ThermoCraft
Process Thermal Simulation Platform — Python-native, parameterized, optimizable, and extensible simulation toolkit for coupled heat + mass transfer + reaction kinetics in food, pharmaceutical, and chemical process industries. Includes built-in uncertainty quantification (Morris / Sobol / Monte Carlo / PCE), regulatory compliance reporting (FDA 21 CFR 113, EU 853, GB 8950), and production scheduling.
Features
Core physics (suite-agnostic)
- 1D/2D transient heat conduction (explicit / implicit / Crank-Nicolson / enthalpy) + optional FEniCSx 2D/3D FEM backend
- Reaction kinetics: Bigelow first-order, Weibull, advanced kinetic & quality models (Arrhenius)
- Mass transfer, convective mass transfer, drying (GAB sorption), evaporation, thermo-mass coupling, multiphase domains, particle generation, headspace modelling
- Consistent unit handling (
thermocraft.core.units) and material property models
Application suites — Food
- Sterilization (C1): Ball formula & numerical F₀, quality degradation, retort profile, process deviation analysis, continuous equipment (hydrostatic sterilizer, rotary retort, scraped-surface HX, ohmic heating), microwave heating (Lambert's law)
- Freezing (C2): Plank (1913) & numerical freezing time, enthalpy / apparent-heat-capacity phase change
- UHT (C5): tubular / plate heat-exchanger design (LMTD / ε-NTU), residence time distribution, F₀ / Pu
- Shelf-life: Baranyi-Roberts growth + Ratkowsky temperature dependence, ASLT (Q₁₀); spoilage / pathogen database
- Scheduling: greedy LPT list scheduler + Optuna search (capacity, cleaning, steam-feasibility)
Analysis & UQ
- Morris screening (μ* / σ) and Sobol global sensitivity (Saltelli S1/ST + bootstrap CI + convergence)
- Monte Carlo UQ (LHS sampling, parallel evaluation, P(F₀ < target), CI)
- Polynomial Chaos Expansion (PCE) with orthonormal Hermite / Legendre bases
- Analytic / full sterilization surrogate models for fast UQ
Application suites — Pharma (Phase 2)
- Lyophilization (C3): end-to-end freeze-drying (freezing / primary / secondary) with a moving-boundary (Stefan) solver, Knudsen + molecular vapour transport, four in-solver safety constraints (collapse / meltback / condenser overload / choked flow), cycle-time optimisation, Pikal / Velardi literature validation
- Lyophilization — Tier 1 commercial physics: pressure-dependent vial heat transfer Kv(P), QbD design-space scan (
lyo design-space), dried-layer resistance Rp(X), pressure-rise test with MTM inversion (lyo prt), and parameter estimation (lyo calibrate) - Lyophilization — Tier 2 batch & chamber system: batch / vial-position model with edge-vial effect (
lyo simulate --batch, weighted P50/P95/P99 envelope), chamber-pressure closed loop with condenser mass balance (lyo simulate --chamber-closed-loop), and cGMP-style batch record (lyo report, MD/PDF + electronic batch-record fields) - Lyophilization — Tier 3 freezing structure, calibration & secondary drying: freeze-recipe model (controlled nucleation / anneal hold / frozen-fraction trajectory), nucleation→ice-crystal→pore→Rp structure linkage, mannitol JMAK crystallization raising the effective collapse temperature, Bayesian calibration (
lyo calibrate --bayesian, Laplace posterior + 95 % credible intervals), robust design space (lyo design-space --robust, Monte-Carlo parameter uncertainty with a 0.95 feasibility boundary), and spatially-resolved secondary drying (1-D diffusion-desorption PDE, water-activity GAB/BET/Oswin endpoint) - Lyophilization — Tier 4 PAT & intelligent control: synthesized PAT sensors (
