Materials & Chemical Processing Simulation and Design: Coupled CFD, FEA and 1D-System Modeling

Esimlab’s engineering team CFD and FEA solutions for the Materials & Chemical Processing is helping companies to significant engineering improvement from equipment and processes to chemical and petrochemical refining to glass and metals manufacturing –  forming and casting -. ESimLab’s engineering team solution includes CFD for chemical process Industry, FEA for process industry and expand to cover electromagnetic and system design engineering concerns.

ESimLab engineering team use advanced CAE software with special features for mixing the best of both FEA tools and CFD solvers: CFD codes such as Ansys FluentStarCCM+ and FEA Codes such as ABAQUS, Nastran, LS-Dyna and the industry-leading fatigue Simulation technology such as Simulia FE-SAFE, Ansys Ncode Design Life to calculate fatigue life and MSC Actran and ESI VA One for Acoustics and VibroAcoustics simulations

With combination of deep knowledge and experience in sophisticated FEA and CFD based design tools and coupling with 1D System modeilng Software such as Matlab Simulink, Esimlab engineers can solve any problem with any level of complexity in Materials & Chemical Processing Design and Optimization

FEA and CFD based Electric Motor design and simulation
CFD and FEA consultant at ESimLab

FEA and CFD Based Simulation

CFD based Reactor Analysis and Engineering

Using comprehensive multiphysics simulation platform that encompasses fluid mechanics, structural mechanics, impact and safety analyses, customized mixing tools, pressure vessel analysis, electromagnetic and control systems, and heat and mass transfer analyses we can model a diverse range of reactions, including gaseous and liquid, single-phase and multiphase, and homogenous and heterogeneous. Our engineering simulation for reactor design including CFD for chemical reactor design, FEA structural and thermal analysis and instrumentation and control software used for design and analysis of chemical reactors enable our reaction engineers to answer what-if questions as they design and enhance reactors performance, energy usage, reactor yield and product uniformity. We optimize reactor performance by investigating the effects and impacts of feed locations, vessel geometries and internals, vibrations, failures, dead spots, shear rates, resident time distributions, hot spots, and particle size distributions.

ESimLab engineering simulation for reactor design software tools help a wide range of customers to simulate and improve a wide variety of reactors and reaction types.

  • Stiff chemistry
  • Competing and parallel reactions
  • Catalytic reactions
  • Heterogeneous and homogeneous reactions
  • Surface and volumetric reactions
  • Laminar and turbulent flows
  • Single-phase and multiphase reactions
  • Fluidized bed reactions
  • Multi-tube reactors
  • Membrane reactors
  • Microreactors
  • Stirred tank reactors
  • Fixed reactors
  • Autoclave reactors
  • Emulsion
  • Hydrogenation

CFD Simulation and Optimization of Combustion

CFD for combustion systems enable the simulation of a broad range of particulate concentrations, from dilute flows to packed beds. Simulations provide local velocities, particulate concentrations and traces, composition of combustion gases, fuel conversion rates, temperatures, and other critical data. These insights enable Esimlab’s combustion engineers to investigate operational issues such as local temperature peaks, combustion efficiency and mixing problems. ESimLab’s engineering team simulation are helping customers to overcome the following and many other combustion-related challenges:

  • Improve burner configurations in industrial furnaces
  • Reduce NOx emissions from petroleum refineries
  • Investigate novel clean energy technologies
  • Predict and improve CO emission rates
  • Model and minimize thermal stresses in combustion equipment
  • Reduce soot formation in furnaces
  • Optimize flare stack designs

FEA and CFD based Heat Transfer Equipment Design and Analysis

ESimLab engineering simulation for heat transfer solutions help clients to gain critical insight, and select the right design for the right application. Heat transmission by conduction, convection and radiation in laminar or turbulent flows for fluids, such as steam, thermal liquids, liquid metals and non-Newtonian fluids, can be design and analyze and new concept can be developed using engineering simulation for heat generation and heat transfer equipment. Using these solutions our engineers can identify hot spots, associated thermal stresses, equipment design and process efficiencies, and other issues that affect system performance.

ESimLab CFD consultant service for heat exchanger design and Finite element based Structural mechanics and thermal analysis software tools provide a well-established engineering platform to help improve the design and analysis of energy-saving concepts, equipment reliability, structural integrity and related efficiency gains through virtual prototyping in a broad range of heat transfer applications. ESimLab engineering simulation are helping customers to overcome the following and many other Heat transfer and thermal analysis-related challenges:

  • Air-cooled heat exchangers
  • Boilers
  • Burners
  • Chillers
  • Condensers
  • Dryers
  • Evaporators
  • Flares
  • Heaters
  • Heating and cooling tanks
  • Ovens
  • Plate type exchangers
  • Reboilers
  • Shell and tube heat exchangers
  • Superheaters

