CFD modeling of hydrodynamics and mass transfer of Rhodamine B in annular reactor

The hydrodynamics and mass transfer are the two crucial issues in annular reactors. An accurate prediction of these issues is required for design, optimization and scale-up applications. The present study deals with the modeling and simulation of flow through an annular reactor at different hydrodynamic conditions using computational fluid dynamics (CFD) to investigate the hydrodynamics and mass transfer. CFD modeling was utilized to predict velocity distribution, average velocity and average mass transfer coefficient in the annular geometry. The results of CFD simulations were compared with the mathematically derived equations and already developed correlations for validation purposes. CFD modeling was found suitable for predicting hydrodynamics and mass transfer for annular geometry under laminar flow conditions. It was observed that CFD also provides local values of the parameters of interest in addition to the average values for the simulated geometry.     

Viscoelastic flow analysis using the software OpenFOAM and differential constitutive equations

Viscoelastic fluids are of great importance in many industrial sectors, such as in food and synthetic polymers industries. The rheological response of viscoelastic fluids is quite complex, including combination of viscous and elastic effects and non-linear phenomena. This work presents a numerical methodology based on the split-stress tensor approach and the concept of equilibrium stress tensor to treat high Weissenberg number problems using any differential constitutive equations. The proposed methodology was implemented in a new computational fluid dynamics (CFD) tool and consists of a viscoelastic fluid module included in the OpenFOAM, a flexible open source CFD package. Oldroyd-B/UCM, Giesekus, Phan-Thien–Tanner (PTT), Finitely Extensible Nonlinear Elastic (FENE-P and FENE-CR), and Pom–Pom based constitutive equations were implemented, in single and multimode forms. The proposed methodology was evaluated by comparing its predictions with experimental and numerical data from the literature for the analysis of a planar 4:1 contraction flow, showing to be stable and efficient.     

A GPU-based incompressible Navier–Stokes solver on moving overset grids

In pursuit of obtaining high fidelity solutions to the fluid flow equations in a short span of time, graphics processing units (GPUs) which were originally intended for gaming applications are currently being used to accelerate computational fluid dynamics (CFD) codes. With a high peak throughput of about 1 TFLOPS on a PC, GPUs seem to be favourable for many high-resolution computations. One such computation that involves a lot of number crunching is computing time accurate flow solutions past moving bodies. The aim of the present paper is thus to discuss the development of a flow solver on unstructured and overset grids and its implementation on GPUs. In its present form, the flow solver solves the incompressible fluid flow equations on unstructured/hybrid/overset grids using a fully implicit projection method. The resulting discretised equations are solved using a matrix-free Krylov solver using several GPU kernels such as gradient, Laplacian and reduction. Some of the simple arithmetic vector calculations are implemented using the CU++: An Object Oriented Framework for Computational Fluid Dynamics Applications using Graphics Processing Units, Journal of Supercomputing, 2013, doi:10.1007/s11227-013-0985-9 approach where GPU kernels are automatically generated at compile time. Results are presented for two- and three-dimensional computations on static and moving grids.     

The flow of non-Newtonian fluids down inclines

Equipment units (e.g. tray column heaters) in many chemical engineering and mineral processing industries involve the flow of non-Newtonian fluids down inclined plates. When designing these equipment units the non-Newtonian fluid flows often are not fully understood and so the designs are not properly optimised. In this study the flow down a series of inclined plates was experimentally and numerically investigated to better understand the flow for various fluids and to validate a computational fluid dynamics (CFD) model.In the experimental rig there were a series of consecutive plates inclined at 45°. An optically clear polymer solution was used to simulate a yield pseudo-plastic material and allowed flow visualisation to be undertaken of the flow. The fluid film thickness was observed to decrease down the consecutive plates. Experiments were also carried out using a yield pseudo-plastic mineral slurry and the results were found to be qualitatively similar.An analytical model was developed to calculate the fluid film layer thickness on the first plate and a CFD model was used to compute the flow down a series of flat plates. The CFD model employed a homogeneous multiphase model and surface-sharpening algorithm. The CFD model accurately predicted the fluid film thicknesses and flow patterns. The validated CFD model can now be used with confidence as a design tool.     

A two-phase, two-component model for vertical upward gas-liquid annular flow

In this paper, a new two-fluid two-component computational fluid dynamics (CFD) model is developed to simulate vertical upward two-phase annular flow. The two-phase VOF scheme is utilized to model the roll wave flow, and the gas core is described by a two-component phase consisting of liquid droplets and gas phase. The entrainment and deposition processes are taken into account by source terms of the governing equations. Unlike the previous models, the newly developed model includes the effect of liquid roll waves directly determined from the CFD code, which is able to provide more detailed and, the most important, more self-standing information for both the gas core flow and the film flow as well as their interactions. Predicted results are compared with experimental data, and a good agreement is achieved.     

