- INTRODUCTION
- AEROSPACE
- AUTOMOTIVE
- BUILDINGS & STRUCTURALS
- DATA CENTER
- HEAT EXCHANGERS
- HVAC
- OIL & GAS
- RAIL TRANSPORT
- TURBOMACHINERY
- POWER
- PROCESS
COMPUTATIONAL FLUID DYNAMICS
Computational Fluid Dynamics (CFD) is a branch of fluid mechanics used to analyze & solve the problems in the flow of fluids with the help of principles,calculations & algorithms. CFD has seen dramatic growth throughout the world over the last several decades. CFD modeling is a key tool used to analyze flows and their interaction with complex surfaces in pipes, manifolds, separators, etc. This technology has widely been applied to various engineering applications such as automobile and aircraft design, civil engineering and so on. It provides an accurate representation of the expected flow profiles, which can be used to predict the product performance. Many traditional methods using physical prototypes will be complemented or may even be replaced by this approach.
Areas We Work
- Single phase and Multiphase flows
- Internal and External flows
- Fluid Structure Interaction (FSI)
- Hydrodynamic analysis
- Aeroacoustics
- Combustion
- Cost Effective
- Reliable results
- Design Evaluation
- Performance Evaluation
- Reduced turn around time
- Effective simulation of flow in fluids
- Unlimited level of detail in the system
- Powerful visualization capabilities
- Analyze difficult & dangerous experiments
Advantages of CFD
AEROSPACE
Aerospace industry is under high pressure to build more efficient, quieter and greener aircraft, space vehicles, propulsion units, etc. Furthermore, these demands are due to strict regulations, higher material costs, higher fuel costs and more demanding customers. Using CFD analysis as part of their development process, Aerospace manufacturing companies and suppliers can evaluate designs and predict product performance, reducing the number of costly and time-consuming physical prototypes in the design cycle.
Our Services Include
Axial compressor optimization
- Flow losses reduction in rotor and stator
- Enhancing flow distribution
- Improve overall performance and off-design validation
- Design and development of rotor, stator and casing
Axial turbine optimization
- Flow losses reduction in blade and nozzle
- Enhanced flow distribution and heat transfer
- Improve overall performance and design validation
Combustor design and optimization
- Flow losses reduction in combustion chamber
- Enhanced flow distribution and combustion simulation
- Improve overall performance and off-design validation
- Design development and optimization
Other services
- Suggestions to improve auxiliary systems performance.
- Hexa Meshing, Drafting Service
AUTOMOTIVE
Automotive industry characterized with dynamic environment and frequent design changes requires optimized designs to reduce product cost and cycle time. With highly capable flow, heat transfer and coupled analysis models, use of CFD techniques within automotive industry has increased rapidly. Application of CFD within automotive industry ranges from system level (External aerodynamics, Underhood thermal simulation) to component level (Engines, Turbochargers, Exhaust manifold and HVAC ducts) design and optimization. Obtaining critical data that is not possible using conventional experiments is possible using CFD. Modern CFD codes and post processing tools provides a magnified insight of the flow physics to the eyes of engineers, enhancing their capabilities to change the design quickly and optimize the performance of the components at the design stage itself.
External Aerodynamics
External aerodynamics of vehicles plays an important role in the design of fuel efficient, stable and high speed vehicles. Aerodynamics drag and lift force have a strong impact on the vehicle's fuel consumption, handling behavior and on the cooling system. Applying CFD for predicting aerodynamic loads and associated factors has grown rapidly. It is adapted as a standard tool for design evaluation at the product development stage by most of the manufacturers.
Our expertise in these areas could assist you with,
- Drag prediction through wind tunnel case studies
- Pressure and velocity distribution on vehicles
- Performance predication and optimization of vehicle bodies
- Disc brake or conventional brake drum cooling
- Aquaplaning
Internal Combustion Engines
Modeling and Simulation of the working process of internal combustion engines has now become an integral part of any engine design and development process. CFD techniques have a long known presence in this field and play a vital role in the development of modern engines. Helping engineers to design and build engines with better fuel efficiency and meet stringent emission norms at a reduced cost and time. With the help of CFD in-cylinder flow process particularly air/fuel mixture flow pattern within engine, fuel injection and mixing process, combustion and contents of exhaust gas could be predicted and analyzed to a greater detail.
