Fluid Flow: Fans, Filters, Pumps, etc. FloEFD is licenced CFD program of FFT Eng. Co. Ltd. Capability of the program is shown below with some examples. İbrahim ÇAKMANUS, PhD. Mech. Eng. 1
Air Cooled Cooler/Fan Predicted with FloEFD Challenge: Design a quiet air-cooled cooler/fan to meet stringent European Environmental Control Board standards Solution: FloEFD Pro Benefits: - Developed a groundbreaking design which achieves up to 80% thermodynamic efficiency - traditional designs only achieve about 60% - Bronswerk product saves 15% of electricity usage & could result in 20% of generation capacity saving in Holland alone over the course of 10 years. FloEFD Pro is a natural extension of traditional CFD that is easier to use and more intuitive for Mechanical Engineers. The information generated with FloEFD Pro is far beyond data obtainable through experimentation and or measurement. We would not have been able to solve this challenge without FloEFD Pro Guus Bertels, Senior Engineer, Bronswerk Heat Transfer BV
Centrifugal Pump Efficiency Curves Predicted with FloEFD Efficiency [-] FloEFD was used to compare analysis results with physical prototypes for centrifugal pumps with rotating impellers One of the things they tested in CFD was the NPSH - the Net Positive Suction Head The CFD results were compared against physical prototypes and were found to be close to test measurements. Ω=2960 RPM V=200 m3/h 1.2 Predicted Efficiency curve for different flowrates 1 0.8 0.6 0.4 0.2 Velocity in swirler 0 0 50 100 150 200 250 300 Capacity [m3/h]
Centrifugal Fan Efficiency Curves Predicted with FloEFD
Cross Cylinder Rotation Validation With FloEFD In this case validation of the cross cylinder rotation in lateral flow is considered. The calculated aerodynamics coefficients are compared with experimental data reported in [NASA Technical Notes 209. Tests of rotating cylinders, Elliott G. Reid, December, 1924] U 0 D= 4 ½ 1 ¼ C L 4,5 4 3,5 3 2,5 2 Experiment - 10m/s Experiment - 15m/s FloEFD dt - 1/50 FloEFD dt - 1/100 FloEFD dt - 1/200 FloEFD dt - 1/400 C L vs r D r 2 U 0 ω 1,5 1 0,5 0 0 0,2 0,4 0,6 0,8 1 1,2 1,4 1,6 1,8 2 4,5 C L vs rc D C L 4 3,5 3 2,5 2 Experiment - 10m/s Experiment - 15m/s FloEFD dt - 1/50 FloEFD dt - 1/100 FloEFD dt - 1/200 FloEFD dt - 1/400 1,5 1 0,5 Flow field at ω=200 rpm and U 0 =10 m/s (r=0.12) 0 0 0,2 0,4 0,6 0,8 1 1,2 1,4 1,6 1,8 C D
Phase Separation: Filters, Cyclones, Separators and Tanks
Theory and Testing with FloEFD Simulation Challenge: Verify pressure loss as fluid passes through their filter designs without having to rely on inaccurate physical tests Solution: Test virtual models in FloEFD Benefits: - Eliminated the need for physical prototypes and inexact theoretical pressure drop models - Obtained precise results quickly quite early in their development processes now permitting projects to be done on time The option that we now have with FloEFD provides us with a great increase in levels of security at the development stage. K. Cartarius, R&D Team Manager, Boll & Kirch
Cyclone / Trombone Design Wear and Performance Investigation Non uniform flow results in poorer performance, high losses in production, and non-uniform wear The performance of the original design (opposite) was investigated This led to a new design concept (below) that was simulated and optimized: Source: www.esteq.co.za
Process Industry Fluidized Bed Development Time by Half Fluidized-beds suspend solid particles on upward-blowing jets of fluid producing a turbulent mix of fluid and solids. Glatt creates custom-made equipment. Challenge: Since all products are large & custom made, each design change results in a different flow, pressure & temperature condition Solution: Simulate each new design with FloEFD and prove it performs to specifications Benefits: Cut out two or three stages in their development process effectively cutting development time by half We re pretty fast. We have no production facilities of our own so all jobs have to be outsourced. Every omitted stage saves time and money. Michael Jacob, Engineering Development, Glatt Ingenieurtechnik
FloEFD is used to Innovate New Filter & Separator Designs Challenges: Simulate & optimize DF-C Cyclone compressed air filter separators Solution: Utilize FloEFD CAD-embedded CFD software Benefits: - CFD has helped to develop reliable, maintenance-free cyclonic separators - Simulation helped to optimize these innovative high efficiency, low energy loss filters for liquid and solid particulates from 5 to 10µm.