lyo simulate --pat: Pirani/CM ratio, wireless probe), multi-criterion endpoint detection (lyo endpoint, ratio/temperature/PRT/fusion < 10 % error), model-based adaptive control (lyo control: feedforward + PI shelf/pressure control with anti-collapse override, ~4× faster than the open-loop baseline), per-batch energy & cost (lyo energy+ optimizermin_energy), and lyo-specific sensitivity analysis (lyo sensitivity: Morris/Sobol over kv/rp/P/T_shelf/nucleation_T) - Fluid-bed drying (C4): two-phase (emulsion + bubble) drying model with Wen & Yu / Mori & Wen / Gunn / Sit & Grace correlations, U/Umf reporting, falling-rate kinetics (Page / Henderson-Pabis / linear), drying-time optimisation
Application suites — Thermal Systems
- Heat pumps & district networks: vapour-compression design point (CoolProp), AHRI 540 compressor fits, fin-and-tube heat-exchanger sizing (Wang / Shah / Gungor-Winterton), multi-standard seasonal performance (GB IPLV / EU SCOP + energy label / US SEER-HSPF), cross-option LCOH (heat pump vs boiler vs district), ground-source borefield sizing (Kavanaugh + cylindrical-source G-factor, ASHRAE / GB 50366), transcritical CO₂ cycles (gas cooler + IHX), defrost model + COP maps, equipment catalog with COP-vs-capacity interpolation, Hardy-Cross / Newton-Raphson district-network hydraulics + Optuna pipe sizing, and transient network heat transport with weather compensation and storage tanks
- Furnaces & waste-heat recovery: stoichiometric combustion + adiabatic flame temperature (NIST Shomate), closed-form heat balance, multi-layer refractory walls (ISO 6946, optional FEM), flue-gas recovery (air preheater / waste-heat boiler / heat pipe) with acid-dew-point protection, hydrogen / ammonia fuel switching with zonal uniformity, in-furnace gas radiation, O₂-trim combustion control, transient batch thermal cycles, Optuna efficiency optimisation
- Building HVAC: CTF-based peak loads, ASHRAE solar geometry, dual annual-energy engines (fast bin method + full-year hourly 8760 h), carbon accounting + TOU / demand-cost tariffs, 3-objective Pareto optimisation (energy × carbon × cost), UQ sensitivity screening (Morris / Sobol), future-climate SSP scenarios (2050/2080), ASHRAE 62.1 ventilation + CO₂ DCV, Fanger PMV/PPD thermal comfort (ASHRAE 55), VAV / DOAS system energy models, three-standard compliance (GB 50189 / ASHRAE 90.1 / EU ERP), engineering report PDF, thermal bridges (ISO 10211, optional FEniCSx FEM), envelope scan & optimisation
Compliance & reporting
- FDA 21 CFR 113, EU 853 (F₀ ≥ 3, EN/FR/DE), GB 8950 (中文) reports → Jinja2 + reportlab PDF
- Batch compliance validation from CSV (FDA / EU / GB criteria)
Data
- 1,265 food property entries (8 categories; USDA SR Legacy + ASHRAE Ch.19 curated expansion, each with provenance
source=usda_<FDC_ID>/ashrae_2022), 118 microbial kinetics entries, 48 quality kinetics entries, 99 growth-kinetics entries (CSV-backed, cross-validated against USDA PMP boundaries; microbes carryT_range_Cand D-valueuncertainty_pct; derived freeze-point/latent-heat correlations documented inworkspace/calibration_database/tools/) - Thermal / built-environment data (source-keyed CSVs, literature-calibrated by
benchmarks/validation_thermal_data.pyagainst ISO / AHRI / JANAF / ASHRAE anchors): 43 thermal materials (49 registered — Ch.33 insulations, masonry, metals, woods, soils, stones, ice), 22 surface radiation properties (emissivity / solar absorptivity, Ch.4), 27 equipment catalog entries across 10 categories (chillers, heat pumps, VRF, boilers, furnaces, AHU, pumps, cooling towers), 9 occupancy schedules, engineering defaults (heat-pump / furnace / thermal-bridge Psi / ground / ventilation / combustion / carbon pricing); Ch.1 psychrometrics cross-validated against the ASHRAE saturation tables
Quick Start
# From PyPI (after the v0.2.0 release) or from source:
pip install thermocraft # or: pip install -e ".[dev]"
thermocraft --version # smoke check: prints v0.2.0
# Sterilization simulation + plot
thermocraft sterilize --config examples/canned_tuna_sterilization.yaml --plot
