A hybrid modeling approach for predicting non-Newtonian flow through multilayer sintered composite-cloths

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ABSTRACT The accurate determination of pressure loss across filter media is of central importance in the design of filtration processes, as it directly affects energy efficiency and thus operating costs. While Darcy-based approaches reliably describe the flow of Newtonian fluids, no transferable models exist for non-Newtonian fluids flowing through multilayer sintered metal wire composite-cloths, despite their widespread use in industrial applications such as polymer melt filtration or heavy fuel oil filtration in marine engines. To address this gap, this study develops and systematically compares several modeling approaches for predicting the flow velocity of shear-thinning fluids through such composite-cloths, relying on quantities available in industrial practice, such as standardized air permeability measurements. The investigated approaches comprise a physics-based white box model derived from a modified Darcy law, a purely data-driven black box model based on gradient boosting, including a target-scaled variant, and hybrid models combining both paradigms in serial and parallel configuration. All models are evaluated across ten random data splits and compared using paired statistical tests. The hybrid structures outperform the purely data-driven model, with the parallel configuration achieving the lowest error at a mean MAPE of 5.59 ± 1.85 %. The reported performance reflects interpolation within the investigated parameter space of three cloth types, six pore sizes, and three silicone oils. Overall, the proposed hybrid modeling framework provides a viable method for predicting the flow velocity of non-Newtonian fluids in multilayer sintered metal wire composite-cloths.

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