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CFD SIMULATION FOR INDUSTRIAL PROCESSES

The Modeling and Simulation (ModSim) area of ProCycla aims to promote the use of Computational Fluid Dynamics (CFD) as a tool to design and optimize industrial processes involving the use of fluids.

Computational fluid dynamics consists of the use of computers and numerical techniques to solve all those physical problems that are related to the movement of fluids, as well as other associated phenomena such as heat transfer, chemical reactions and dragging of solids.

Sample of an aeration system in an open tank with water. Made with OpenFoam and visualized in Paraview.

By building a digital twin, we can help you select the best reactor geometry or process operating conditions.

We offer flexibility in the use of software, being able to use either commercial programs such as Ansys, Inc or open access programs such as OpenFoam to perform the simulations and solve the mathematical equations that express the laws that govern fluids.

What types of systems can we represent with CFD?

Fluid dynamic modeling (CFD) involves solving the equations that govern the transport of motion, mass and energy of a fluid, considering its variations in time and space.

Therefore, CFD-based virtual prototypes are the models that allow the most realistic representation of fluid dynamic phenomena, enabling the study of a wide variety of industrial processes, including:

  • Single-phase and multiphase systems
  • Systems with Newtonian and non-Newtonian fluids
  • Systems with mechanical and pneumatic mixing
  • Systems with laminar, transitional and turbulent flow regimes

What characteristics of a system can we study with CFD?

Emptying of water in a closed tank. Simulation performed with OpenFoam and visualized in Paraview.

Virtual prototyping can be used to study key features to optimize the efficiency and performance of industrial processes, such as:

  • flow patterns,
  • occurrence and distribution of dead volumes,
  • vortex formation,
  • residence time distribution,
  • component concentration profiles,
  • temperature profiles, etc.

Unlike other types of models, digital twins have the advantage of allowing to characterize the mentioned variables both in space and time, achieving a complete understanding of the process.

Advantages in the use of CFD techniques

CFD techniques have many advantages. First of all, they allow us to obtain very valuable information on each of the variables of industrial flows and reduce the costs derived from experimentation or new designs.

CFD gives us the possibility of analyzing systems or conditions that are very difficult to reproduce experimentally without affecting the development of the process, such as very high or low temperatures, relative movements, etc. However, it is important to have a qualified professional to run programs and define models.

In addition, it allows to reduce the carbon footprint generated by any industrial process.

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