Chemical Engineering

Introduction

Chemical engineering is a multidisciplinary branch of engineering that combines natural and experimental sciences with life sciences (such as biology, microbiology, and biochemistry), as well as mathematics and economics, to design, develop, produce, transform, transport, operate, and manage industrial processes that convert raw materials into valuable products.

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Many of the processes in chemical engineering include chemical reactions, and the area takes cues from chemists seeking novel ways to make goods and research the mechanisms within chemical reactions. Chemical engineers then use this chemical information to create designs. As a result, there are two main subgroups that better answer the question “What is chemical engineering?” – to be more specific:

  • Designing, constructing, and running facilities and machinery for large-scale industrial chemical, biological, or related operations.
  • Developing new or modified chemicals for a diverse range of products

Chemical engineers may specialize in one or both subgroups, but a finished product will require effort from both sides. Economic viability, resource management, health and safety, sustainability, and environmental effect will all be factors to consider.

CFD in Chemical engineering

CFD is widely utilized in various professions and sectors, including aerospace, chemical production, polymer processing, petroleum exploration, and medical research. Chemical engineers now routinely study and model the interaction between fluid flow and chemical processes using the power of computational fluid dynamics simulation. CFD, for example, may be applied to reactive flows, combustion and heat transfer, and mass transport. Using CFD tools will assist a chemical engineer in better understanding physical and chemical processes, resulting in significant process and product advancements in the industry.

The use of CFD in the chemical engineering and process industries has reduced the cost of product and process development and optimization activities (by reducing downtime), shortened time to market, improved design reliability, increased conversions and yields and aided in the resolution of environmental, health, and right-to-operate issues. Chemical engineering CFD simulation includes models prepared for flow splits, reactor vessels, gaseous emissions, dosing points, process optimization, membrane impact, contaminated waste, and hazardous emissions. 3D modeling can confirm whether a new chemical engineering design meets objectives or examines why a poorly operating system fails.

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CFD on simulating the reactions

Reaction engineering is a discipline of chemical engineering that deals with the design and optimization of chemical reactors. The purpose is to optimize the transport processes (heat transfer, mass transfer, and mixing) to increase the yield/conversion of desired products while also ensuring the reactor’s safety. This implies maximizing yield while decreasing expenditures. These expenses might be connected to feedstock, energy input, heat removal or cooling, stirring or agitation, pumping to increase pressure, frictional pressure loss, etc.

From computational fluid dynamics, reaction engineering applies transport phenomenon and chemical kinetics knowledge to industrial systems.

Reactor design includes several vital facets: Phase, or state of the reactants and products, reaction type (single, multiple, parallel series, or polymerization); whether a catalyst is involved; flow distribution and mixing; transport of the species; and mode of operation (i.e., batch, semi-batch or continuous). The underlying transport processes are crucial—fluid flow, heat transfer, mass transfer, and reactions—where CFD simulation can add substantial value.

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CFD to Predict Combustion in Chamber

To simulate combustion, knowledge about the system’s fluid mechanics must be understood. All transportation phenomena should be correctly represented in such models. Chemical reaction schemes must also be known to estimate the formation of combustion products and species and predict the ignition, stabilization, and extinction of flames. Radiation also takes place due to the presence of soot formed during combustion, and also, there is radiative heat transfer from the wall of the combustion chamber. Fuel combustion is a multiphase system, with liquid fuels being a two-phase system consisting of liquid and gas phases and solid fuel being a three-phase system. The challenges faced are to model the breaking up of the liquid fuel, its reaction, and the distribution of the reactants in three-dimensional spatial systems. These models, which form part of CFD, have become an indispensable tool for combustion modeling.

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MR CFD

Simulation of Heat Exchanger in CFD

Heat exchangers are essential components of numerous systems, including power plants, process industries, and heat recovery units. Its unavoidable requirement has required research into efficient and dependable designs, resulting in an optimum share of overall system performance.

