Petrochemical engineering is a discipline of chemical engineering that deals with the operations of refining petroleum or crude oil using sophisticated technology and the activities involved in the production of hydrocarbons. Extracting crude petroleum from the Earth’s core is also part of this discipline. In today’s world, petrochemical engineering also includes operations related to extracting minerals. It is one of the fields of Chemical Engineering that teaches people how to collect raw materials from the Earth ethically and successfully using proper equipment and machinery.
A comprehensive list of petrochemical products would be extended. However, the following are some of the most common petrochemicals utilized by ordinary people, not just industrialists:
- Motor oil
- Natural gas
- Plastics of all types
- Petroleum jelly
Supercomputers are used by petroleum engineers to evaluate exploration data, model reservoir dynamics, and automate oilfield production and drilling activities.
How to Improve Gas & Petrochemical Engineering using CFD simulation?
Computational Fluid Dynamics (CFD) is a powerful tool for simulating fluid flow, heat transport, and associated processes in various scientific and engineering issues. Unlike experiments that only allow data to be extracted from a limited number of locations in the system (such as pressure and temperature probes, heat flux gauges, and so on), CFD permits the analyst to examine a large number of areas in the region of interest and generates a comprehensive set of flow parameters for analysis. CFD provides the ability to simulate any physical condition theoretically. As energy demand grows, additional sources are being explored, and drilling operations expand worldwide.
Any improvement in drilling, production, or planning can save the operators money. As a result, having a plan and developing an efficient approach ahead of time is critical in the case of costly and uncertain oil and gas well operations. CFD is used in petrochemical engineering applications such as bit performance optimization, convective heat transfer between casings and annular fluids, flow in porous media such as mud filtrate invasion, simulation of multiphase flow for designing separators, cement displacement, erosion prediction, risk analysis during blowout events, drilling hydraulics and hole cleaning optimization. Wellbore stability analysis and cutting transport in the rig.
CFD on Simulation of Reactors
A chemical reactor is a container in which a chemical reaction takes place. Chemical reactor design encompasses a wide range of chemical engineering concepts. Chemical engineers build reactors to optimize the reaction’s net present value. Designers guarantee that the reaction continues as efficiently as possible toward the intended output product, resulting in the best yield while needing the least money to buy and run. Energy intake, energy removal, raw material prices, labor, and other regular operational expenditures are all included. Heating and cooling, pumping to increase pressure, frictional pressure loss, and agitation is all examples of energy shifts.
In chemical process applications, computational fluid dynamics is helping to save millions of dollars. It gives process engineers a thorough insight into how individual unit activities work inside. As a result, several chemical and process businesses are investing in CFD software and training for their engineers to increase efficiency in fluid flow, heat, and mass transfer operations.
Chemical reactors may be estimated using several conservation equations related to fluid motion and energy, architectured using CFD fluid-flow patterns and temperature fields.
CFD usage for Scrubber
The exhaust gases from marine diesel engines contain harmful air pollutants such as sulfur dioxide, nitrogen oxide, and complex particulate matter. Scrubber systems (also known as chemical or gas scrubbers) are air pollution management equipment that may remove certain particles and/or gases from industrial exhaust streams. The first air scrubber was created to remove carbon dioxide from an early submarine’s atmosphere.
In recent years, the improvements made in nozzle design and liquid atomization have provided the possibility of process optimization like never before. Nozzle characteristics and placement must be optimized to reduce the system implementation cost and mitigate the risks of inadequate pollution reduction to improve the Scrubber. In situ analysis would provide the best assessment of a spray’s characteristics in the tower; however, often, this is cost-prohibitive or not physically possible. Instead of inline optimization, computational fluid dynamics projects have become very useful for this application. With CFD, engineers can assess the spray quality within the actual spray process region by simulating the gas conditioning process.
Desalination of Seawater using CFD
Seawater desalination is the best-adapted process for counties with high solar energy. Solar distillation systems typically consist of wood or steel plate to increase the intensity of the sunlight.
Due to a temperature difference between the front glass cover and the water in the basin, solar still operates on the principle of evaporation and condensation. Sun continues to collect solar energy that falls on the front glass cover, raising the temperature of the polluted water. The heated water evaporates and condenses on the lower surface of the glass cover, and all impurities remain in the basin. However, evaporation-condensation is critical for increasing the freshwater production rate in such systems. As a result, evaluating the effectiveness of a still solar design necessitates both actual work and the creation of appropriate mathematical models that investigate the many aspects of the solar still.
This article covered a small number of CFD applications in improving Petrochemical Engineering. The Petrochemical industry is full of applications for CFD, from the combustion in a gas flare to the simulation of Venturi Scrubber to produce the separation of particles from the gas flow, which is a significant challenge in the industry.
Fluid dynamics are fundamental to most facets of the Petrochemical sector. Although real prototypes are standard for later stages of development, design, and optimization during earlier stages can be significantly accelerated with CFD studies.
The MR-CFD team conducted numerous outsourced simulation projects for industrial and research Gas & Petrochemical Engineering applications. With several years of experience simulating various 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 a Gas Flare is freelanced and carried out to study the parameters of the occurred combustion.
ANSYS Fluent software was used to simulate combustion in a gas flare in the presence of wind. A flare system is a combustion device used in industrial units such as oil and gas refineries and oil and gas well production, particularly on offshore platforms. Gas flares are responsible for the perfectly regulated combustion of natural gases emitted during oil extraction. In reality, some natural gas collects on top of the oil in the reservoirs throughout the oil extraction process. As a result, collecting and storing natural gas is preferable, but if it is not probable, they burn it.
The employment of the flare system to burn these gases firstly prevents them from exploding and burning dangerously and uncontrollably. Second, burning Methane, converting it to carbon dioxide, and releasing it into the atmosphere does less damage than methane release.
The flame and discharged gases from the chimney were analyzed using CFD to build and equip a Furnace. The furnace is used to supply heat for numerous operations exceeding 400 degrees Celsius in the oil, gas, and petrochemical sectors. It is frequently essential to lower the viscosity of heavy mineral flood oil to assist this procedure by heating the oil in the furnace. The goal of this research is to boost Methane’s temperature.
Scrubbers are used in cement kilns, chemical and pharmaceutical plants, industrial boilers, gold factories, metallurgical industries, and incinerators. As a result, the simulation parameters for a sample scrubber will be used in the next experiment. With these parameters, we may simulate various scrubbers of various sizes.
In this research, a Venturi 720 series scrubber, size 720-2, was simulated. However, owing to the simulation settings of this size, the ideal condition for the target industry may be achieved in less time if we wish to employ Venturi scrubber for other industries (with the different gas flow or particle flow).
MR-CFD, an Expert in the Field of Petrochemical 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 Petrochemical simulations are categorized as follows:
- CFD Simulation of Reactor design
- CFD Simulation of reacting liquid/gas flows
- Chemical reaction CFD simulation (combustion, NOx removal, …)
- CFD Simulation of orifice and fluid measurements
- Multiphase CFD simulation (gas-liquid separators, sedimentation, …)
- Chemical species transport CFD Simulation
- CFD Simulation of solidification and melting
- CFD Simulation of Mixers
You may find the related products to the Gas & Petrochemical simulation category in Training Shop.
Our services are not limited to the mentioned subjects, and the MR-CFD is ready to undertake different and challenging projects in the Gas & Petrochemical Engineering 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 benefit from MR-CFD expert consultation for free and then order your project to be simulated and trained.
By outsourcing your project to the MR-CFD as a CFD simulation freelancer, you will not only receive the related project’s resource files (Geometry, Mesh, Case & Data, …), 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.