CFD simulation and design optimization of heat exchanger purge manifold for mosman stainless steel bv
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Optimized the manifold system for injecting air into the Mosman Bulk Solids Heat Exchanger (BSHE). The final design considerably reduced manufactoring cost, meanwhile maintaining an even air distribution
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velocity near these bends. But it isobserved that the velocity of flue gases surprisingly increases near
the lower bends as compared to upper ones. The model issolved using conventional CFD techniques by
FLUENT software. In which the individual tubes are treated as sub-gridfeatures. A geometrical model
is used to describe the multiplicity of heat-exchanging structures and the interconnectionsamong them.
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This document summarizes a research paper that analyzed heat transfer in an economizer using computational fluid dynamics (CFD). It discussed how fins can be added to economizer tubes to increase the heat transfer surface area between flue gases and boiler feedwater. The document reviewed previous research on economizer design optimization and failures. It described the working of CFD analysis using equations of continuity, momentum, and energy to model fluid flow. The study used the k-ε turbulence model in CFD software to analyze heat transfer with and without fins on an economizer.
CFD ANALYSIS OF ECONOMIZER TO OPTIMIZE HEAT TRANSFER
Economizer is the best mechanical component which is used for trapping the heat of flue gasses. Economizers can be best applied in electricity generating power plants. Best way of
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Water treatment is one of the most pressing environmental and public health challenges in the world
In our recent CFD project, we addressed a crucial concern in a caustic soda injection system for potable water. Efficient mixing is key, not just for effectiveness but also safety in water treatment and the existing system had very ineffective mixing.
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CFD-analyse er super effektivt til at finde årsag til problemer og forbedre ydeevnen i komplekse systemer!
Her er et godt eksempel: På et stort naturgasfyret kraftværk, hvor de udnytter overskudsvarme til at generere damp og energi, havde de undret sig over, at deres kedel ikke producerede så meget damp, som forventet.
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En inspektionen havde vist, at en betydelig mængde varm røggas sandsynligvis blev ledt udenom de hedeflader, hvor varmen skulle afgives.
Udfordringen var om dette alene kunne forklare den nedsatte ydelse.
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På baggrund af vores resultater installerede Tetra Engineering dækplader, der reducerede bypass-flowet. Det forbedrede kedlens ydeevne og øgede elproduktionen.
Det er altid tilfredsstillende, når vi kan hjælpe med at løse komplekse udfordringer. Hvis dine systemer også har brug for et eftersyn eller optimering, så giv os et kald!
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CFD analysis is incredibly effective at solving mysteries and improving the performance of complex systems!
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It is always satisfying when we can help solve complex challenges like this. Do your systems also need a check-up or optimization? Give us a call!
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- 1. Gasværksvej 26, DK 9000 Aalborg www.R-R-Consult.com www.LinkedIn.com/company/R&R-consult Info@R-R-consult.com CFD simulation and design optimization of heat exchanger purge manifold for Mosman Stainless Steel BV
- 2. Gasværksvej 26, DK 9000 Aalborg www.R-R-Consult.com www.LinkedIn.com/company/R&R-consult Info@R-R-consult.com R&R Consult helped analyse and optimize the design of the Mosman Bulk Solids Heat Exchanger (BSHE). The BSHE is used for cooling or heating free-flowing bulk solids, via a pillow plate heat exchanger. In order to reduce the risk of caking in the pillow plate bank, dry air is injected at several horizontal planes and then flows upwards through the pillow banks and bulk solids. The air is injected via air inlet manifolds and distributed through multiple nozzles/studs in each manifold. The nozzles are welded on the manifolds, which is a costly manufacturing process. R&R Consult helped optimize the design of these manifolds by using Computational Fluid Dynamics (CFD). The objective was to achieve a uniform air distribution while minimizing pressure drop and manufacturing costs. We significantly optimized the original design based on empirical design equations regarding manifold design and several state of the art numerical simulations. This yielded considerably reduced manufacturing costs. Furthermore we established an optimum nozzle number/diameter combination in order to minimize flow variation in the nozzle row and generate the necessary flow uniformity inside the heat exchanger. The updated manifold design not only meets the prerequisites for efficient de-moisturization. It also keeps the injected air from interfering with the product flow and considerably reduces manufacturing cost. The case served as another example of combining fluid mechanical experience, knowledge and CFD for cost-efficient design analysis and optimization. The simulation process saw interesting meshing challenges, e.g. a full geometric discretization of all nozzles in the inlet manifold. This provided data concerning individual nozzle flow rates, and was used to minimize flow variation in the longitudinal direction of the manifold, while providing information regarding manifold pressure drop. Mosman Bulk Solids Heat Exchanger Flow uniformity, variation between ± 9% from mean Path lines from distributor Velocity through distributor CFD simulation and design optimization of heat exchanger purge manifold for Mosman Stainless Steel BV