Service for CFD and FEA Simulation

Computational Fluid Dynamics (CFD)

CFD is used to analyze and optimize the behavior of fluids (gases or liquids) in process equipment and piping systems, ensuring performance, safety, and efficiency.

Capabilities Include:

• Fluid flow modeling (laminar/turbulent, single/multi-phase)
• Pressure drop & velocity profile analysis
• Heat transfer & thermal distribution studies
• Mixing behavior in reactors, tanks & blending systems
• Flow maldistribution in heat exchangers & condensers
• Performance assessment of scrubbers, filters, ducts & chimneys
• Air flow and temperature mapping in HVAC systems
• Erosion & cavitation predictions in high-velocity flow systems

Software Tools:
ANSYS Fluent, OpenFOAM, COMSOL Multiphysics, SimScale, Autodesk CFD, DWSIM (open source for process simulation)

Finite Element Analysis (FEA)

FEA is used to evaluate the mechanical behavior of components and systems under various loading conditions to ensure structural integrity and design optimization.

Capabilities Include:

• Static & dynamic structural analysis
• Thermal stress & fatigue analysis
• Buckling analysis for columns, vessels & thin-wall structures
• Vibration, modal & harmonic analysis for rotating equipment
• Impact, deformation & displacement prediction under mechanical loads
• Stress analysis for nozzles, flanges, jackets & supports
• Seismic & wind load structural integrity checks

Software Tools:
ANSYS Mechanical, SolidWorks Simulation, ABAQUS, COMSOL, STAAD.Pro

Typical Applications in Process Industries

• Reactors & Pressure Vessels: Internal baffle optimization, agitation studies, stress under operating pressure
• Heat Exchangers: Tube-side/shell-side performance, fouling impact, flow-induced vibration
• Scrubber & Absorption Systems: Gas-liquid contact simulation, residence time improvement
• Cyclones, Silos, & Bag Filters: Particle separation efficiency & flow uniformity
• Piping Systems: Flow distribution, water hammer, thermal expansion stress
• Stack & Chimney Design: Buoyancy, wind loading, and pollutant dispersion
• Pump/Compressor Skids: Suction/discharge flow path optimization
• Cooling Towers & HVAC Ducts: Thermal effectiveness and airflow patterns

Deliverables Provided

• Simulation Reports with visual outputs (Contours, Vectors, Streamlines)
• Design Recommendations and Improvement Suggestions
• CAD-integrated results for design validation
• Validation against experimental/test data (if available)
• Comparative Study Reports (Base vs. Optimized Designs)
• Technical Documentation with boundary conditions, assumptions & interpretations