# Freezing simulation
thermocraft freeze --config examples/frozen_peas_blast_freezer.yaml --plot
# UHT simulation
thermocraft uht --config examples/uht_milk_137C.yaml --plot
# Uncertainty quantification (Monte Carlo)
thermocraft uq run --config examples/canned_tuna_sterilization.yaml --n-samples 2000
# Regulatory compliance report (FDA / EU / GB)
thermocraft compliance report --config examples/canned_tuna_sterilization.yaml \
--regulations fda_113,eu_853,gb_8950
thermocraft compliance-batch batch_plan.csv --regulations fda_113,eu_853,gb_8950
# Production scheduling demo
thermocraft schedule --config examples/process_system/scheduling_demo.yaml
# Lyophilization (freeze-drying) simulation + safety report
thermocraft lyo simulate --config examples/lyo_sucrose_5pct.yaml --plot
thermocraft lyo safety-check --config examples/lyo_sucrose_5pct.yaml
thermocraft lyo optimize --config examples/lyo_sucrose_5pct.yaml --n-trials 50
thermocraft lyo design-space --config examples/lyo_sucrose_5pct.yaml --no-plot
thermocraft lyo prt --config examples/lyo_sucrose_5pct.yaml --no-plot
thermocraft lyo calibrate --config examples/lyo_sucrose_5pct.yaml --params "h_shelf,rp"
# Tier 2 — batch, closed-loop chamber, batch record
thermocraft lyo simulate --config examples/lyo_sucrose_5pct.yaml --batch --vials-per-shelf 1000 --n-shelves 10
thermocraft lyo simulate --config examples/lyo_sucrose_5pct.yaml --chamber-closed-loop
thermocraft lyo report --config examples/lyo_sucrose_5pct.yaml --batch --format pdf --batch-id B01
# Tier 3 — Bayesian calibration, robust design space
thermocraft lyo calibrate --config examples/lyo_sucrose_5pct.yaml --params "h_shelf,rp" --bayesian --n-samples 500
thermocraft lyo design-space --config examples/lyo_sucrose_5pct.yaml --robust --n-mc 100 --no-plot
# Tier 4 — PAT sensors, endpoint, adaptive control, energy, sensitivity
thermocraft lyo simulate --config examples/lyo_sucrose_5pct.yaml --pat
thermocraft lyo endpoint --config examples/lyo_sucrose_5pct.yaml --method fusion
thermocraft lyo control --config examples/lyo_sucrose_5pct.yaml --T-int-setpoint -36
thermocraft lyo energy --config examples/lyo_sucrose_5pct.yaml
thermocraft lyo sensitivity --config examples/lyo_sucrose_5pct.yaml --method morris
# Fluid-bed drying simulation + optimisation
thermocraft fbd simulate --config examples/fbd_paracetamol.yaml --plot
thermocraft fbd optimize --config examples/fbd_paracetamol.yaml --n-trials 50
# Thermal Systems — heat pumps, networks, furnaces, building HVAC
thermocraft hp design --config examples/thermal/hp_r32_office.yaml --with-hex
thermocraft hp annual --config examples/thermal/hp_r32_office.yaml --carbon
thermocraft hp ground --config examples/thermal/hp_ground_source.yaml
thermocraft hp lcoh --config examples/thermal/hp_vs_boiler_vs_network.yaml
thermocraft network solve --config examples/thermal/district_heating.yaml
thermocraft furnace design --config examples/thermal/tunnel_kiln_ceramic.yaml --fuel hydrogen
thermocraft furnace balance --config examples/thermal/tunnel_kiln_ceramic.yaml --transient
thermocraft furnace recovery --config examples/thermal/tunnel_kiln_ceramic.yaml
thermocraft hvac load --config examples/thermal/office_beijing.yaml
thermocraft hvac energy --config examples/thermal/office_beijing.yaml --method hourly --carbon --cost
thermocraft hvac energy --config examples/thermal/office_beijing.yaml --sensitivity sobol
thermocraft hvac optimize --config examples/thermal/office_beijing.yaml --objective pareto --n-trials 60
thermocraft hvac compliance --config examples/thermal/office_beijing.yaml \
--standard gb50189-2015,ashrae90.1-2022,eu-erp-en14825 --report pdf
CLI Commands
thermocraft sterilize Food sterilization simulation / optimization
thermocraft freeze Freezing simulation / optimization
thermocraft uht UHT heat-exchanger simulation
thermocraft validate Run validation benchmarks
