Computing power has increased exponentially (Moore’s law is to thank!), making Computational Fluid Dynamics (CFD) a commonly employed tool for solving fluid flow problems. Engineers evaluate fluid characteristics like pressure, velocity, density, temperature, and viscosity through a CFD analysis.
To reproduce an accurate virtual solution, engineers must simultaneously consider the properties of a fluid flow phenomenon. This issue of fluid dynamics simulation was particularly prevalent in problems related to building, infrastructure, oil and gas, and water division sector to provide design solutions. So, how CFD analysis and simulation is offering prolific solutions to these problems? We’ll explore.
Computational Fluid Dynamics (CFD) is the study of fluid flows with numerical methods. CFD can be used to analyze fluid-liquid, fluid-solid, and fluid-gas interactions complex problems. Where lift, drag, pressures, velocities, and speeds are measured in engineering fields such as aerodynamics and hydrodynamics, CFD analysis is common.
A partial differential equation represents physical laws in fluid dynamics. The laws are transformed into algebraical equations, which can then be solved numerically using CFD solvers.
The three phases of a CFD analysis are as follows:
A computer model is developed by idealizing and discretizing the problem statement. To model and predict flows (viscous/inviscid, compressible/incompressible, steady/non-steady), assumptions are made. Other processes include mesh generation and boundary condition application.
Computing power comes in handy during this phase of solving, where the solver performs the computations. However, the efficiencies and capabilities of different solvers vary when trying to solve certain physical phenomena.
A post-processing phase visualizes and analyzes the results obtained. Based on that, the analyst can validate the results and conclusions. The results can take many forms, including graphic representations, tables, or static images.
Complex multidimensional fluid flow motions and associated heat transfer around various industrial equipment and facilities are essential to predict.
For many years, CFD analysis has been used to solve various engineering problems, and extensive experience and knowledge have been developed for successful applications of CFD.
Let us see how it works in the three primary industries: building and Infrastructure, Oil and Gas, and wastewater treatment plants:
Computational Fluid Dynamics (CFD) help predicts solutions to complex problems. Methodologies like this are especially suitable for evaluating what structures do and how they affect the environment.
Among other methodologies, CFD has a significant difference. It can predict the flow of energy and air, temperature-dependent movement based on geometry at each point.
Using this method, engineers can judge the performance of a building by analyzing airflow around objects, airflow through buoyancy, or the distribution of air within a building.
Thus, CFDs are helpful for a range of purposes like building design process in various ways, including:
Analysis of Thermal Comfort
Assessment of the risk of droughts resulting from wind movements, thermal buoyancy, and mechanical ventilation
Natural ventilation caused by buoyancy or wind
The efficiency of HVAC systems
Measures of pedestrian comfort based on wind speeds
Availability of air conditioning
Contamination, moisture, and heat dispersion resulting from a construction site
Ventilation systems that control smoke and CO
Data Centres – efficient ventilation and cooling systems
Composition and transport of moisture in the air
Thermal Bridging (2D, 3D)
Façade analysis
Including the dispersion of snow, hail, sand, and dust
The movement of liquids in pipes or channels
Industrial CFD can be a powerful and practical tool for designing equipment, optimizing refinery processes, designing offshore oil rigs/platforms, and studying fire risks and safety issues.
For instance, drill bits for efficient oil exploration/drilling use hydro cyclones for solid separation, offshore wind loading, fire dispersal, and mitigation strategies. All these need an exceptional analysis for accuracy. So again, CFD helps to make it seamless.
Drilling offshore involves mechanically drilling a hole through the seabed to reach the surface. Also, petroleum is typically extracted from rock formations underneath the seabed by deep-sea exploration and then extraction. Ensuring offshore rigs are solid against strong winds requires a CFD analysis to maintain oil flow inside piping systems.
Crude oil is converted into chemical products during the distillation process, such as liquefied petroleum gas (LPG), gasoline, diesel oil, and fuel oils. Other petroleum refinery processes include chemical engineering, equipment, and machinery. Optimum refinery processes can be achieved with CFD analysis.
A wastewater treatment plant system consists of many components that must work together harmoniously to function correctly. Water treatment plants must meet the following objectives:
maintaining high-quality standards
improving the efficiency of the treatment process
reducing project costs, and
increasing operational efficiency.
An effective treatment water flow system within the plant is vital to achieving these objectives. Chemical concentrations, residence time, contact time, and mixing efficiency all affect the dynamic nature of these flow processes.