Validation of CFD‐CSD coupling interface methodology using commercial codes

Coupling interface between computational fluid dynamics (CFD) and computational structural dynamics (CSD) is required to provide exchange of information for the simulation of fluid–structure interaction (FSI) phenomena. Accuracy and consistency of information exchanged through coupling interface between the independent CFD and CSD solvers plays a central role in the simulation and prediction of FSI phenomenon, like flutter. In this paper validation of an implemented coupling interface methodology is presented for subsonic, transonic and near supersonic mach regime. The test case chosen for this purpose is the flutter of AGARD445.6 standard I‐wing weakened model configuration for subsonic to near transonic flow regime. Gambit^® and Fluent^® are used for CFD grid generation and solution of fluid dynamic equations, respectively. CSD modeling and simulation are provided by numerical time integration of modal dynamic equations derived through the finite element modeling in ANSYS^® environment. Copyright © 2009 John Wiley & Sons, Ltd.     

Numerical modelling of rotating tangential layers (jets) in shells under strong uniform magnetic field

A numerical study of tangential layers in steady‐state magnetohydrodynamic rotating flows is presented using CFD to solve the inductionless governing equations. The analysis considers two basic flow configurations. In the first, a fluid is enclosed in a cylinder with electrically perfect conducting walls and the flow is driven by a small rotating, conducting disk. In the second, a flow is considered in a spherical shell with an inner rotating sphere. The fluid in both cases is subjected to an external axial uniform magnetic field. The results show that these flows exhibit two different types of flow cores separated from each other by a tangential layer parallel to the axis of rotation. The inner core follows a solid‐body rotation while the outer is quasistagnant. A counter‐rotating jet is developed in the tangential layer between the cores. The characteristics of the tangential layer and the properties of the meridional motion are determined for a wide range of Hartmann numbers. Distributions of angular velocity of circumferential flow and electric potential are obtained and the results are compared with those of analytic methods. Copyright © 2009 John Wiley & Sons, Ltd.     

Solutions of magnetohydrodynamic problems based on a conventional computational fluid dynamics code

It is pointed out that there exists a hidden analogy between magnetohydrodynamic (MHD) and conventional computational fluid dynamic (CFD) equations. This allows the generalization of any conventional CFD code so that the effects of MHD can be accounted for. This generalization is actually made for the FLUENT CFD code. Although this generalized FLUENT code can easily be adjusted to any MHD environment, it has been specifically designed for metallurgical applications. Predictions of the code are validated against the analytical solutions for the Poiseuille-Hartmann flow and for the shielding of magnetic field oscillations by a conducting medium (skin effect).     

Physical criterion study on forward stagnation point heat flux CFD computations at hypersonic speeds

In order to evaluate uncertainties in computational fluid dynamics （CFD） computations of the stagnation point heat flux, a physical criterion is developed. Based on a quasi-one-dimensional hypothesis along the stagnation line, a new stagnation flow model is applied to obtain the governing equations of the flow near the stagnation point at hypersonic speeds. From the above equations, the compatibility relations are given at the stagnation point and along the stagnation line, which consist of the physical criterion for checking the accuracy in the stagnation point heat flux computations. The verification of the criterion is made with various numerical results.     

Diffusion-based coarse graining in hybrid continuum–discrete solvers: Theoretical formulation and a priori tests

Coarse graining is an important ingredient in many multi-scale continuum–discrete solvers such as CFD–DEM (computational fluid dynamics–discrete element method) solvers for dense particle-laden flows. Although CFD–DEM solvers have become a mature technique that is widely used in multiphase flow research and industrial flow simulations, a flexible and easy-to-implement coarse graining algorithm that can work with CFD solvers of arbitrary meshes is still lacking. In this work, we proposed a new coarse graining algorithm for continuum–discrete solvers for dense particle-laden flows based on solving a transient diffusion equation. Via theoretical analysis we demonstrated that the proposed method is equivalent to the statistical kernel method with a Gaussian kernel, but the current method is much more straightforward to implement in CFD–DEM solvers. A priori numerical tests were performed to obtain the solid volume fraction fields based on given particle distributions, the results obtained by using the proposed algorithm were compared with those from other coarse graining methods in the literature (e.g., the particle centroid method, the divided particle volume method, and the two-grid formulation). The numerical tests demonstrated that the proposed coarse graining procedure based on solving diffusion equations is theoretically sound, easy to implement and parallelize in general CFD solvers, and has improved mesh-convergence characteristics compared with existing coarse graining methods. The diffusion-based coarse graining method has been implemented into a CFD–DEM solver, the results of which are presented in a separate work.     