Mixer Design and Analysis with FEA and CFD based Simulation

Numerical flow simulations with CFD provide important insights into the flow processes of the entire system vessel agitator and the associated components, the finite element method (FEM) is also used to gain a deeper insight into the mechanical design of agitators, vessels, and their components. It allows a more reliable design, thereby preventing damage and loss of production. The load data obtained by measurements as well as the flow simulations and the geometry information obtained from the CAD system serve as important input parameters or general data for subsequent FEA analysis. The FEA method has now found its way into almost all conceivable physical disciplines. The most important fields of application in agitation and mixing technology are:

In addition to the generally static loads resulting from the process pressure and the temperature, agitator vessels and their components are subject to a high dynamic load emanating from the agitator. For example, alternating bending moments and transverse forces as well as torsional moments and axial forces as reaction forces are passed from the agitator top to the vessel. Vessel components (e.g. baffles, gassing devices, heat exchanger tubes, and supply/drain pipes) are also subjected to a fluctuating load because of their turbulent inflow.

ESimLab engineering simulation are helping customers to overcome the following Mixing analysis-related challenges:

  • Blending
  • High-shear mixers
  • Water treatment
  • Hydrogenation
  • Crystallization
  • Jet mixers
  • Emulsion
  • Laminar mixing
  • Fermentation
  • Solids suspension
  • Gas dispersion and sparging
  • Food mixing
  • Residence time distribution
  • Mixing vessel design
  • Glass-lined reactor systems
  • Polymerization

Multiphase Simulation

ESimlab Use Coupled Finite Element(FEA)-CFD and-or Magnetic coupling technologies to engineering simulation for multiphase flow. This Technologies used in different range of application to overcome complicated environment of simulation:

  • Solid drying systems
  • Hydrocyclones
  • Bubble columns
  • Loop reactors
  • Centrifugal extractors
  • Mist eliminators
  • Crystallization
  • Surface aerators
  • Cyclone separators
  • Packed columns
  • Solid suspensions
  • Packed beds
  • Droplet separation
  • Particle size reduction systems
  • Dust collection systems
  • Particulate systems
  • Emulsion
  • Precipitators
  • Fluidized-bed catalytic cracking
  • Scrubbers
  • Fluidized-bed systems
  • Sedimentation devices
  • Foams
  • Sieve plates

Particle Simulation: SPH, CFD, FEM and DEM

Using a variety of advanced modeling techniques to study both continuous and particulate phases,with combination of Finite element method(FEA), DEM and CFD, we can handle simulation of particle included systems and their properties including following parameters:

  • Particle flows
  • Cohesion
  • Material wear
  • Particle size distribution
  • Particle mechanics
  • Surface and morphology
  • Particle–particle interaction
  • Turbulence and dispersion
  • Geometry effects
  • Erosion
  • Particle attrition
  • Homogeneous and hydrogenous reactions
  • Particle flows
  • Electrostatic effects

CFD and FEA based Filtration System Design and Optimization

CFD for separation and filtration includes modeling of transport of solid particle are used by diverse set of customers to understand and reduce erosion in solid separation and extraction devices. ESimLab’s engineering simulation team has experience in using FEA and CFD for separation and filtration systems, give clients a clearer understanding of filtration optimization through in-depth studies of filter media, particle deposition and caking, pressure drop, throughput, back flushing, and mechanical design.

Below is a list of applications where CFD for separation and filtration as well as the associate structure and thermal analysis are used in the material and chemical process industries.

  • Centrifugal filters
  • Gravity separators
  • Chromatography
  • Sublimation
  • Ultrafilters
  • Jet impactors
  • Cyclones
  • Leaching
  • Demisters
  • Magnetic separators
  • Filter media
  • Membrane separation
  • Distillation trays and plates
  • Packed beds
  • Electrostatic precipitators
  • Pressure filters
  • Extractors and screw-conveyors
  • Purifiers
  • Flotation
  • Sedimentation tanks
  • Hydrocyclones
  • Structured packing
Multiphase Flow Simulation Abaqus, Ansys, Fluent, Siemens Star-ccm+, Matlab
oil-gas-Materials & Chemical Processing Simulation and Design: Coupled CFD, FEA and 1D-System Modeling
oil-gas-Materials & Chemical Processing Simulation and Design: Coupled CFD, FEA and 1D-System Modeling

Considering complexity and needs to have new procedure and constitutive equation, we must try to develop new FEA and CFD based software to overcome engineering challenges.

FEA and CFD based Programming needs experience and deep knowledge in both Solid or fluid mechanics and programming language such as Matlab, Fortran, C++ and Python.

Esimlab’s engineering team use advanced methodology and procedure in programming and correct constitutive equation in solid, fluid and multiphysics environment based on our clients needs.

We use subroutine’s with programming languages such as Fortan, C and Python in CFD and FEA sofware such as Abaqus, Ansys, Fluent and Star-ccm+ to add new capability and Constitutive equation.