Our expertise in these areas could assist you with,
- Performance assessment of IC engines
- Air flow distribution pattern analysis
HVAC & R system
Within automotive industries, design and optimization of HVAC & R systems for passenger cars and refrigerated trucks is an important aspect. It requires adequate and detailed interest during the early stages of design. CFD is being adopted and used extensively by most the manufacturers in design and optimization of HVAC & R systems and its components for automotive applications. Mostly it is used to study the thermal comfort within passenger cabins, temperature distribution within refrigerated trucks and to assess the performance of various auxiliary systems at the early stages of design.
Our expertise in these areas could assist you with,
- Performance assessment of cabin HVAC system and its components
- Predicting and improving thermal distribution within cabins
Underhood Thermal Simulation
Thermal management within passenger cars and commercial vehicles is of vital importance in the process of vehicle development. Thermal protection from tightly packed engine compartments, exhaust gas handling systems, tail pipe and other accessories play a major role in enhancing passenger comfort and safety features. CFD is used for predicting the cooling requirements of passengers and other temperature sensitive components, thermal load obtained from engines and other accessories without the necessity of investing more time and cost in doing experimental analysis.
Our expertise in these areas could assist you with,
- Thermal analysis of passenger cabins and engine compartments
- Air flow requirements for better heat dissipation within cabins and frontal areas
- System and component level thermal and performance assessment
Other Services Include
- Powertrain System
- Fuel Injection System
- Vehicle Thermal Management System
- After Treatment System
- Acoustics
- Sloshing
BUILDINGS & STRUCTURALS
Aerodynamics and air flow around tall buildings and sky scrappers towards an optimized external shape of buildings, reduced drag forces and stress induced due to wind load, residents and pedestrian comfort zone have always been a major challenge for modern day architects and engineers. Most of these problems arise due to building shapes and wind flow.
With the application of CFD, these challenges have been overcome through designing buildings with better external shapes and suitable for the demographical locations. It also helps in determining optimal height for buildings at an earlier stage of design. In addition, application of CFD within construction industries has reached to an extent where architects and engineers are using it for assessing the potential of energy harvesting within tall buildings, making it to be more energy efficient and thereby reducing its carbon foot print.
Our expertise in these areas could assist you with,
- Building external aerodynamic analysis
- Structural load assessment
- Pedestrian comfort area assessment
- Urban planning
- Effective thermal management within buildings
- Improve energy efficiency and reduction in carbon foot print
- Exploiting wind energy for power generation
DATA CENTER
Housed with computer systems, storage systems and associated components, data centers require better environmental controls like air distribution, adequate thermal insulations, proper ventilation, fire suppressing systems and better accessibility.
Ambient conditions especially air flow and temperature distribution within data center are important parameters for safe and uninterrupted operation. Use of CFD as a tool for better air flow and thermal management within data center is gaining more importance.
Our expertise in these areas could assist you with,
- Data center air flow management
- Assessing temperature, pressure and velocity distribution
- Hot and cold spot identification
- 3-D thermal mapping
- Air conditioning and ventilation system performance assessment
HEAT EXCHANGERS
Predicting the heat transfer process, heat transfer co-efficient, temperature and fluid flow distribution are of primary importance in the design and operation of heat exchangers. CFD is widely being used as an effective tool for flow visualization, design improvements and optimization of various heat exchanger systems like boilers, radiators, condensers and economizers.
The capabilities of CFD have enabled engineers to improve the existing systems without increasing its down time. CFD in heat exchanger design is used for investigating fluid flow maldistribution, heat transfer process modeling, fouling, pressure drop and thermal analysis.
Our expertise in these areas could assist you with,
- Thermal performance assessment of radiators
- Shell and tube heat exchangers design assessment
- Steam condensing system design assessment
HVAC
CFD in HVAC industry is used for various design and optimization applications, ranging from commercial, residential building air distribution ducts, tunnel ventilation for mines, auxiliary component of ventilation system, Air Handling Units (AHUs), Air Conditioning systems (AC), Fans and its components and process plant ducts. CFD technique has enabled engineers to predict the pressure drop along ducts, heating load calculation, heat transfer rate for effective and optimum insulations required at a very early stage of design, facilitating them to deliver cost effective and efficient solutions with shorter lead time for various and growing demands.
Our expertise in these areas could assist you with,
- Duct optimization
- Industrial fans performance assessment and optimization
- Air flow distribution within buildings
- Thermal comfort of occupant within the room
OIL & GAS
Oil and Gas industry operation involves use of highly sophisticated equipments with complex physics likely reactions, mutiphase flow, non-Newtonian rheology and mixing etc. Due to varied operating conditions, these equipments are subjected to high rate of erosion and has very low life expectancy during operation. Application of CFD within oil and gas industry towards the design and optimization of such equipments has grown rapidly. The results of CFD simulation provides a qualitative evaluation of flow process and associated phenomenon such as erosion and slugging. This helps designers and operators to solve flow problems, extend the life of equipments, flow lines and deliver the product safely and efficiently. CFD is mainly used for pipe line and associated components evaluation, hydrodynamics simulation, heat transfer analysis, nozzle flow applications, pump analysis, acoustic analysis, multiphase flow and mixing.
