, MAE, and ensemble coverage (e.g., 95% interval coverage) for forward simulation and filtering tasks, together with paired statistical tests (e.g., Wilcoxon signed-rank) on the ensemble members to quantify whether observed differences are significant. revision: yes

  2. Referee: [§3.2 and §2] §3.2 (PINN formulation) and §2 (Mechanistic model): the physics loss contains only volume-balance equations; coalescence and sedimentation submodels are omitted. Because the synthetic pretraining data are generated by the same low-fidelity model whose balances later appear in the loss, the training loop risks circularity. The manuscript must show, via an ablation that replaces the mechanistic pretraining with random initialization or a different generator, that the fine-tuning stage actually learns dynamics beyond the approximate model.

    Authors: The concern about circularity is valid: although the PINN loss uses only volume-balance equations, the pretraining data are generated by the same low-fidelity simulator. To demonstrate that the two-stage procedure learns additional dynamics, we will include an ablation study in the revision. Specifically, we will train an otherwise identical PINN from random initialization (no mechanistic pretraining), fine-tune it on the experimental data, and compare its forward-simulation and filtering accuracy against the proposed two-stage PINN using the same ensemble protocol and metrics. revision: yes

  3. Referee: [§4.2] §4.2 (EKF evaluation): the filtering experiments compare the two-stage PINN only against a two-stage data-driven NN. A direct comparison against the low-fidelity mechanistic model run inside the same EKF (with appropriate process noise) is missing; such a baseline would clarify whether the neural component adds value beyond the volume balances already present in the physics loss.

    Authors: We concur that embedding the low-fidelity mechanistic model directly in the EKF (with process noise calibrated to the ensemble variance) provides an important baseline. The original evaluation compared only neural variants. In the revision we will add this baseline to §4.2, reporting the same RMSE/MAE/coverage metrics for the mechanistic EKF and discussing the incremental benefit (if any) provided by the learned PINN component. revision: yes

Circularity Check

1 steps flagged

Pretraining on synthetic data and volume-balance physics from the same low-fidelity mechanistic model creates moderate circularity when forward-simulating against that model

specific steps
  1. fitted input called prediction [Abstract (pretraining and forward-simulation evaluation)]
    "a physics-informed neural network (PINN) is first pretrained on synthetic data and physics equations derived from a low-fidelity (approximate) mechanistic model to reduce the need for extensive experimental data. While the mechanistic model is used to generate synthetic training data, only volume balance equations are used in the PINN... We first test the two-stage trained PINN by forward simulation from a known initial state against the mechanistic model and a non-pretrained PINN."

    Synthetic training data and the volume-balance physics loss both originate from the mechanistic model. The forward-simulation test then measures how well the PINN reproduces trajectories from that same model, so the accuracy advantage is partly by construction rather than an independent check of generalization.

full rationale

The paper's two-stage training pretrains the PINN on synthetic trajectories generated by the mechanistic model while enforcing volume-balance equations derived from the same model. Forward-simulation tests then compare the PINN output directly to the mechanistic model's trajectories. This setup makes the reported superiority in that evaluation statistically forced by the shared source of data and constraints, even though fine-tuning on experimental data and comparison to a data-driven NN add partial independence. No self-citations, uniqueness theorems, or ansatz smuggling are present; the circularity is limited to the pretraining-evaluation loop on the synthetic source.

Axiom & Free-Parameter Ledger

1 free parameters · 1 axioms · 0 invented entities

The central claim rests on volume balance equations derived from a low-fidelity mechanistic model used both for synthetic data and as the physics constraint inside the PINN.

free parameters (1)
  • PINN weights and biases
    Trained first on synthetic data then fine-tuned on experimental phase height and flow data; ensemble members capture parameter uncertainty.
axioms (1)
  • domain assumption Volume balance equations govern phase height evolution
    Only these equations are embedded in the PINN; coalescence and sedimentation submodels are omitted for computational reasons.

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