CFD modeling of three types of separators
Objective: Evaluate the effectiveness of air and solid particle removal, pressure losses, velocity field, and residence time for three existing models:
- Gravity sludge separator-degasser
- Coalescing air separator
- Coalescing dirt separator
Scope of work
- Preparation of CAD (provided) and generation of CFD mesh.
- Creation of a multiphase model:
- Liquid (continuous phase, water/water+glycol)
- Gas (dispersed phase – air, bubbles)
- Solid particles (DPM or Eulerian for high concentrations).
- Calculation of steady RANS (k-ω SST) + selectively transient for coalescing models.
- Parametric cases:
- Velocity: 0.3, 0.6, 1.0, 1.5 m/s
- Air: 0.1%, 0.5%, 1%, 3% vol
- Solid particles: 50, 200, 500, 1000 mg/L
- Bubble sizes: 0.2–2 mm
- Particle sizes: <5, 5–20, 20–100, 100–500 µm
- Verification of mesh-independence (minimum 3 levels of mesh) and mass balance control.
- Deliverables:
- PDF report with methodology, graphs, performance tables, ΔP, residence time
- Presentation (PPTX) for grant application
- CSV with results of key parameters
- CFD files: case, mesh, results (VTK/Paraview, PNG), transient animations
CFD requirements
- Software: ANSYS Fluent / OpenFOAM / STAR-CCM+
- Turbulence models: k-ω SST for RANS; optionally LES for screening
- Multiphase models: Euler-Lagrange (DPM) for particles, PBM for coalescence (if applicable)
- Walls: no-slip, thermal insulation (if heat carrier is considered)
Checkpoints and indicators
- Inlet/outlet mass flow and balance
- Effectiveness of air removal (%)
- Effectiveness of particle capture by size classes
- Velocity field, recirculation zone, pressure losses (ΔP)
- Residence time
Key expected results
- Mass and volumetric flows at inlet/outlet
- Graphs of "effectiveness vs flow rate"
- Velocity fields, phases, particles, visualizations of recirculation zones
- Tables with ΔP, residence time, effectiveness of gas and particle removal
Applications 1
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