Environmental Control of a Conditioning Tower Simulate flows in all types of components and within a wide variety of unit operations In this example they were asked to analyze flows through a Conditioning Tower Simulate the current mining plant equipment as installed on site and then with FloEFD they were able to improve the flow at the top inlet to the unit They created a more sweeping design with internal baffles leading to a more uniform flow distribution. Conditioning Tower Analysis (with flow straightener below) Source: www.edart.co.za
Hydrocyclone to Remove Very Small Particles By predicting velocity and turbulence profiles with FloEFD they were able to optimize the design to meet all the customer s requirements Fraction removed vs. particle size Source: www.hecbv.nl
Sand Particle Separator Parametric Studies In this example an oil and gas company wanted to know where different sized sand particles would report to in their separator Here FloEFD used to evaluate various sand particle sizes in the swirling flows produced within the vessel: Source: www.edart.co.za
Electrostatic Precipitator Design Improved with FloEFD FloEFD predicted the 1m/s flow over the electrostatic collection plates in the original design To correct the non-uniformity, the guide vanes were moved closer to the precipitator inlet Different screen configurations were used to spread the incoming flow evenly and limit the velocity, giving the optimal design. Original Design Final Design Source: www.esteq.co.za
Parametric Studies in Cyclone Design In this classical water cyclone design there was a need to understand how flows build up at the far side of the vortex finder FloEFD to do this parametric study relatively quickly compared to an experimental approach. CFD Analysis of a liquid cyclone for different inlet velocities Source: www.edart.co.za
Optimization of a Double Drum Waste Separator Double Drum Separator for Nihot, a leading manufacturer of waste separation equipment Air flow allows the separation of the waste into light, medium and heavy fractions. The heavy fractions are collected by a rotating drum; the light go down an expansion chamber before air is returned to the fan, but this can contain some of the light fraction, which is undesirable. "The FloEFD simulations have meaningful results for Nihot. We have more insight into the workings of waste equipment. Nihot therefore seems especially interesting for these simulations and more to do yourself." H. van der Meij, Operational Manager Nihot Recycling Technology BV Source: www.hecbv.nl
Detailed Insight into Electromagnetic Filter Design Series of electromagnetic filters provide the highest level of filtration of aggressive and corrosive liquids and gases with rapid hands-free cleaning. By using FloEFD were able to gain a good understanding of the flow distribution through the various filters and velocities along the magnets, and hence the performance of the design: Source: www.hecbv.nl
FloEFD Validation: High Efficiency Gas Cyclone (Non-isotropic swirling Flows) 3000 Comparison of predicted and measured total pressure drop for a Stairmand HE cyclone 2500 2000 dp, Pa 1500 1000 500 Experiment EFD calculations 0 0 5 10 15 20 25 30 U inlet, m/s Time evolution of the total pressure drop of a Stairmand HE cyclone at 10 m/s gas inlet velocity 400 300 dp, Pa 200 100 Experiment EFD calculation Reference: Griffiths, W.D., Boysan, F., 1996, Computational fluid dynamics (CFD) and empirical modelling of the performance of a number of cyclone samplers, J. Aerosol Sci, Vol 27, 2, 281-304 0 0.3 0.7 1.1 1.5 1.9 Time, s
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