Industrial equipment

CFD modeling for industrial equipment

The optimization of industrial equipment is a key issue for companies, in order to improve performance and product quality, or reduce production costs. Computational fluid dynamics (CFD) is an essential solution for modeling fluid flows, heat transfers and complex interactions in industrial processes. Thanks to CFD simulation, companies can optimize the design and efficiency of their equipment, while limiting the number of tests and prototypes required for development.

Here are the main applications of CFD simulation for industrial equipment.

Heat exchangers

• Geometric optimization: Heat exchangers are crucial for cooling, heating and energy recovery in industrial processes. CFD simulation can be used to optimize heat transfer and fluid flow inside heat exchangers. Coupled with optimization methods, simulation can help improve energy efficiency, reduce heat loss and maximize the performance of industrial systems by proposing geometric modifications that are difficult to intuit.
• Simulation of real-life operating conditions: heat exchangers function in environments where operating conditions (temperatures, pressures, flow rates) can vary considerably. Thanks to CFD simulation, it is possible to test different operating scenarios, such as variations in the flow rate or temperature of incoming fluids, and assess the impact on overall equipment performance (efficiency under partial or maximum load conditions, or disturbances).
• Reducing pressure losses: pressure losses in a heat exchanger are a key factor influencing overall energy efficiency. The higher the pressure drop, the more energy is required to pump fluids through the equipment. By simulating fluid flows in these complex geometries, it is possible to visualize turbulence, stagnation zones or recirculation phenomena that increase pressure drops, and to make the necessary adjustments.
• Flow balancing : these pressure losses can also lead to flow imbalances, resulting in localized overheating or loss of efficiency. CFD simulation ensures that fluid flows are balanced throughout the equipment.

Design of industrial ventilation systems

• Thermal comfort and air renewal: one of the key objectives of a ventilation system is to guarantee optimum air circulation in industrial spaces. CFD simulation can be used to model air flows in closed environments, identifying stagnation zones, undesirable draughts or areas where air quality may deteriorate, and then correcting these phenomena by modifying system design or the positioning of supply and exhaust air.
• Targeted cooling or blowing/extraction: Some industrial equipment or processes require localized cooling zones, or special attention to the risk of back-contamination. CFD simulation helps design ventilation systems that direct fresh air flows to these specific zones, or create air curtains protecting sensitive areas of an industrial process.
• Natural vs. mechanical ventilation: by modeling internal flow and external meteorological conditions, as well as the effects of architecture, it is possible to evaluate the possibility of using natural ventilation, and to compare the results obtained with forced mechanical ventilation.

Optimization of combustion systems

• Burner design: Burners must be designed to ensure homogeneous mixing of air and fuel, and complete combustion. Modeling makes it possible to test different burner designs and simulate the impact of geometry on air flow, mixing and flame stability. These simulations enable us to design burners that optimize combustion efficiency and reduce the production of pollutants.
• NOx and soot formation: The formation of nitrogen oxides (NOx) and soot particles is a major problem in industrial combustion systems. By simulating temperatures, residence times and concentrations of chemical species, CFD enables to better understand the conditions that favor the formation of these pollutants, and to propose solutions for reducing them.
• Optimization of heat flows: By modeling heat transfer by conduction, convection and radiation, CFD provides a better understanding of how heat propagates in the combustion chamber.
• Optimization of fuel injection systems: Fuel injection systems are crucial in determining combustion quality. CFD simulation enables us to model fuel flows, evaporation and mixing processes, as well as droplet atomization. By adjusting injection conditions, it is possible to improve combustion and ensure better fuel distribution, leading to increased efficiency.

Turbomachinery

• Pump and compressor design: for certain applications, depending on fluid properties, flow rate and specific speed, it may be difficult to find suitable commercially available booster pumps and compressors. OptiFluides can help you design a new pump to meet these needs.
• Improving diffusers: diffusers are essential for slowing down and regulating flows at turbine or compressor outlets. Thanks to CFD, it is possible to simulate pressure and velocity variations in diffusers, enabling their design to be optimized to minimize pressure drops and ensure efficient conversion of energy to the fluid.
• Cavitation detection: by modeling the flow and pressure conditions that favor cavitation in turbomachinery, we can identify areas at risk, and propose design adjustments to avoid these destructive phenomena.

   

Fluid networks

• Reducing pressure losses: pressure losses in piping and fluid transport systems can reduce energy efficiency, especially in hydraulic circuits. OptiFluids helps you to identify and correct the critical areas at the origin of these losses.
• Network equilibration: CFD simulation can also be used to determine the flow rate in each branch of a network, and to make the necessary modifications to achieve the desired flow rates in each branch.
• Model reduction: in order to integrate the system studied into control or monitoring software, simulation can be used, for example, to characterize the flow/pressure drop law as a function of operating conditions.

Filtration and particle separation systems

Filtration and particle separation systems are essential for treating air, water and chemicals in many industrial sectors. Cyclones, decanters and porous membranes are just a few examples. These systems can be modeled by integrating flows and particle behavior.

Conclusion

These examples show how CFD simulation can improve performance, reduce costs and extend equipment life. This is just a non-exhaustive list, and it’s a safe bet that if you’re faced with a problem involving fluid flow in your product design, simulation can provide some answers. Industrial companies can thus innovate, increase their competitiveness and meet environmental challenges.

If you’d like to optimize your industrial equipment using CFD simulation, our team will be happy to provide you with tailor-made solutions. Contact us for further information!