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Chemical Process IndustryMass, Heat and Species Transport Simulation Solutions for the Chemical Process Industry
Simulation Software for a new frontier in engineering innovation
Advanced PhysicsEulErIAn MulTIPHASE ModEl:
The Eulerian multiphase model provides an effective means for
modeling two-phase and multiphase flows, including those with
reactions. With the extensive range of sub-models provided, which
include: drag, virtual mass, lift and turbulent drag forces, break-up
and coalescence models for bubbles, the Eulerian multiphase model
is ideal for studying flows in bubble columns, and gas and solid
dispersion in stirred reactors. With the granular flow model, the
Eulerian multiphase model also finds applications in fluidized beds
and FCC risers.
WAll-fIlM ModEl:
A unique wall-film model is available to represent the liquid film
formed on the wall due to droplet impingement. The “splashing”
feature of the wall-film model allows “daughter” droplets to be
reflected back into the flow upon impingement of a “mother”
droplet on the liquid film. The wall-film model provides a unique
capability to examine the wall effects in detail, for example the
changes in wall heat transfer due to the liquid film. It can be
used in designing distillation column inlets to minimize droplet
carryover over or the mixing behavior of NH3 or urea injection
for SCR applications.
dISCrETE PArTIClE ModEl (dPM):
The Lagrangian discrete particle model provides an
effective means of modeling particle movements
in equipment. Erosion of safety valves due to
impingement of particles or droplets can be examined.
Separation efficiency of particles in cyclone separators
can be determined together with pressure drops
across the unit. Coupled with the built-in heat and
mass transfer models, the evaporation of liquid spray
can be simulated.
Cd-adapco’s STAr-CCM+ software is well known for its ability to model extremely complex geometries. It is an integrated CAd geometry, meshing, solver and post-processing tool providing start-to-end solutions. Equipment can be modeled with complex physico-chemical phenomenon in great detail within short time.
With its comprehensive range of physical models, CD-adapco software is an effective analysis environment for a wide range of CPI applications such as mixing
and reactions in CSTRs (Continuously stirred tank reactors), catalytic surface reactions in packed bed reactors, evaporation of liquid droplets in spray dryers,
separation of particles in cyclone separators, heat transfer in compact heat exchangers, and particle erosion of safety valves in pipelines. Field functions
are user defined subroutines, giving the user a unique way to couple custom models with the existing models, thus increasing the flexibility of applications.
STAR-CCM+ comes with a world class support and a dedicated support engineer for each customer.
Introduction
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dISCrETE ElEMEnT ModEl (dEM):
The granular flow of particles can be modeled using the
DEM. Each particle is treated as a discrete body in the
Lagrangian framework. Particle shape import from CAD
is possible. The flow of particles is fully coupled with
the fluid flow. Good scalability is achieved in parallel
computation for large problems. DEM method finds
applications in hoppers, forage blowers, particle transport
as well as granulation in pharmaceutical industry and
food industry.
frEE SurfACE ModEl:
VOF (volume of fluid) method is used for solving free
surface flows. Several advanced features have been
developed for simulation of cavitation, heat and mass
transfer. The model is therefore ideal for studying
liquid sloshing in containers, filling processes in
tanks; vortex formation in stirred vessels, liquid spills
and displacement of liquid in porous media such as
oil trapped in sandstones can be studied.
LEFT: Cyclone separator
RIGHT: Vortex formation in a stirred vessel
ABOVE: Particle flow through valve - DanflossRIGHT: Tall form spray drier
RIGHT: Solids flow in a blast furnace
Simulation of multicomponent liquid and gas phase mixtures can be performed with or without reactions. Global chemical reaction mechanisms can be defined within the EBu (eddy break up) and dArS-Cfd model.
Accurate predictions of pollutants or product distribution in partial oxidation
reactions need the use of detailed chemical kinetic mechanisms. The
DARS-CFD software has been fully integrated with STAR-CCM+. In the
combined software, STAR-CCM+ provides the overall framework for handling
the three-dimensional complex geometry, solving the flow equations, and
the transport equations for species and energy for the whole flow field.
DARS-CFD can be used to develop libraries for detailed chemistry models
to capture finite-rate chemistry effects using “stiff” equation solver that are
then used efficiently for CFD simulation.
STAR-CCM+ and DARS software is also available for modeling gas-surface
reactions. The range of applications includes: reactions in reforming
processes, catalyzed reactions in packed bed reactors and chemical vapor
deposition (CVD) in microelectronic production. Turbulence-Chemistry
interactions can be accounted for by using the EDC (eddy dissipation
concept) model.
Combustion can be modeled with a choice of the PPDF (presumed probability
distribution function with either equilibrium or flamelet formulations) model,
PVM (progress variable model, based on enthalpy), for non-premixed or
partially premixed flames. The CFM (coherent flame model) is implemented
for premixed flames.
The particle reaction models let you simulate the process of reacting solid
particles with the Lagrangian Multiphase models. It includes the particle
devolatilization and particle combustion sub-models where the particle
components can devolatilize or react with a material in a gas phase to form
desired products in gas/solid phases.
The NOx and Fuel-NOx sub-models as well as the soot sub-model give the
capability to predict these pollutant species for environmental applications
in furnaces, boilers, thermal oxidizers and coal combustion.
Species Transport & Chemical reactionsGas dispersion in mixing vessel Mixing vessels – Siemens -Axiva Static mixer – Sulzer Innotec
The multi-stream multi-domain modeling capability in Cd-adapco software allows several fluid streams in the calculation domain totally separated by dividing walls.
With its conjugate heat transfer model, heat exchange between different
fluids separated by complex heat transfer surfaces can be computed
efficiently. Heat exchangers such as compact heat exchangers, plate-fin heat
exchangers and shell-and-tube heat exchanges can be modeled effectively
and accurately. The coupling with finite element code like Abacus also gives
the possibility to perform stress analysis on heat exchangers.
Heat Transfer Applications
ABOVE: Fixed bed reactor, Hoechst
ABOVE & BELOW: Heat Exchangers – Mesh & streamlines
RIGHT: CO2 mole fraction in a Methane burner
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