Computer supported process simulation

In process technology of the chemical industry, constantly increasing requirements are imposed on process safety and product quality.  At the same time expensive errors in engineering and process management should be avoided. With the aid of computer supported process simulation based on CFD (Computational Fluid Dynamics), these errors can be avoided in advance, since it is possible with this technology to virtually develop optimisations in process management or equipment design before project implementation. The methodology of CFD is numbered among the finite element technologies. The area being simulated is sub-divided into a number of volume cells and one speaks in this case of the discretization of this model.  In an iterative solution process, a set of differential equations is solved for each cell, the so-called Navier-Stokes-equations. The Navier-Stokes-equations describe the flows of Newtonian fluids and gases. The overall problem is solved according to the definition of the process’s framing conditions under the premises of mass, impulse and energy content. Additionally, the turbulence problem in the flow can be coupled with state equations for chemical reactions, e.g. combustion. Based on the technology described, the following topics can be developed:

• Development of reactor designs (e.g. guide vane configuration, performance of static mixers, etc)
• Optimisation of heat exchangers with respect to incoming flow and gradation
• Minimising pressure losses
• Development of burner designs
• Increasing production capacities
• Adapting furnace systems (rotary kilns, shaft furnaces, tunnel furnaces)
• Improving energy efficiency
• Design of combustion changes
• Simulation of trajectories of streams loaded with particles (E-filter-design, cyclonic separators)
• Etc.

Representative simulation examples can be found in the folder “Computer Aided Engineering“ in the download area.