Computational Fluid Dynamics

and Heat Transfer for Industrial

Application
Presented by
R Ben Mansour
Lecture 1 for ME505
KFUPM, Aug 26, 2024
CFD -- A Practical Fluids Tool
Computational Fluid Dynamics
provides a practical tool for :

Design and development,

Process optimisation,

Fluid flow research

Why Computational Fluid Dynamics ?

Lead time in design and development

significantly reduced
CFD can simulate flow conditions not
achievable in experimental model tests
CFD provides more detailed and
comprehensive information
CFD is more cost-effective than
physical model testing
CFD provides:
Global information Local information
Pressure drop along a Maximum air velocity and
duct or through tube location in a ventilated
bank room

Mass flow rate through Control of maximum flue

heat exchanger gas velocity to avoid
economiser erosion

Wind loads on a building Critical burn out location

in heated steam pipes
 Future of CFD
The United States computational fluid dynamics market
size reached US$ 896.7 Million in 2023. Looking
forward, IMARC Group expects the market to reach US$
1,638.8 Million by 2032, exhibiting a growth rate (CAGR)
of 6.72% during 2024-2032.

United States Computational Fluid Dynamics Market

Report by Deployment Model (Cloud-Based Model, On-
Premises Model), End User (Automotive, Aerospace and
Defense, Electrical and Electronics, Industrial
Machinery, Energy, Material and Chemical Processing,
and Others), and Region 2024-2032
 Interior Flows

Interconnecting
floors & levels
forced and natural
convection
elevators & escalators
Hazard analysis
smoke & toxic gas
transport
fire spread and safety
measure determination
CFD Commercial Solvers Solvers
FLUENT 4.5 -- general purpose finite volume;
many physical models, multi-phase; pressure-based
FLUENT 6 -- general purpose finite volume;
unstructured grid; “aerospace applications”
solution adaption--optimal grid
Ansys Fluent 16 and more (Apr 2015)
NEKTON -- coatings; extrusion; viscous material
FIDAP 8 -- general purpose finite element;
pressure-based; multi-physics problems
MIXSIM -- mixing vessel analysis
ICEPAK --- electronic cooling
Aerospace Engineering & Defence
Rockets: pressure; heat transfer;
plumes-- particulate & radiation
Shock Waves & Explosions:
steady & unsteady -- solution adaption
Vortex Flows: delta wings; control
surface interference
Store Separation: static & dynamic
2D Multi-Element Airfoil
2D Multi-Element Airfoil
 Faster Product Introduction
Concept & Preliminary Design:
review many alternative configurations
only retain the few best preliminary designs

Reduce the Need for Prototypes

(Boing 777 Example):
avoid cost and time of model construction
physical models provide few measurements
CFD gives a lot of detailed information
greater accuracy per unit cost
Automotive Engineering

External Flows: surface pressure, drag;

coefficient; trailing vortices
Engine Compartment: radiator flows;
water jackets; dust deposition
Combustion Chamber: inlet valves;
combustion models; fuel air mixing
Passenger Comfort: climate control;
HVAC; turbulence modelling
Valve, Rotor Stator
CFD’s Emerging Role in Design
Key issue is the maturity of process
integration with CAD
40
1997
1995
35

30

25

20

15

10

0
Climate Engine Disc External Underhood/
sense
Control Cooling Brake Aero Underbody
Reversal Cell of a Shell Boiler
Project Outcomes
Flow patterns predicted
effectively
CFD provided valuable
insight to improve the
boiler design & to
retrofit equipment for
greater accuracy

Flow streamlines reveal the importance

of complex cyclic vortices
 Waste Incinerator Optimization
(ABB Combustion Engineering Inc.)

