EngineeringCFD

Specialists
In Fluid Dynamics
Contents
I. EngineeringCFD
II. Introduction to CFD
III. Capabilities and Scope
IV. Multiphase Examples
V. Case Studies
VI. Summary
Principle Engineer
Curtis Marsh
13 years design experience for the
chemical process industry.
Expert Computational Fluid
Dynamics (CFD) analyst.
Specialising in multiphase and
multiphysics simulations.
Proven technical ability supported by
excellent inter-personal skills.
Design Services
Chemical Process
Plants
Equipment
Suppliers
Engineering
Consultancies
Rusal
FLSmidth
Vaudreuil
Windalco
SKM
Momentum
RioTinto
Alcan
QAL
Yarwin
Cadburys
Fonterra
Hulme Supercars
Project Integration
What is CFD?
CFD = Computational Fluid Dynamics
Computer models that predict how fluids behave
Uses mathematical models to describe aspects of
fluid behaviour
Use commercial CFD software from ANSYS
Based on the finite volume approach
Know the basics?
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CFD Step 1
Geometry Creation
Create from 2D
drawings
Import from a range
of CAD packages
Parasolid
IGES
STEP
ACIS
CFD Step 2
Develop mesh
Define boundary
conditions
CFD - Step 3
Setup boundary
conditions
Initialise solution
CFD Step 4
Iterate to
convergence
Steady state
problems
Transient problems
CFD Step 5
Post-Process
Results
Quantify
Mass flux
Velocities
Pressures
Forces
Lift/Drag
Free surface
CFD Capabilities
Single phase
Multiple phases
Chemical species
Chemical reactions
Combustion
Erosion
Heat transfer
Mass transfer
Phase change
Mechanical movement
Ventilation
Solidification
Equipment Types
Piping systems
Pressure vessels
Cyclones
Dryers
Filters
Calciners
Furnaces
Burners
Tanks
Flash vessels
Overflows
Launders
Pumps
Agitators
Mixing devices
Choke valves
Gas dispersion
Gas lift devices
Slug catchers
Multiphase Examples
Free Surface
Model
Can be applied to:
Launders/Overflows
Sloshing in Tanks
Slug Flow
Gas-Liquid Separators
Water-Oil Separation
Link to animation
(engineeringCFD.com)
Multiphase Examples
Discrete Phase
Model
Can be applied to:
Particle separation
Particle impact
Sprays
Droplets
Erosion
Multiphase Examples
Granular
Solids Flows
Can be applied to:
Cyclones
Pneumatic conv.
Settling solids
Link to animation
(engineeringCFD.com)
Multiphase Examples
Rotating
Equipment
Can be applied to:
Agitated Tanks
Pumps
Blowers
Compressors
Link to animation
(engineeringCFD.com)
Case Studies
Project examples
Flashing Flows (Rusal Aughinish)
Alumina Calciners (FLSM/RioTinto/SKM)
Segregated Fluids
CASE STUDY:
FLASHING FLOWS
Rusal Aughinish
Ireland
Alumina Refinery
1.8 million tonnes pa.
Complex multiphase flow
Historically difficult to design
Rapid phase change from
liquid to vapour
Potentially extreme erosion
rates
Objective
Design a balanced system
which maintains stable levels
within each vessel
Flashing Flows
Calculation Steps
Determine Flow Field
Super Heat
Saturation Temp
Bubble Nucleation
Interfacial Area
Mass & Energy Transfer
FLUENT
EngineeringCFD
Subroutine
Validation
Experiment 7.01 kg/s
Calculated
Flow
7.12 kg/s
(+1.6%)
Flash Vessels
Project scope was
to determine the
effect of piping
modifications
Orifice
Plate
Process Data 910 kg/s
Calculated Flow 980 kg/s
(+8%)
Application of the Flashing Flow Model
Piping design for multiphase flow
Orifice plate sizing
Evaluation of proposed vessel modifications
Development of new inlet nozzles to improve
separation within flash vessels.
Flash Tank Projects
CASE STUDY:
ALUMINA CALCINERS
FLSmidth
RioTinto Alcan
Rusal Aughinish
Sinclair Knight Merz
Queensland Alumina
Design Challenges
Complex processes
Combustion / pyrolytic reactions
High Solids Loading
Heat Transfer
And complex problems
Particle breakdown
Refractory erosion
Emission targets
Limits on production
Calciner Furnaces
Complex coupled
physical processes
Combustion
High Solids Loading
Calcination process
Heat Transfer
Changing gas
composition
Solids
Burners Gas Flow
Calciner Furnaces
Link to animation
(engineeringCFD.com)
Projects
Many projects have benefited from our
modelling expertise
Development of new furnace geometries
(RUSAL/FLSM)
Change gas distribution to improve combustion
(RUSAL)
Modify geometry to increase capacity
(SKM)
Developed new hydrate feed points
(RioTinto/FLSM)
CASE STUDY:
SEGREGATED FLUIDS
Segregated Fluids
VOF free
surface model
Suitable for a
wide range
of flow
regimes
Liquid Mass Flux
G
a
s

M
a
s
s

F
l
u
x
VOF Model
Fluid Properties
Key Physical Processes
Surface tension
Wall contact angle
Compressibility of gas phase
Pressure distribution
Wall/body interaction forces
Pipe Flow Example
Ideal Gas
= 50 kg/m
3
Light Liquid
= 700 kg/m
3
Heavy Liquid
= 1200 kg/m
3
Surface Tension
0.014 N/m
Surface Tension
0.1 N/m
Contact Angles
90 degrees
Complex Flow
Link to animation
(engineeringCFD.com)
EngineeringCFD
Adding Value to the design process:
Proof of concept
Determine key design variables
Extract key performance data
Explore the full design envelope
Problem solving new & existing equipment
EngineeringCFD
Ultimately EngineeringCFD provides:
Rapid project development
Risk mitigation
Reduced commissioning/maintenance costs
Greater process efficiencies
EngineeringCFD.com