CFD is a discipline that applies numerical analysis to solve mathematical equations to understand the fluid flow, heat transport, and chemical processes. It is equally helpful in developing a heat exchanger system from the start and troubleshooting/optimization by offering design changes. CFD works on the simple principle of dividing the entire system into small cells or grids and applying governing equations to these discrete elements to find numerical solutions for pressure distribution, temperature gradients, flow parameters, and the like in less time and at a lower cost due to less required experimental work. The CFD findings are of acceptable quality.

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MR CFD

Conclusion

This article covered a small number of CFD applications in improving Chemical engineering. The chemical industry is full of applications for CFD, From the chemical reactors to investigate fluid flow parameters in each cell to the simulation of evaporation and condensation phenomena in different situations and to melting and solidifying fluids. Fluid dynamics are fundamental to most facets of the Chemical sector. Although real prototypes are standard for later stages of development, design and optimization during earlier stages can be significantly accelerated with CFD studies.

MR-CFD Services

The MR-CFD team conducted numerous simulation projects for industrial and research chemical engineering applications. With several years of experience simulating a wide range of problems in various CFD fields using ANSYS Fluent software, the MR-CFD team is ready to offer extensive services of simulation configurations. For example, the simulation of Gasification in a Gasifier Chamber is carried out to study the temperature and pressure of each component in the chamber.

The gasification process consists of chemical processes that transform a carbon-based material into carbon monoxide, hydrogen, and carbon dioxide. This process’s output is regarded as a renewable energy source with several industrial applications.

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CFD was used to design and equip a Cyclone in which the particle’s behavior is investigated. Centrifugal fluid-flow devices are widely used in the industry for the segregation of multiphase flow mixtures into their constituent fluid components. Flow cyclones have been studied extensively to understand better the underlying fluid-flow mechanics and their implications on the separation efficiency of fluid/solid mixtures.

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Mixing processes are involved in nearly all manufacturing processes and are fundamental to the successful operation of various applications. Some of the common methods where mixing is used in industry are clarification, cell culture growth, fermentation, polymerization, and blending. These processes are found in many applications, such as the paint, food, pharmaceutical, minerals, and water treatment industries.

Huge budgets are spent each year on processes and technologies that allow improved mixing of two or more materials. Many millions are lost because of non-efficient mixing due to poor product performance and reduced efficiency.

The ANSYS Fluent Software can be used to simulate the mixing of different substances. The following study is simulated Mixing of Carbon Dioxide and Ethanol.

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MR-CFD Chemical Engineering Services

MR-CFD, an expert in the field of Chemical simulations

With several years of experience in simulating various problems in different CFD fields using ANSYS Fluent software, the MR-CFD Company is ready to offer extensive modeling, meshing, and simulation services. Our simulation Services for Chemical simulations are categorized as follows:

  • Simulation of  reactions
  • CFD Simulation of combustion (premixed, species transport, non-premixed, partially mixed)
  • Simulation of heat exchangers
  • CFD Simulation of chemical reactors
  • Simulation of mass transfer (evaporation, condensation, cavitation)
  • The melting and solidification simulation

You may find the related products in the categories mentioned above in our Training Shop by clicking on the following link:

https://www.mr-cfd.com/product-category/engineering-field/chemical/

Our services are not limited to the mentioned subjects, and the MR-CFD is ready to undertake different and challenging projects in the Chemical Modeling field ordered by our customers. We even accept carrying out CFD simulation for any abstract or concept design you have in your mind to turn them into reality and even help you reach the best design for what you may have imagined. You can consult with our experts freely and without any charge, and then order your project by sending the details of the problem to us using the following address.

[email protected]

By entrusting your project to the MR-CFD, you will not only receive the related project’s files (Geometry, Mesh, …), but also you will be provided with an extensive tutorial video demonstrating how you can create the geometry, mesh, and define the needed settings(pre-processing, processing and post-processing) in the ANSYS Fluent software all by yourself. Additionally, post-technical support is available to clarify issues and ambiguities.

MR-CFD experts are ready to fulfill every Computational Fluid Dynamics need. Our service includes both industrial and academic purposes considering a wide range of CFD problems. MR-CFD serves in three main categories: Consultation, Training, and CFD Simulation. Order your project to be simulated in the shortest time, with the highest quality.

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