Modeling with computational fluid dynamics allows for reliable prediction of complex interactions between treatments and can help in ensuring that the design objectives are met.
CFD models make it possible to study flow processes in three dimensions: sediment transport, chemical reactions, thermal processes, mixing processes, and aeration processes.
These processes work well for the types of simulations needed to advance the design of wastewater components and systems, but they all have their unique strengths and weaknesses.
Hence, modeling for design support begins with the choice of an appropriate process. Furthermore, mathematical models for simulating flow turbulence vary between processes, making it essential to choose the proper model to simulate chemical reactions, mixing processes, and sedimentation processes appropriately.
Numerical and computational simulation becomes more relevant as product development cycles shorten and products depend on precise performance to succeed. Fast, reliable, and easy workflows enable accurate performance predictions so that engineers can optimize before building the prototype.
With CFD simulation solution firms like Mechartes, which provides computational power and optimized workflow at affordable prices, manufacturers, even those on tight budgets, can benefit from these advantages at lower costs.
With cross-sectional analysis, CFD has the potential to discover much more than it could with physical models. CFD plays a vital role in reducing the risk involved with design elements by predicting their functionality earlier in the process, unlike later stages where changes will cost more.
Mechartes’ greater confidence in the outcome of their design intent is a direct result of introducing CFD simulation earlier in the process. As a result, it is possible to make changes quicker and easier when less uncertainty and more risk mitigation. In addition, using CFD simulation in conjunction with FEA simulation, virtual prototypes are created for verification rather than testing.
With Mechartes CFD analysis, engineers can analyze several CFD simulations in conjunction with FEA simulation issues related to turbulent and laminar flows, compressible and incompressible fluids, and multiphase flow. Here’s how it’s done:
Mechartes has gathered extensive experience in evaluating the effectiveness of smoke exhaust systems in facilities such as airports, malls, museums, and arenas.
Temperature, Humidity, Thermal Radiation, and Air Velocities are essential factors that determine thermal comfort inside a building. Mechartes use CFD to model these parameters accurately.
Different configurations of computer room air conditioning (CRAC) are numerically studied to determine the thermal performance of data centers.
In the building, construction, and infrastructure industries, pipelines are essential investments. Therefore, Mechartes uses CFD pipeline projects, simulation-based designs play a significant role.
Wind-driven flows can negatively impact the structure, ventilation, & performance of equipment. The analysis from Mechartes helps to identify them in the early stage to save the impact.
In order to measure the sound pressure levels outside a building, Mechartes conducts an acoustic study.
Clients may encounter various issues when operating the plant day-to-day.
Mechartes uses advanced engineering tools and mathematical studies to investigate the root cause of the problem and find a solution.
Internal tanks are designed so that water and oil will be separated through gravity. In addition, Mechartes ensures the design within the tank maximizes the hydrodynamic flow behavior.
To achieve maximum homogenization inside the LFHO Storage Tanks, Mechartes determines the location and orientation of mechanical mixers.
Fatigue assessment by Mechartes using FEA helps estimate the design life and determine the equivalent Von-Mises stress in the inlet separator.
In water treatment, the objective is to make the water more suitable for the specific end-use.
Using the de-duster design, up to 90 percent of clinker dust can be captured and separated before the flue gases enter the boiler.
Mechartes provides a detailed efficiency analysis study based on numerical analysis to resolve the problem. In addition, advanced engineering tools are used to validate the solutions.
By doing CFD analysis, Mechartes help improve the flow profiles throughout the downcomer duct and reduce the pressure drop.
Fatigue failure analysis helps to identify structure failures caused by automobile OEMs
Mechartes is doing many ongoing projects across the globe for clientele like Ae7, Fabslink, Syska, Kinetics Middle East, PDD, etc., The projects include:
CFD outdoor thermal comfort
CFD thermal comfort modeling
CFD external flow analysis of chillers & generators’ fuel gases dispersion
Stress Analysis and Support Design
CFD Smoke and Evacuation Analysis for Atrium and Car parking
Previously they have worked for Ruhrpumpen, Genetco, B&W Engineering, QIEFM, Meindhardt, etc., on projects like pulsation analysis, CFD Modelling for POD 4,5 and 6, CFD Modelling for Data Center and Drups Room, etc.
As a result of Mechartes’ venture into CFD, clients can now patent innovations and protect their core differentiation, an essential aspect of their business strategy. Check out our list of esteemed clients here.
Need an expert consultation in implementing CFD analysis and CFD simulation? Mechartes offers a comprehensive service of CFD analysis and simulation.
