EngineeringCFD General Presentation - Web Version

							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


                       Rusal
Vaudreuil
                               FLSmidth


            Windalco
                        Equipment                        Engineering
                         Suppliers                      Consultancies
                                                                               RioTinto
                                                                               Alcan
                                                                               QAL
                                     Chemical Process                          Yarwin
                                         Plants           SKM
                                                          Momentum
                                                                        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?
                                          Click here to skip
                        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          • Heat transfer

• Multiple phases       • Mass transfer

• Chemical species      • Phase change

• Chemical reactions    • Mechanical movement

• Combustion            • Ventilation

• Erosion               • Solidification
                                 Equipment Types
•   Piping systems     •   Agitators
•   Pressure vessels   •   Mixing devices
•   Cyclones           •   Choke valves
•   Dryers             •   Gas dispersion
•   Filters            •   Gas lift devices
•   Calciners          •   Slug catchers
•   Furnaces
•   Burners
•   Tanks
•   Flash vessels
•   Overflows
•   Launders
•   Pumps
                           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.
 Flashing Flows
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
                 Calculation Steps

       FLUENT    Determine Flow Field

                    Saturation Temp


                       Super Heat

EngineeringCFD     Bubble Nucleation
  Subroutine

                     Interfacial Area


                 Mass & Energy Transfer
                         Validation

Experiment   7.01 kg/s

Calculated   7.12 kg/s
Flow
             (+1.6%)
                             Flash Vessels

• Project scope was
  to determine the             Orifice
  effect of piping              Plate
  modifications

Process Data      910 kg/s

Calculated Flow   980 kg/s

                  (+8%)
                       Flash Tank Projects

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.
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            Solids

–   High Solids Loading
–   Calcination process
–   Heat Transfer
–   Changing gas
    composition
                             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                             VOF Model
surface model
• Suitable for a   Gas Mass Flux
  wide range
  of flow
  regimes




                                                 Liquid Mass Flux
                         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
 ρ = 50 kg/m3

Surface Tension
  0.014 N/m
  Light Liquid
 ρ = 700 kg/m3
Surface Tension
    0.1 N/m

 Heavy Liquid
ρ = 1200 kg/m3              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