Designing equipment by using Designing equipment by using CFDCFD
Benefits and pitfallsBenefits and pitfalls
Geert JanssenAdvanced Thermal Transfer Equipment
A2TE
CFD - PhoenicsCFD - Phoenics
CORA2 – graduate studiesPhoenics user since 1985
– Analysis• Flow in intake manifolds of IC engines• Flow & heat transfer process industry
– Design from 1990• Heat transfer equipment
– Ovens and furnaces
Applied CFDApplied CFD
Better understanding– Flow– Heat transfer– Mass transfer– Chemics
Sensitivity analysisPriceworthyfast
Why limited CFD usageWhy limited CFD usage
Long learning curveSpecialists required
– Jargon– physics insight and knowledge ?– Standard rules from handbooks?
Design <-> modelling – Communication skills
Example - 1Example - 1
OvenPerforated plates
– Flow distributors
Example - 2Example - 2
Molten metal in tundishTarget
– Continuous casting– No slag inclusions– No bubbles
TundishTundish
Symmetric inflowSteady state ?No match with
experimental dataBlame on CFD?
Designing equipment & Designing equipment & CFDCFDRules of thumbStandard textbooksSome understanding of physicsCFD ‘tricks’Designers skills or strong
interaction with designer
Example 3 - ageing ovenExample 3 - ageing oven
Continuous belt ovenBase of lamp (automotive)3 lanes: 3 x 800 pcs/hrHeating to 200°C and holding for 4
hrsCooling to 50°CFloorspace approx. 5 m2
Temperature differences < 5°C
Ageing oven - 2Ageing oven - 2
Heat transfer and pressure drop from packed bed relations
Required velocities through belt– Heating section– Cooling section
Fan in holding section identical to those of other sections
Ageing oven - 3Ageing oven - 3
Ageing oven - 4Ageing oven - 4
Ageing oven - 5Ageing oven - 5
Ageing oven - 6Ageing oven - 6
CFD model took 3 daysConceptual design 2 weeks
Ageing oven - Ageing oven - 77
Ageing oven - Ageing oven - 88
Example 4 curing ovenExample 4 curing oven
Contact lensesAutomated processPolypropylene: 95°C ± 3°CAt least 15 minutes at 92°C
(minimum)Heating up in 10 – 12 minutesAluminium trays, 1300 grams
– 1 tray in 40 seconds
Curing oven - trayCuring oven - tray
Curing oven - analyticalCuring oven - analytical
Calculation of required heat transfer coefficient (mass – time)
High value needed (75 Wm-2K-1)Multiple jets
One heat-up zone– Costs (fan, controller, cabinet)
Curing oven - trayCuring oven - tray
Curing oven - trayCuring oven - tray
Curing oven - trayCuring oven - tray
Curing ovenCuring oven
Conclusions from tray calculations– Required air-inlet temperature >
105°C
Curing oven – cross Curing oven – cross sectionsection
Curing oven - power Curing oven - power changechange
Curing oven - belt levelCuring oven - belt level
Curing oven – CFD modelCuring oven – CFD model
CFD models: 2 weeksConceptual design 4 weeks
ConclusionsConclusions
Use of CFD can be very profitableOften CFD alone does not ‘do the
trick’– Handbooks– Rules– Experience