Generating Performance Improvements

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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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Separator
 
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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Reactors
 
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.