PROJECT DETAILS

• Clients: Bioazul & Captoplastic
• Date: 2024-2025
• Technology: CFD Simulation

   

INTRODUCTION

In this project we have studied and optimised the flow in an industrial water treatment unit. For this we have used Computational Fluid Mechanics (CFD) simulations where turbulent flow models and air-water multiphase simulation models were required. The software used for the project is ScFlow from MSC Cradle.  

INITIAL STUDY USING CFD SIMULATION

In this phase we studied the initial equipment proposal. Experimental results are available with a small laboratory-scale model, where cleaning efficiency tests have been carried out as a function of the inlet flow rate. First, CFD models of the laboratory equipment are prepared, using the appropriate meshing and boundary conditions, and simulations are launched. The post-processing of these studies shows results that fit well with the experimental measurements, thus validating the methodology. This is followed by the study of the equipment at industrial scale. To this end, we maintain the mesh density used in the previous models and carry out the CFD studies. The velocity fields obtained allow us to identify regions to improve, taking into account the information from the laboratory-scale study, which requires optimisation of the design. In this phase, an aeration study is also carried out on the equipment by means of multiphase simulation, using an Eulerian model. The result of an air isosurface can be seen in the following image.    

OPTIMISATION OF THE FLOW IN THE EQUIPMENT

In this phase we worked on improving the efficiency of the equipment, reducing and homogenising the speed inside it. To this end, we define a series of improvement proposals, varying the inputs and outputs of the system and introducing elements inside it to favour homogeneous distribution. The proposals must always be compatible with the restrictions of the equipment and the surrounding systems, so they are agreed with the client before proceeding with the CFD simulation. After calculating and post-processing the new designs, we arrive at a configuration where the water velocities are very close to the theoretical minimum with the desired equipment size.  

DESIGN AND OPTIMISATION OF THE CONNECTIONS TO THE INSTALLATION

In the previous phase, a suitable equipment design was obtained based on the numerical and experimental results at laboratory scale. All that remains is to design a connection system to the installation that achieves an appropriate distribution of the flow, which circulates through a single pipe, and must enter the equipment through several channels. Due to space and operational restrictions, some proposals based on regulation elements are not feasible. For this reason, work is being done to design a system with a manifold that facilitates the distribution of the flow, slowing down the water that enters at high speed and achieving a uniform distribution at the inlets to the equipment. A similar device is also designed for the outlet, in order to reduce local accelerations in the system. The following image shows an example of one of the configurations studied in the process with some streamlines.