CFD (Computational Fluid Dynamics) Analysis Service

Summary

In engineering design, a great attention is paid to CFD (Computational Fluid Dynamics) analysis technique to predict complicated multi-dimensional fluid flow motions and related heat transfer.
TOYO has been utilizing the CFD analysis technique for many years to solve various engineering problems in petroleum and petrochemical plants, and have accumulated various knowledge and experiences for successful CFD application to actual design purposes.
TOYO provides CFD analysis services with our best knowledge and application techniques.

Features of Service

• Referring to our experiences and knowledge, we carefully consider what would be the essentially important phenomena laying in Customer's facing problems,
• Based on the above consideration, we propose the best suited computation model and CFD code for the analysis to realize accuracy and efficiency,
• Our highly-experienced experts create an analysis report with comprehensive explanation and deep consideration on the computation results and with practical suggestions or recommendations to overcome Customer's facing problems, and,
• Even if Customer's facing problems can not be analyzed only by the standard functions of our CFD codes (FLUENT, PHOENICS), we can perform the required analysis by adding proper physical models developed based on our expertise.

Services

Extensive Experiences

We have been utilizing CFD analysis technique for usual engineering design such as;

• Vortex formation analysis in a cage valve to prevent acousto-hydraulic excitation,
  - Cage valves at let-down station, etc.,
• Temperature and flow maldistribution analysis in reactors and vessels,
  -Flue gas reactors, Conversion reactors, Decomposers, etc.,、
• Temperature and flow maldistribution and pressure drop analysis in duct systems,
  - Flue gas ducts, Flaring networks, Stacks, Waste heat exchangers, etc.,
• Steam condensation and inert gas accumulation analysis in heat exchangers,
  -Reboilers, Condensers, Feed water heaters, etc.,
• Multi-fluid diffusion analysis in closed or open systems,
  - Toxic or flammable gas leak simulations, Chemical injection systems, etc.,
• Multi-phase flow analysis,
  - Stripper down-comers, Bubble Column Reactors, Pump pits, Preheaters, etc.,
• Combustion analysis,
  - O2 reformers, SSH burners, Furnaces, etc.,
• Optimization of flow distributing devices,
  - Slug catchers, Granulators, Dust Scrubbers, Spargers, etc.,
• Optimization of equipment arrangements to minimize undesirable interaction
  - Cooling towers, Air coolers, Air heaters, etc.
• And More!
• TOYO has accumulated a lot of experiences and knowledge on successful CFD application through the many kinds of analysis implementation as shown above. Customers can fully utilize our experiences and knowledge for solving their own problems.

Examples of CFD Application

Ex.1
Analysis of Temperature and O2 Concentration Distributions around Cracking Heaters

Diffusion of flue gas from heater stacks to the air has been analyzed in order to optimize stack height. The O2 concentration at the monitoring point strongly depends on the wind speed and stack height. It drops to less than its limit (18vol%) at some conditions.
The stack height is optimized so as to maintain the O2 concentration level above its limit at all the wind conditions considered. Figure 1 shows the temperature distribution on a vertical plane.

Ex.2
Steam Condensation Analysis for Feed Water Heater

Figure 2 shows stream lines from steam inlets and distributions of steam condensation rates at baffle locations in a Feed Water Heater. The steam condensation rate varies according to steam flow structure in the Feed Water Heater.
In this analysis, it has been confirmed that the maximum tube crossing velocity is low enough to prevent tube vibration and the maximum inert gas concentration is also sufficiently thin not to cause corrosion and not to reduce heat transfer performance.

Ex.3
Two Phase Flow Analysis for Bubble Column Reactor

Liquid is driven by ascending gas bubble supplied from perforated area of lower baffle plate (hatched gray color in Fig.3). In this Bubble Column Reactor design, torus like liquid-phase flow in and around the tube bundle with sufficient tube-crossing velocity needs to be realized to obtain required heat transfer, condensation, reaction and mixing in each cell bounded by two baffles (tubes are not indicated in Fig.3).
By this analysis, it has been confirmed that the baffle plates are properly designed so as to realize the above requirements with a small modification. Bubble velocity is indicated by sphere colors and liquid velocity is shown by vector colors in Fig.3.