Baseline Design Optimised Baseline Design Optimised

Velocity magnitude (left) and temperature (right) distributions in
baseline & optimised design configurations
Laboratory Analysis Work-space
Experiments with
ammonia release
Ammonia is emitted from
the beaker (red streak)
Design of work-space to
avoid ammonia inhalation
AirPak positions vent & fan
to allow efficient operation
3D tetrahedral mesh of
297,210 cells
RNG k-epsilon turbulence
model
Platform for Fluid Flow Research

Reliable Thermofluid Predictions

Adjunct to Measurements:
detailed information
fast set up of alternative configurations
interpretation via effective graphics

User Defined Subroutines:

add special effects
replace standard treatments
 Application of
User Defined Functions
Special models available via user functions: e.g. electric
boost and bubbler models for glass applications, MHD,
blade momentum source model etc.
Helicopter downwash modeled with blade momentum
source model
CFD for Chemical & Process
Industry Equipment
Separators Packed Beds
Mixers Fluidized Beds
Reactors Risers
Pumps Furnaces
Seals Spray Dryers
Valves Heat Exchangers
Flow Distribution Flares
M/ment & Controls Filters
Incinerators Bubble Columns
 Mixing Tank Flows (MIXSIM)

Original configuration produced

poor mixing of suspension
Different designs & operating
conditions simulated
Equipment was modified using
the CFD results
Courtesy of Reduced time & hardware costs
Donaldson
Company Hardware redesign costs only
Different shafts & impellers $2000 saving over $50,000
investigated to give a uniform
suspension
Multiphase Models
Dispersed phase model (DPM)

Eulerian multiphase model

Granular multiphase model

VOF free surface model

Particle cloud multiphase model

Reactor Modelling
(Multiphase Capability)
Void fraction in
Void fraction in a
a Bubble Column
Fluidised Bed
Gas-liquid
Gas-solid system
system
Modelled using
Aim to minimise
the Granular model
phase
Heat transfer & segregation &
species (fuel, O2,) to promote
transport recirculation cells
Chemical gas Modelled using
reaction using the the Eulerian
Finite rate model model
 Particle Separation:
Free Surface Slurry Flow
Spiral Concentrators
in Mineral Processing

Different designs examined to

enhance radial separation of
particles (CANCES & JKMRC)
 Spiral Concentrator:
Flow Depth & Fluid Velocity
12
Series1
Model: 4 t /h
10
Depth (mm)

Series3
Model: 8 t /h
8 Expt.:
Series44 t /hr
Expt.:
Series68 t /hr
6

4 Fluid Velocity
2
2.5
0
0 0.05 0.1 0.15 0.2 0.25 0.3
2
Radial distance from central column (m)

Velocity (m/s)
Experimental
Expt. 1mm depth

Flow Depth using 1.5

CFD
CFDke
1mm depth
CFD 6mm depth
Series1

VOF model 1
Expt. 6mm depth
Series5

0.5

0
0 50 100 150 200 250 300

Distance from central column [mm]

 Biomedical Flows
(FLUENT 5 & FIDAP 8)
Artificial Organs: heart valves; filters;
blood pumps; meters & flow controllers
Blood Flows: aneurysms; cell counters;
oxygenators; wall distortions
Lung Flows: inhalers; sleep apnea;
blockage modelling & alleviation
Digestive Tract: stomach ulcers;
swallowing malfunction; drug absorption
 Thomas Jefferson Study
Hypothesis: Regions of high pressure
(contours shown below) correlate with
probable aneurysm rupture sites

Initially examined Next, used Spiral CT

a simplified to acquire vessel geometry
and LDV to acquire in-vivo
aneurysm geometry pulsatile flow data
Some KFUPM Research Work
Aerospace Engineering, Automotive Engineering
Air Conditioning, Thermal Comfort

Biomedical Flows

Environmental Flows, Fire Modelling

Power Generation & Combustion

Turbomachinery, Pumps, Compressors, Fans

Heat Exchangers, Erosion, Corrosion, Fouling

Conclusions
CFD is an Effective Design Tool
for industrial applications

Good Platform for Fluid Flow

Research (R&D and Universities)
==> via User Defined Subroutines