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Chemical & Process Industry at a Glance

Immense variety of products from the chemical & process industry affect every aspect of our lives. Simulation helps sustain today’s race for innovation by bringing, environment friendly, energy efficient materials reducing the time to market and raw material costs.

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Generating Performance Improvements

Find out how multidisciplinary simulation and design exploration can help to solve the toughest challenges that the chemical & process industry has to offer.


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High-Temperature Processes
STAR-CCM+ meets the challenge of designing and validating burner and flare performance by virtual analysis of combustion and coupling to radiative heat transfer prior to prototype deployment. The flamelet combustion models, complex chemistry models, particle reactions and radiation cover the breadth of your combustion modelling needs, be it solid, liquid, gas, pollutants or surface reactions. For detailed chemistry modelling, DARS is a STAR-CCM+ tool for 0D and 1D management, analyses of chemical reactions and Flamelet library generation. Together, the digital twin can analyse flame stability and performance to meet process requirements while reducing emissions and cost.
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Particle Transport
Design adequacy for particle flows (power consumptions, pressure drops, pulsating flows, shear, mixing efficiency, etc) is expensive to verify. Simulation can verify such designs and the transport and mixing of particles at a lower cost for screw augers, belt/pneumatic conveyors, feeders and hoppers. STAR-CCM+, with its Discrete Element Method (DEM) capability, is the only commercial tool that offers fully coupled dense particle and flow simulation. With STAR-CCM+, your transport system designs can be fully validated and optimized virtually, saving valuable engineering time and cost.
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Stirred Vessels
Poor mixing can result in the loss of millions of dollars in the Chemical & Process Industry. Scale-up of the mixing process from lab to plant scale, development of stirred reactors, experimental testing and troubleshooting existing ones are all difficult and expensive tasks. Admixtus, a STAR-CCM+ tool, brings an automated setup for simulation of stirred vessels to the hands of the process development engineers. With Admixtus, plant scale mixing simulations can be automatically setup, run and optimized, leading to a successful design with better mixing and confident scale-up, reducing cost and errors while improving performance.
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Static Mixer
Static mixers involve mixing fluid stream with varying viscosity. Molecular diffusion and rheology of the components have a stong influence on mixing efficiency. STAR-CCM+ offers particle flow modeling, rheology modeling and Eulerian/Lagrangian multiphase models to cover the full breadth of static mixer components. Application of STAR-CCM+ and HEEDS to your static mixer design improves mixing efficiency and quality with reduced design cost and time.
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For separators, be it cyclones, filters or membranes, ensuring separation efficiency and meeting process requirements while keeping design costs down is crucial. Physical testing is expensive, difficult to visualize complex multiphase flows and adds safety concerns. STAR-CCM+ offers complete multiphase modeling tools (Eulerian, Lagrangian, Volume of Fluid) to predict separator performance, flow uniformity, efficiency and identify problem zones like re-entrainment. With HEEDS, a through understanding and improvement of separator designs is possible early in the design cycle.
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Gas-liquid reactors, fermenters, bubble columns and packed bed reactors have multiphase flows accompanies by reactions. Within such flows, the specific details of the interaction between the two phases is important to understand accurately. Scale-up of such equipment can be challenging since two-phase flows have a more inherently complex nature than single-phase flows. STAR-CCM+® allows for extremely detailed modeling of such flows with accuracy to predicting key design parameters such as hold up, interphase mass transfer, residence time distribution and more.
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Heat Exchangers
STAR-CCM+ offers a full suite of simulation capabilities for heat exchangers including multiphase flow, conjugate heat transfer which can be coupled to finite element based thermal stress and deformation, all from within a single integrated user interface. Combined with the design exploration power of HEEDS, your heat exchangers can be optimized for maximum performance and efficiency early in the design cycle.
In Depth

Beyond Process Simulation: What process simulation doesn’t tell you, Computational Fluid Dynamics (CFD) can.

The Chemical and process industry includes manufacturers of consumer and industrial chemicals, process equipment manufacturers and engineering, procurement and construction.

Every year, millions of dollars are lost due to inefficiencies in mixing, spraying, coating, curing and other manufacturing processes. Analytical methods and experimental measurements answer some of these challenges, but many unknowns still arise. Imagine having the ability to optimize these processes virtually, reducing waste and saving time.

New and innovative chemicals and processes are discovered in labs, then transferred to plant scales of thousands of tons per year. This transfer requires rigorous engineering and it is here that CFD plays a role:  analyzing designs, troubleshooting, scaling-up, expanding capacity, comparing alternative designs of reactors etc. 

Easing scale-up pains with simulation

With STAR-CCM+ the power of CFD is now accessible to a process engineer with limited simulation experience but sufficient process knowledge. Combined with a dedicated tool for mixing (Admixtus), STAR-CCM+ offers a virtual process design and development platform for fluid flow, heat transfer, reactions and particle flows. HEEDS brings automated design exploration and optimization to this process, enabling the industry to save millions of dollars in improved process and equipment design and troubleshooting. DARS offers management and analyses of chemical reactions for your combustion needs. From mixing to separators to reactors to particle transport to combustion, we offer a multidisciplinary design process to create a digital twin, enabling you to optimize and fine-tune your process and equipment early in the design cycle.

Case Studies

Don't Just Simulate; Innovate!

See how our customers have been using our products to generate design improvements and stay ahead of the innovation race.