Three-dimensional water entry of a solid body: A computational study

Marine vessels are continuously subject to impulsive loading from impact on the water surface. Understanding and quantifying the hydrodynamics generated by the three-dimensional (3D) water impact of a solid body is central to the design of resilient and performing vessels. Computational fluid dynamics (CFD) constitutes a viable tool for the study of water entry problems, which may overcome some of the drawbacks associated with semi-analytical and experimental methods. Here, we present a new computational study of the 3D water entry of a solid body with multiple curvatures. The method of finite volume is utilized to discretize incompressible Navier-Stokes equations in both air and water, and the method of volume of fluid is employed to describe the resulting free-surface multiphase flow. Computational results are validated against available experimental findings obtained using particle image velocimetry in terms of both the flow kinetics and kinematics. Specifically, we demonstrate the accuracy of our CFD solution in predicting the overall force experienced by the hull, the pile-up phenomenon, the velocity field in the water, the distribution of the hydrodynamic loading, and the energy transfer during the impact. Our approach is expected to aid in the validation of new semi-analytical solutions and to offer a viable means for conducting parametric studies and design optimization on marine vessels.     

A CFD comparative study of bubble break-up models in a turbulent multiphase jet

In this paper several bubble break-up models are compared. They have been implemented in the CFX-4.4 fluid dynamic commercial code, which uses the population balance equations for describing liquid/gas multi-phase flows. The models have been assessed against published experimental data, obtained for air bubble break-up within a turbulent water jet. The model of Martínez-Bazán, based on purely kinematics arguments, has shown better agreement with the experimental data. The capabilities of using these models coupled to a CFD code for multiphase flow prediction in industrial applications have been demonstrated.     

On the stability and extension of reduced-order Galerkin models in incompressible flows

Proper orthogonal decomposition (POD) has been used to develop a reduced-order model of the hydrodynamic forces acting on a circular cylinder. Direct numerical simulations of the incompressible Navier–Stokes equations have been performed using a parallel computational fluid dynamics (CFD) code to simulate the flow past a circular cylinder. Snapshots of the velocity and pressure fields are used to calculate the divergence-free velocity and pressure modes, respectively. We use the dominant of these velocity POD modes (a small number of eigenfunctions or modes) in a Galerkin procedure to project the Navier–Stokes equations onto a low-dimensional space, thereby reducing the distributed-parameter problem into a finite-dimensional nonlinear dynamical system in time. The solution of the reduced dynamical system is a limit cycle corresponding to vortex shedding. We investigate the stability of the limit cycle by using long-time integration and propose to use a shooting technique to home on the system limit cycle. We obtain the pressure-Poisson equation by taking the divergence of the Navier–Stokes equation and then projecting it onto the pressure POD modes. The pressure is then decomposed into lift and drag components and compared with the CFD results.     

Numerical simulation of the flow field in the vicinity of an axial flow fan

The main purpose of the current investigation is the development and evaluation of a numerical model used to simulate the effect of an axial flow fan on the velocity field in the vicinity of the fan blades. The axial flow fan is modeled as an actuator disc, where the actuator disc forces are calculated using blade element theory. The calculated disc forces are expressed as sources/sinks of momentum in the Navier–Stokes equations solved by a commercially available computational fluid dynamic (CFD) code, Flo⁺⁺. The model is used to determine the fan performance characteristics of an axial flow fan as well as the velocity fields directly up‐ and downstream of the fan blades. The results are compared with experimental data. In general, good agreement is obtained between the numerical results and experimental data, although the fan power consumption, as well as radial velocity downstream of the fan blades, is underpredicted by the fan model. Copyright © 2001 John Wiley & Sons, Ltd.     

Axisymmetric flow and heat transfer of the Carreau fluid due to a radially stretching sheet: Numerical study

The prime objective of this article is to study the axisymmetric flow and heat transfer of the Carreau fluid over a radially stretching sheet. The Carreau constitutive model is used to discuss the characteristics of both shear-thinning and shear-thickening fluids. The momentum equations for the two-dimensional flow field are first modeled for the Carreau fluid with the aid of the boundary layer approximations. The essential equations of the problem are reduced to a set of nonlinear ordinary differential equations by using local similarity transformations. Numerical solutions of the governing differential equations are obtained for the velocity and temperature fields by using the fifth-order Runge–Kutta method along with the shooting technique. These solutions are obtained for various values of physical parameters. The results indicate substantial reduction of the flow velocity as well as the thermal boundary layer thickness for the shear-thinning fluid with an increase in the Weissenberg number, and the opposite behavior is noted for the shear-thickening fluid. Numerical results are validated by comparisons with already published results.     