thermocraft db Food / kinetics database queries
thermocraft shelf-life Shelf-life prediction
thermocraft deviation Process deviation analysis (FDA 21 CFR 113)
thermocraft continuous Continuous equipment (hydrostatic / rotary / SSHE / ohmic)
thermocraft schedule Batch scheduling
thermocraft sensitivity Morris / Sobol sensitivity analysis
thermocraft uq Uncertainty quantification (MC / PCE)
thermocraft compliance Compliance report generation (fda / eu / gb)
thermocraft compliance-batch Batch compliance validation
thermocraft lyo Lyophilization suite (simulate / optimize / validate / safety-check)
thermocraft fbd Fluid-bed drying suite (simulate / optimize / validate)
thermocraft hp Heat-pump suite (design / annual / seasonal / ground / lcoh / optimize)
thermocraft network District heating/cooling network (solve / optimize)
thermocraft furnace Furnace suite (design / balance / recovery / optimize)
thermocraft hvac Building HVAC suite (load / energy / scan / optimize / thermal-bridge / compliance / design)
thermocraft --version Show version
Architecture
thermocraft/
├── core/ # Suite-agnostic physics engines (heat transfer, kinetics, units, PDE solvers, solver dispatcher)
├── suites/
│ ├── food/ # Sterilization, Freezing, UHT, Shelf-life, Scheduling
│ ├── pharma/ # Lyophilization, Granulation
│ └── thermal/ # Heat pumps & district networks, Furnaces & recovery, Building HVAC
├── analysis/ # Sensitivity (Morris/Sobol), UQ (MC/PCE), surrogate models
├── compliance/ # FDA 21 CFR 113 / EU 853 / GB 8950 report generation, batch validator
├── io/ # Export (CSV/JSON), matplotlib plotting, retort profiles
├── config/ # Pydantic schemas + YAML defaults
├── data/ # Food property & kinetics databases
└── cli/ # Typer command-line interface
Layering is strictly inward: cli → suites/analysis/compliance → core. New solvers register through solver_dispatcher; new reports through ReportFactory — no changes to existing modules required.
Running Tests & Benchmarks
# Fast unit-test set (default; ~5-6 min, 1800+ tests). Full-precision
# integration cases (Bayesian / robust design space / closed-loop control /
# Optuna Pareto / calibration fits) are marked `slow` and run in a dedicated
# CI job: `pytest -m slow`.
python -m pytest tests -q -m "not slow"
# Full-precision slow set (dedicated CI job)
python -m pytest tests -q -m slow
# Validation benchmarks (physical-simulation / process-system / advanced-
# analysis / thermal-systems / multi-source, auto-collected)
python -m pytest benchmarks -q
# Analytical-solution benchmarks (script-based, run explicitly)
python benchmarks/validation_ball_1923.py
python benchmarks/validation_plank_1913.py
python benchmarks/validation_literature.py
# Lint & type check
python -m ruff check src
python -m ruff format --check src
python -m mypy src
Benchmarks named
validation_*.pyare not auto-collected by pytest; run them explicitly as above (also wired into CI).
Documentation
Hosted docs: https://thermocraft.readthedocs.io (auto-built from main and versioned by git tags).
Full documentation (RST / Sphinx) lives in docs/source/: theory (sterilization, freezing, UHT, heat pumps, furnaces, building HVAC), suite overviews (food / pharma / thermal systems), advanced guides (sensitivity analysis, uncertainty quantification, compliance, thermal design-space optimisation, HVAC compliance) and tutorials (food & pharma + thermal systems). See docs/source/index.rst.
Requirements
- Python ≥ 3.11
- NumPy ≥ 1.26, SciPy ≥ 1.12, pandas ≥ 2.1, matplotlib ≥ 3.8
- CoolProp ≥ 6.6 (thermophysical properties)
- Pydantic ≥ 2.5, PyYAML ≥ 6.0
- Typer ≥ 0.12, Click ≥ 8.1
- Optuna ≥ 3.5 (optimization)
- Optional: FEniCSx / dolfinx ≥ 0.8 + mpi4py (2D/3D FEM backend; requires WSL2 on Windows)
License
Apache-2.0
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