Mixing Tank
Rational design of mixing process, stirrers and other components of a mixing tank could be obtained via predicting some of the key parameters like mixing time, effectiveness of impeller or blade design in the process of mixing. Since these data are required by engineers at an early stage to offer better and efficient mixing tank, CFD based simulation techniques are used. An integrated approach that relates the design of impeller, vessel geometry to the flow field produced, energy balance and design requirements which are vital for the design of stirred tanks is possible using CFD.
Our expertise in these areas could assist you with,
- Performance assessment of mixing blades
- Flow and velocity distribution pattern
- Design optimization of blades and tank
Other Services Include
- Multiphase flow analysis in pipes
- Multiphase flow analysis in manifolds & pipe junctions
- Multiphase flow analysis in pumps & separation equipments
- Sand erosion and sand blockage assessment
- Sloshing analysis
- Surge phenomenon
- Cavitation phenomenon
- Water hammer analysis
- Gas phase and liquid phase reactor flow analysis
- Slurry flow analysis
RAIL TRANSPORT
External aerodynamics, thermal comfort of passengers and acoustics characters of rail vehicles are important features in the design of modern rail transport system. CFD techniques are used by most of the manufacturers as a cost effective tool in achieving the design objectives at a less time.
Our expertise in these areas could assist you with,
- Analyze and optimize cabin HVAC systems
- Vehicle external aerodynamics analysis
- Analyze thermal comfort of passengers within cabin
TURBOMACHINERY
Use of CFD within turbomachinery companies has grown extensively. Process of designing and optimizing modern turbines, pumps and compressors with better aerodynamic characteristics and higher efficiency has been made easier through the application of CFD. Flow and acoustic characteristics of turbomachines are being well predicted with higher level of accuracy at the design stage itself. CFD offers shorter design cycles for better performance, cost effectiveness and weight reduction. CFD is also used for achieving noise reduction, pressure loss reduction, avoiding cavitation, better blade designs and heat transfer modeling.
Our expertise in these areas could assist you with,
- Performance assessment of pumps
- Cavitation modeling
- Industrial fan performance assessment and design optimization
- Performance assessment of wind mills
- Design and shape optimization of wind mill blades
Other Services Include
- Axial and radial compressor optimization
- Flow losses reduction in rotor and stator
- Enhance flow distribution
- Improve overall performance and off-design validation
- Design and development of rotor, stator and casing
- Axial and radial turbine optimization
- Flow losses reduction in blade and nozzle
- Enhanced flow distribution and heat transfer
- Improve overall performance and design validation
- Axial and centrifugal pump optimization
- Flow losses reduction in impeller and volute
- Enhanced flow distribution and NPSH prediction
- Improve overall performance and off-design validation
- Design development and optimization of impeller & volute
- Testing and other services
- Designing the prototype and testing, APQP activities
- Suggestions to improve auxiliary systems performance
- Hexa meshing, Drafting service
POWER
Increasing demand for power and strict legislative requirements on the emissions are posing bigger challenges for fossil fuel based thermal power plants. Clean combustion, emission reduction and improved efficiency of equipments are some of the key elements for its long run. This requires developing new designs or retrofitting the existing system through minor modifications improving the performance of the system and plant efficiency. In order to achieve these objectives at a reduced cost and lead time without compromising in the quality of results, power plants are using CFD extensively. It is applied towards cost effective design and optimization of HVAC systems and components, Ducts, Mixers, Cyclone Separator, Dust Collecting Systems, ElectroStatic Precipitator (ESP), Air PreHeater (APH), Boiler and its components, Economizers and Condensers.
Ducts
Ducting systems are inevitable elements of any equipment or process within power plants and other process industries. Design optimization of industrial ducts to achieve uniform flow pattern without increase in pressure column, is of paramount importance to improve the plant efficiency and reduce auxiliary power consumption. Using CFD to visualize the flow pattern inside the duct and assess the thermal characteristics of ducts along with associated equipments is being adopted by most of the power plants and process industries as a standard and cost effective tool.
