Computational Modeling Services

Spray Analysis and Research Services provides Computation Fluid Dynamics (CFD), Finite Element Analysis (FEA), and Fluid Structure Interaction (FSI) modeling for our customers to help achieve an optimized spray-related solution. Using simulation, it is possible to gain a better understanding of the keys factors that impact the success of an application. Computer modeling allows you to investigate multiple parameters that may be difficult or impossible to replicate in a laboratory environment. Some of the common key parameters that are identified for further understanding through detailed modeling are:

  • Gas flow patterns and distribution
  • Temperature distribution with indications of hot/cold regions
  • Gas pressure changes
  • Spray interaction – particle transport, phase change and resulting impact on environment
  • Evaporation length and wall wetting
  • Chemical reactions focused on pollution reduction NOx, SOx, etc.
  • Evaluation of spray injector materials to withstand extreme gas flow conditions

CFD models use complex numeric schemes that require extensive user time commitments and computational resources. Users must compile and prepare a wide variety of specific information, often requiring weeks or months of work. Computational work begins with processing the flow domain geometry of interest, i.e. meshing. Once the simulation geometry (mesh) is processed and required data is input properly into the CFD modeling program, the simulation work begins. The computation time will be dependent on the complexity of the model and computational resources available for the simulation.
Our custom CFD models integrate data collected in our spray labs and proprietary design elements of the injectors, which offer many benefits, such as:

  • Liquid and gas flow in scrubbers, towers, ducts and dryers
  • Spray droplet trajectories and distributions in towers and ducts
  • Internal flow characteristics of spray nozzles
  • Gas and liquid mixing in two-fluid nozzles
  • Wall impact and shadowing
  • Pollution reduction effectiveness
  • Blending in large vessels

A Unique Approach

Standard CFD models use theoretical numeric codes that require extensive user time commitments and computational resources. Users must compile and prepare a wide variety of specific information – often requiring weeks or months of work. Once the data is input into the CFD modeling program, the computational work begins. The computation time will be dependent on the complexity of the model. Standard desktop computers can be used, however, computations can take weeks to complete.

Our custom CFD models use data we’ve collected in our spray labs – which offers many benefits, such as:

  • Known, not estimated, model inputs for the spray characteristics to ensure realistic representation of each injector
  • Known, not estimated, rheological inputs to ensure adequate capture of physics
  • User Defined Function (UDF) to model drop-wise condensation with simultaneous evaporation and improve complex mass transfer of urea/ammonia in de-NOx applications
  • Accurate and extensive model validations to ensure optimal best practices for simulations

Principals & Methods
Spray Modeling
Fluid Structure Interaction
Modeling Literature