What Is a CFD Simulation?
Computational Fluid Dynamics (CFD) simulation services is the most accurate and cost-effective approach available today for conducting research, helping to prevent high expenses in the future. The method involves creating a precise digital replica of an industrial object to facilitate calculations and check all necessary technological parameters for operational enterprises and those in the design phase.
How Does It Work?
Computational Fluid Dynamics (CFD) is a branch of science and engineering that deals with numerical modeling and analysis of fluid and gas flows, including heat transfer. CFD uses computer methods and algorithms to solve equations describing physical processes, such as the Navier-Stokes equations.
The purpose of Computational Fluid Dynamics (CFD) is to investigate the behavior of fluids and gases under multiple conditions, allowing engineers to analyze and optimize various systems such as gas turbine plants, heating furnaces, aerodynamic shapes, heat exchangers, burners, boilers, and many processes, where understanding the dynamics and interaction of fluids and gases, as well as heat transfer, is crucial.
CFD engineering services are applied both at the design phase and for verifying the effectiveness of the decisions made for a working enterprise to identify bottlenecks and search for optimal operating modes in production.
Computational modeling is suitable for use in many industries:
- metallurgy,
- power industry,
- petrochemical industry,
- machine building.
CFD allows the company specialists to promptly respond to incoming requests, perform necessary calculations and studies, and provide the customer with consultations and the issuance of technological solutions.
Workflow of a CFD Consulting Services
The process of computational modeling consists of several stages:
- Description and selection of the calculation concept.
- Create a three-dimensional calculation model. 3. Set boundary conditions.
- Calculation and subsequent analysis of the results.
Mathematical modeling starts with creating a detailed three-dimensional model of the studied object. Our specialists develop a model of any complexity based on the customer’s drawings.
The computational model considers all calculation areas – domains, contacts, and interactions. The precision of the model’s design determines how reliable the computation results are.
Model of a double-flow tuyere stock.
Meshing and creation of mesh interfaces
The critical step in the finite element method is mesh generation. This is dividing the model into small parts (finite elements). Based on them, a system of equations can be written, describing the solution of the central equation. The mesh also represents the geometric domain in which the physical problem will be solved.
The solution’s convergence depends on the mesh quality and selection of the appropriate mesh generation method.
The convergence of the solution in the Finite Element Method (FEM) indicates how accurately the numerical solution approximates the proper solution of the mathematical problem as the number of elements increases, or other parameters of the method improve. In the context of FEM, convergence is a crucial concept, indicating that the solution approaches the actual behavior of the physical system.
The closer the numerical solution is to the proper solution, the more convergent the method is considered. Visually, convergence can be represented as a reduction of the error between the numerical solution and the exact solution with an increase in mesh resolution (number of elements) or other parameters of the Finite Element Method (FEM).
However, convergence does not imply that increasing the number of elements always leads to a more accurate result. Incorrect parameter choices, improper formulation of boundary conditions, or other aspects can also influence convergence and the accuracy of the solution.
The choice of element size is a sensible balance between the computer’s calculation speed, accuracy, and computation capacity.
Fragment of the tuyere stock mesh
CFD Simulation
The calculation is performed after creating a three-dimensional model, generating an optimal mesh, and defining boundary conditions.
Calculation is performed on computational clusters with sufficient RAM capacity to accommodate all computational domains.
The criterion for the calculation termination is convergence of the result.
The calculation can be in a stationary, quasi-stationary, or non-stationary setting.
The physical time of the calculation varies from several hours to several days and sometimes weeks.
Upon completing the calculation, we analyzed the results we obtained.
Long-term calculation of multiphase flow in a non-stationary setting: 83 seconds of real-time correspond to several hours of computational time. (!) The calculation converges.
Analysis and Presentation
The obtained results are visualized Upon completion of the calculations. We create views and cross-sections of the model, verifying the credibility of the results, including flow rate, pressure, heat flux, temperature, density of the medium, flow velocity, etc.
We visualize flow lines and the movement of particles.
At any computational point, it is possible to obtain all medium characteristics.
The client has a complete visualization of the computational domains and a comprehensive work description. If necessary, we conduct a comparative analysis, show the dynamics on graphs, and summarize the results in tables.
The figure depicts the solid phase-captured particles in the cyclone.
Scope of Our CFD Consulting Services
We are happy to offer our CFD modeling and thermal calculations services. The CFD consultants at M HEAVY TECHNOLOGY are ready to provide you with professional expert assistance.
Applying advanced technologies, we will design optimal equipment configurations or individual elements of technological units, determine the best operating modes for installations, and solve many other problems.
M HEAVY TECHNOLOGY uses software calculation complexes to conduct experiments and find optimal solutions for technological processes of:
- metallurgical and blast furnace production facilities, as well as auxiliary productions in the metallurgical industry;
- energy facilities for thermal and electrical energy generation;
- gas cleaning and dust collecting units
- and other objects of metallurgical and mining and processing complexes.
Our consultants are highly qualified experts in the field of thermal calculations. The specialists at M HEAVY TECHNOLOGY have extensive experience performing projects of various complexity and will assist you in achieving your goals. We will conduct precise thermal calculations to help you make reasoned decisions in your projects and ensure their successful implementation.
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Why Choose CFD from M HEAVY TECHNOLOGY
Cooperation with our company is a successful decision for several good reasons.
Unique Experience of the Company’s Specialists
The company can offer unique knowledge and experience in finding solutions to solve complex problems. All CFD engineering solutions M HEAVY TECHNOLOGY have been implemented at enterprises and have been highly appreciated by Customers.
Expanding Markets and Customer Base:
Сollaborating with our company can provide access to new markets, customers, and audience segments. This can contribute to the expansion of products or services, as well as the broadening of geographical coverage.
Risk Reduction and Workload Distribution:
Partnerships with the company can share engineering and technical risks. This can be especially beneficial when implementing large projects or introducing complex solutions.
Access to Resources and Infrastructure:
Cooperation can access existing infrastructure, computing capacities, equipment, or other resources that can significantly accelerate development and implementation.
Joint Marketing Impact:
Partnerships with our company can amplify marketing impact by jointly conducting advertising campaigns, events, and promotions, contributing to increased brand awareness and attention.
Achievement of the Synergies:
Combining the efforts and resources of two companies can lead to a synergistic effect, promoting a more efficient and successful achievement of common goals.
These aspects emphasize the importance of collaborating with a company to achieve mutual benefit and success in a dynamic and competitive business environment.
M HEAVY TECHNOLOGY CFD Professionals and Engineers
CFD Case Studies
One of our recent projects was implemented at a phosphorus plant in Kazakhstan – thermal calculation of the ore-thermal furnace for phosphorus sublimation and computer modeling of processes inside the electric furnace.
We defined the following:
- Calculating temperature fields inside the electric furnace in quasi-steady-state mode.
- Hydrodynamic modes in various zones of the electric furnace, velocity fields of furnace gas, and slag.
- Conditions and rates of phosphorus reduction reactions.
✔️ Based on the calculation results, we determined thermal loads on the lining of the electric furnace, selected optimal lining materials, and optimized the cooling system.
A small part of the images from this CFD project are shown below, without formulas and conclusions.
Distribution of electric field potentials across the surface.
Distribution of electric field potentials in the cross-section XY.
Distribution of current density in the cross-section XY.
Volumetric heat generation. Isosurfaces.
Temperature distribution. XY plane. View of slag tap holes.
Skull formation isotherm
Isotherms of skull formation, YZ plane (existing cooling system on top, air cooling on bottom)