PIONEER PROCESS TECHNOLOGY GROUP
FLOW TECHNOLOGY

 

 

Process Technology - Computational Fluid Dynamics (CFD)

Chemical process industries involve a wide range of process equipment and a process unit is required to perform a variety of duties. Therefore, it becomes essential to predict its performance at different operating conditions. The flow field in chemical industry is very complex and conventional method of analysis is not adequate. Experimental measurements are not always possible. While measurements provide point data, often a large array of multiple data points is required to fully diagnose the problem. Often such large data points are impossible and time consuming. Computational fluid dynamics (CFD) is a tool to assist analysis and troubleshoot such equipment. Given the economics of chemical and process plant, even a small improvement in efficiency and performance can result in huge cost serving increase in revenue.

Chemical process industries are facing new challenges predominantly increased market competition, cleaner environment, higher customer expectations and increased profitability. To meet these challenges, it is essential to integrate key technologies in the design and operational processes. Computational fluid dynamics (CFD) has been identified as one of the key technologies for the chemical and process industries into the future. CFD methods are widely used in automotive and aerospace industry to examine fluid flow, heat and mass transfer.

Traditional three-stage approach of taking the product from laboratory scale to pilot scale and later to production scale is no longer attractive. Product and process developments are often undertaken simultaneously, as a result, rapid prototyping and analysis is required. To meet these challenges, CFD has been identified as one of the technologies that is expected to lead chemical process industries into the future. The integration of the CFD methods will shorten the product development and process optimization time. For a chemical process company, not only the R&D staff but should understand the benefits of CFD but also the plant and production managers.

CFD modeling is a rapid, economical and less risk approach to chemical process design and optimization. We are CFD specialists who understand how to apply CFD as tool for process design or troubleshoot an existing design.

Benefits of CFD

Faster time to market
Reduce risk by virtual prototyping
Lower operating costs
Start up right first time
Rapid and reliable scale up
Higher profitability

Processes

Single and Multiphase Flows
Combustion and Reacting Systems
Heat and Mass Transfer
Fluidized Bed Flows
Packed Bed Flows
Reactor Design
Mixing & Reacting Flows
Cyclones Separation
Distillation trays
Filtration and Erosion
Pollutant control
Separation equipment
Free Surface Modeling
Particle Tracking

Equipment

Mixing - Stirred vessels, Static mixers, impeller mixers, Tee mixers
Separation - Cyclones, hydrocyclones, classifiers, centrifuges, filters
Reactors - Fixed bed, fluidized bed, slurry bubble column
Heat Transfer devices - Heat exchangers, jacketed vessels
Mass Transfer Devices- Packed beds, trays, scrubbers
Combustion - Furnaces, incinerators, burners, combustors
Flow Control - Valves, manifolds, flow balancing

Simulation Predictions include:

Velocity flow profile and turbulence fields
Concentrations of reactants, products and by-products
Temperature profiles and reaction yield
Gas hold up and Batch time
Particle size distributions
Solids distributions and blending characteristics
Residence time distribution
Power draw & Mix times

 

Hydrocyclone Separation

Stirred Tank Reactor

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Computational Fluid Dynamics CFD Computer Aided Design