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Designing equipment by using CFD Benefits and pitfalls Geert Janssen Advanced Thermal Transfer Equipment A2TE.

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Presentation on theme: "Designing equipment by using CFD Benefits and pitfalls Geert Janssen Advanced Thermal Transfer Equipment A2TE."— Presentation transcript:

1 Designing equipment by using CFD Benefits and pitfalls Geert Janssen Advanced Thermal Transfer Equipment A2TE

2 CFD - Phoenics CORA2 – graduate studies Phoenics user since 1985 –Analysis Flow in intake manifolds of IC engines Flow & heat transfer process industry –Design from 1990 Heat transfer equipment –Ovens and furnaces

3 Applied CFD Better understanding –Flow –Heat transfer –Mass transfer –Chemics Sensitivity analysis Priceworthy fast

4 Why limited CFD usage Long learning curve Specialists required –Jargon –physics insight and knowledge ? –Standard rules from handbooks? Design modelling –Communication skills

5 Example - 1 Oven Perforated plates –Flow distributors

6 Example - 2 Molten metal in tundish Target –Continuous casting –No slag inclusions –No bubbles

7 Tundish Symmetric inflow Steady state ? No match with experimental data Blame on CFD?

8 Designing equipment & CFD Rules of thumb Standard textbooks Some understanding of physics CFD ‘tricks’ Designers skills or strong interaction with designer

9 Example 3 - ageing oven Continuous belt oven Base of lamp (automotive) 3 lanes: 3 x 800 pcs/hr Heating to 200°C and holding for 4 hrs Cooling to 50°C Floorspace approx. 5 m 2 Temperature differences < 5°C

10 Ageing oven - 2 Heat transfer and pressure drop from packed bed relations Required velocities through belt –Heating section –Cooling section Fan in holding section identical to those of other sections

11 Ageing oven - 3

12 Ageing oven - 4

13 Ageing oven - 5

14 Ageing oven - 6 CFD model took 3 days Conceptual design 2 weeks

15 Ageing oven - 7

16 Ageing oven - 8

17 Example 4 curing oven Contact lenses Automated process Polypropylene: 95°C ± 3°C At least 15 minutes at 92°C (minimum) Heating up in 10 – 12 minutes Aluminium trays, 1300 grams –1 tray in 40 seconds

18 Curing oven - tray

19 Curing oven - analytical Calculation of required heat transfer coefficient (mass – time) High value needed (75 Wm -2 K -1 )  Multiple jets One heat-up zone –Costs (fan, controller, cabinet)

20 Curing oven - tray

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23 Curing oven Conclusions from tray calculations –Required air-inlet temperature > 105°C

24 Curing oven – cross section

25 Curing oven - power change

26 Curing oven - belt level

27 Curing oven – CFD model CFD models: 2 weeks Conceptual design 4 weeks

28 Conclusions Use of CFD can be very profitable Often CFD alone does not ‘do the trick’ –Handbooks –Rules –Experience


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