Dissipative particle dynamics for complex geometries using non‐orthogonal transformation

Dissipative particle dynamics (DPD) was applied to fluid flow in irregular geometries using non‐orthogonal transformation, where an irregular domain is transformed into a simple rectangular domain. Transformation for position and velocity was used to relate the physical and computational domains. This approach was described by simulating fluid flow inside a two‐dimensional convergent–divergent nozzle. The nozzle geometry is controlled by the contraction ratio (CR) in the middle of the channel. The range of Reynolds number and CR, in this paper, was Re = 10hbox??200 and CR = 0.8 and 0.6, respectively. The DPD results were validated against in‐house computational fluid dynamic (CFD) finite volume code based on the stream function vorticity approach. The results revealed an excellent agreement between DPD and CFD. The maximum deviation between the DPD and CFD results was within 2%. Local and average coefficients of friction was calculated and it compared well with the CFD results. Copyright © 2011 John Wiley & Sons, Ltd.     

Fast Flow Field Estimation for Various Applications with A Universally Applicable Machine Learning Concept

This paper presents an approach for the prediction of incompressible laminar steady flow fields over various geometry types. In conventional approaches of computational fluid dynamics (CFD), flow fields are obtained by solving model equations on computational grids, which is in general computationally expensive. Based on the ability of neural networks to intuitively identify and approximate nonlinear physical relationships, the proposed method makes it possible to eliminate the explicit implementation of model equations such as the Navier–Stokes equations. Moreover, it operates without iteration or spatial discretization of the flow problem. The method is based on the combination of a minimalistic multilayer perceptron (MLP) architecture and a radial-logarithmic filter mask (RLF). The RLF acts as a preprocessing step and its purpose is the spatial encoding of the flow guiding geometry into a compressed form, that can be effectively interpreted by the MLP. The concept is applied on internal flows as well as on external flows (e.g. airfoils and car shapes). In the first step, datasets of flow fields are generated using a CFD-code. Subsequently the neural networks are trained on defined portions of these datasets. Finally, the trained neural networks are applied on the remaining unknown geometries and the prediction accuracy is evaluated. Dataset generation, neural network implementation and evaluation are carried out in MATLAB. To ensure reproducibility of the results presented here, the trained neural networks and sample applications are made available for free download and testing.

     

Effect of vertical stacking dies on flow behavior of epoxy molding compound during encapsulation of stacked-chip scale packages

This paper presents three dimensional (3D) simulation of flow visualization in the encapsulation of stacked-chip scales packages (S-CSP), using finite volume method. The S-CSP model is constructed using GAMBIT and simulated using FLUENT CFD software. The epoxy molding compound is Hitachi CEL-9200 XU (LF) and its flow is assumed laminar and incompressible. Cross viscosity model and volume of fluid technique are applied for flow front tracking of the encapsulant. The meshing is performed using tetrahedral elements and the discretization is done by first order upwind scheme. SIMPLE algorithm is selected for solving the governing equations. The top view and 3D view of simulation flow front profiles in the encapsulation process are presented. The percentage of filled volume versus filling time, viscosity versus shear rate and number of voids versus rows of stacked die are plotted. The temperature and pressure distributions within the mold cavity during the encapsulation process are also observed. Further, the possibility and cause of void formation during the encapsulation process are analyzed and discussed in detail. The number of vertical stacking dies and horizontal rows of packages are found to be crucial in the void formation. The numerical results are compared with previous experimental results and found in good conformity.     

Numerical analysis of two-phase flow from a stratified region through a small circular side branch

A numerical analysis using a commercial CFD code, ANSYS CFX, was used to model two-phase flow discharging from a stratified region through a small branch of circular cross-section. The purpose of this study is to assess the capability of the code in predicting the pertinent flow parameters and to generate detailed results that can provide insights into some of the flow phenomena. The inhomogeneous, free surface model was used and the code predictions were evaluated by comparing results with previous correlation equations and experimental data. Results were obtained for the critical heights of the interface at the onsets of gas and liquid entrainment, as well as the mass flow rate and quality during two-phase discharge. Additional results including force balances and pressure contours were also analysed to provide insight into the flow characteristics just before the onsets of liquid and gas entrainment. All results are in good agreement with existing correlation equations and experimental data. CFD modelling is therefore a possible tool for predicting the correct results for discharging two-phase flow for the geometry under consideration; the computation time required to obtain converged results, however, was found to be excessive.