Our expertise in these areas could assist you with,
- Design optimization of industrial ducts
- Analyzing and optimizing flow pattern within ducts
- Analyzing thermal load on ducts
Electrostatic Precipitator
Electrostatic Precipitator used in power plants and cement industry is subjected to a very robust, hazardous and erosive environment. Examining the flow characteristics of ESP within the collection region and associated duct work has gained huge importance to ensure better design and efficient operation that meets the pollution control norms. CFD being a cost effective technique and a controlled environment to evaluate various design elements is gaining significant importance in design evaluation and optimization of ESPs. Time and cost required to undertake experimental works for analyzing the flow unsteadiness, velocity stratification, flow angularity and particulate deposition within an ESP could be reduced through the use of CFD analysis.
Our expertise in these areas could assist you with,
- ESP system and associated ducts flow pattern analysis
- ESP and associated ducts flow process optimization
Air Preheater Heating Element
Transient Analysis of various Air Preheater Heating Element profiles was carried out in a test environment to provide a detailed comparison of Temperature, Pressure, Velocity, Boundary Heat Transfer, Turbulent Kinetic Energy & Nusselt Number. The results are used to select the most appropriate heating element profile for the plant operating condition. CFD Analysis is also carried out to study the flow pattern & establish a uniform flow upstream of the Air Preheater.
The velocity flow streamlines depict the flow behaviour & possible stagnation zones. These zones are studied for their turbulence characteristics & efforts are taken to minimize flow losses.
Combustion
Pulverized coal combustion is of significant importance in thermal power plants. Adequate supply of air and fuel for proper combustion ensures that the required heat transfer occurs to convert water into steam and reduces pollution. Strigent pollutant emission regulations are posing new challenges for boiler and burner manufacturers and requiring them to develop new and optimized boilers and burners or retrofit existing system with an optimized design. CFD plays an important role within power plants to achieve such design objectives within shorter time and reduced cost. Predicting the flow of air and coal within the combustion chamber, fire ball locations, effectiveness of nozzles and burners, gas temperature at key locations and reaction modeling of combustion process are of primary focus in any CFD analysis carried for power plants.
Our expertise in these areas could assist you with,
- Analysis and optimization of industrial burners
- Analysis and optimization of boiler combustion chamber
- Flow pattern and temperature distribution of flue gases
PROCESS
Process industries such as chemical, ceramics, food and metal processing require continuous use of cost effective and reliable techniques for increasing productivity, cost reduction and reduction in energy consumption. Process industry applications of CFD require that the flow to be resolved both in complex geometries and with complex physics. With increased capabilities and proven flow models, CFD provides a very useful and detailed insight of various process and functioning of complex equipments within short span of time and at reduced cost. It has proven to be a very useful and effective tool for optimizing the design of new equipments or improving the existing equipments performance. CFD is used in a wide range of applications within process industries including analysis and optimization of equipments such as rotating kilns, particle separator, mixers, mixing system, nozzles, injectors, extruders, chemical and food processing units.
Nozzles and Injectors
Marginal improvements objected in the design of nozzles, turbines, injection systems and its elements require precise techniques to choose the best alternative designs. CFD technique offering inherent advantage compared to other simulation techniques is used to determine pressure gradients, shocks, velocity distribution, eddy location, stream line curvature and streamwise vortices.
Our expertise in these areas could assist you with,
- Optimization of air and fuel injecting systems within burners
- Optimization of nozzles and injectors
- Performance assessment of injection system and injectors
- Steam injection system modeling and analysis
Quench Tank
Heat treatment process and heat treatment plants require continuous improvement in the design and performance of its systems and associated equipments. Quenching being one of the most critical, energy intensive and time consuming process in a heat treatment cycle, it requires continuous improvement for efficient functioning of heat treatment plants. Key parameters associated with quench tank performance improvement include Part Quality, Heat transfer rate, Effective nozzles and Injecting system, Flow distribution, Cooling time required and Optimal tank size. With the application of CFD, these parameters could be obtained or evaluated at an early stage. It also offers the advantage of predicting the process of agitation and assess the performance of quench tank with lesser experimental work, cost and lead time.
Our expertise in these areas could assist you with,
- Flow pattern and temperature distribution assessment
- Heat transfer and cooling rate prediction
- Process optimization of quenching tanks
Extrusion
Design of extruder components likely the screw shafts and dies which are subjected to excessive wear is a major challenge in the process of extrusion within polymer and ceramics industries. Non-Newtonian flow models available in CFD are well capable of handling such flows. It provides fluid velocity, pressure and temperature values throughout the domains for geometries even with complex shapes. Parametric design studies could be undertaken without difficulties and in a cost effective manner to develop optimized design of components.
Our expertise in these areas could assist you with,
- Performance assessment of extruders
- Optimization of die design