ESimLab use Mathematical Methods and Models for Engineering Simulation. We, focuses on numerical modelling and algorithms development for the solution of challenging problems in several engineering sectors specialized in the development of software for the numerical discretization of partial differential equations, linear algebra, optimization, data analysis, High Performance Computing for several engineering applications.

Together, we enable customers to reduce R&D costs and bring products to market faster, with confidence.

Do you need more information or want to discuss your project?

Reach out to us anytime and we’ll happily answer your questions
Contact us

A world-class consultancy for engineering, technology, innovation, our industry know-how and technical expertise is unrivalled.

Do you need more information or want to discuss your project?

Reach out to us anytime and we’ll happily answer your questions
Contact us

We use advanced virtual engineering tools, supported by a team of technical experts, to global partners in different industries.

Do you need more information or want to discuss your project?

Reach out to us anytime and we’ll happily answer your questions
Contact us

Our Software team is made up of developers, industry experts and technical consultants ensuring we can respond to each client’s individual needs

Do you need more information or want to discuss your project?

Reach out to us anytime and we’ll happily answer your questions
Contact us

Real world Simulation: Combination of experience and advanced analysis tools

Calling upon our wide base of in-house capabilities covering strategic and technical consulting, engineering, manufacturing ( Casting, Forming  and Welding) and analytical software development – we offer each of our clients the individual level of support they are looking for, providing transparency, time savings and cost efficiencies.
ESimLab engineers participate in method development, advanced simulation work, software training and support. Over experiences in engineering consulting and design development, enables ESimLab’s engineering team to display strong/enormous client focus and engineering experience. The ESimLab team supports engineering communities to leverage CFD-FEA simulation softwares and methodologies. It leads to the creation of tailored solutions, aligned with the overall product development process of ESimLab clients.

CAE Simulation: CFD, FEA, System Modeling, 1D-3D coupling

Integrated expertise covering every Equipment component analysis. From concept through to manufacture and product launch, and for new designs or Equipment modifications, we provide engineering simulation expertise across projects of all sizes. Simulation has become a key enabling factor in the development of highly competitive and advanced Equipment systems. CAE methods play a vital role in defining new Equipment concepts.

metal forming simulation: ansys abaqus simufact forming
Metal Forming Simulation
Automotive Engineering: Powertrain Component Development, NVH, Combustion and Thermal simulation, Abaqus, Ansys, Ls-dyna, Siemens Star-ccm EsimLab
Crash Test and Crashworthiness
Finite Element and CFD Based Simulation of Casting esi procast
Casting Simulation
Additive Manufacturing: FEA Based Design and Optimization with Abaqus, ANSYS and Nastran
Additive Manufacturing
MultiObjective Design and Optimization of Turbomachinery: Ansys Fluent, Numeca fine turbo, Siemens star-ccm+, simulia abaqus, Ls-dyna, Matlab
Design of Turbomachinery
CFD Heat Thermal simulation: Abaqus, Ansys Fluent, Star-ccm+, Ls-dyna, Matlab
CFD Heat Transfer
Fluid Structure Interaction FSI with Ansys Abaqus, Fluent Star-ccm Comsol
Fluid Structure Interaction FEA CFD FSI Abaqus Ansys Comsol LS-dyna Wind Turbine EsimLab
Fluid Strucure Interaction
Exhaust Acoustics and vibration: ESI va one, msc actran, abaqus, ansys, fluent, star-ccm , nastran
Acoustics & Vibration
Aerodynamic Simulation CFD Ansys Fluent Siemens Star-ccm+ Numeca xflow cradle
Aerodynamic Simulation
Ansys Fluent, Siemens Star-ccm+ Numeca fine , Avl Fire, Matlab
Combustion Simulation
Multiphase Flow Simulation Abaqus, Ansys, Fluent, Siemens Star-ccm+, Matlab
MultiPhase Flow Simulation
Fatigue Simulation Abaqus Ansys FE-Safe NCode Design Life FEA Finite Element ESimLab
Creep & Fatigue
Multibody dynamics MBD Abaqus, Ansys Fluent, Star-ccm+, Ls-dyna, Matlab, fortran , C++, Python
Multi-Body Dynamics (MBD)
composite impact simulation , Comsol Abaqus, Ansys, Fluent, Siemens Star-ccm+, Aerospace and defenceMatlab, Fortran, Python CFD FEA
Composite Design
welding FEA Simulation Simufact Welding ESI Sysweld Abaqus Ansys ESIMLAB
Welding Simulation
Optimization of Wind Turbine Composite Fracture Mechanic Damage Design Abaqus Ansys Finite Element CFD ESIMLAB
Multi-Objective Optimization
CFD and FEA based Fortran, C++, Matlab and Python Programming
Advanced Fortran, C++, Matlab & Python Programming