Mixer Design and Analysis with FEA and CFD based-Simulation in Chemical and Petrochemical Processing

FEA & CFD Based Simulation Design Analysis Virtual prototyping MultiObjective Optimization

In the chemical industry, proper reactor design is crucial because this is where both mixing and reaction occur. Mixing can be defined as an operation which reduces the degree of nonuniformity of all properties of a system, single or multiphase with one or many components. For a mixing sensitive reaction, the rate of mixing affects both the yield and selectivity of the reaction. Numerical flow simulations with CFD provide important insights into the flow processes of the entire system vessel agitator and the associated components, the finite element method (FEM) is also used to gain a deeper insight into the mechanical design of agitators, vessels, and their components. It allows a more reliable design, thereby preventing damage and loss of production.

Mixer Design and Analysis with FEA and CFD based-Simulation Cradle abaqus ansys star-ccm fluent

The load data obtained by measurements as well as the flow simulations and the geometry information obtained from the CAD system serve as important input parameters or general data for subsequent FEA analysis. The FEA method has now found its way into almost all conceivable physical disciplines. The most important fields of application in agitation and mixing technology are:

Enteknograte engineering simulation are helping customers to overcome the following Mixing analysis-related challenges:

  • Blending
  • High-shear mixers
  • Water treatment
  • Hydrogenation
  • Crystallization
  • Jet mixers
  • Emulsion
  • Laminar mixing
  • Fermentation
  • Solids suspension
  • Gas dispersion and sparging
  • Food mixing
  • Residence time distribution
  • Mixing vessel design
  • Glass-lined reactor systems
  • Polymerization
Mixer Design and Analysis with FEA and CFD based-Simulation Cradle abaqus ansys star-ccm fluent
Enteknograte offers a Virtual Engineering approach with CFD and FEA tools such as MSC Cradle, Ansys Fluent, StarCCM+  for flows simulation and FEA based Codes such as ABAQUS, Ansys, Nastran and LS-Dyna, encompassing the accurate prediction of in-service loads, the performance evaluation, and the integrity assessment including the influence of manufacturing the components.
Heat Transfer Design Chemical Processing Thermal-Analysis simulations FEA CFD Cradle abaqus ansys fluent siemens star-ccm+ 2

Using Simulation to Optimize Reacting Flows and Combustion

From automobile engines to gas turbine generators, reacting flow and combustion is often the key to energy efficiency, emissions, lifespan, product yield, and other performance parameters. Simulation help look deeper into reacting flow and combustion issues to understand the complex chemical reactions, fluid flow, heat transfer, electrical performance, and other factors that determine the performance of your product. Simulation enables our engineers to evaluate more design alternatives more thoroughly than traditional prototype-based design and development methods.


Turbine Nozzle Conjugate Heat Transfer CHTStress and Temperature distribution Fatigue Coupled CFD FEA CHT Ansys Fluent Abaqus Nastran Openfoam Siemens Star-ccm
Conjugate heat transfer (CHT)—the simultaneous prediction of heat transfer in both the fluid and solid portions of the domain—is of critical importance in a full-engine simulation. The accuracy of the predicted combustion in the cylinder is dependent on the temperature boundary conditions in the cylinder. By considering heat transfer in the metal components (e.g., the cylinder head, liner, piston, etc.) in the simulation, the cylinder wall no longer has a user-specified temperature, but instead has temperatures predicted as part of the system simulation.

Reactor Design & Combustion Engineering for Chemical Processing

AVL Fire, Siemens Star-ccm+, Ansys Fluent and Converge
Our engineering simulation for reactor design including CFD for chemical reactor design, FEA structural and thermal analysis and instrumentation and control software used for design and analysis of chemical reactors enable our reaction engineers to answer what-if questions as they design and enhance reactors performance, energy usage, reactor yield and product uniformity.

Heat Transfer-Equipment Design and Analysis for Chemical Processing: Comprehensive CFD & Finite element method

Heat transmission by conduction, convection and radiation in laminar or turbulent flows for fluids, such as steam, thermal liquids, liquid metals and non-Newtonian fluids, can be design and analyze and new concept can be developed using engineering simulation for heat generation and heat transfer equipment. Using these solutions our engineers can identify hot spots, associated thermal stresses, equipment design and process efficiencies, and other issues that affect system performance.

Mixer Design and Analysis with FEA and CFD based-Simulation

In the chemical industry, proper reactor design is crucial because this is where both mixing and reaction occur. Mixing can be defined as an operation which reduces the degree of nonuniformity of all properties of a system, single or multiphase with one or many components. For a mixing sensitive reaction, the rate of mixing affects both the yield and selectivity of the reaction. Numerical flow simulations with CFD provide important insights into the flow processes of the entire system vessel agitator and the associated component.

Multiphase Simulation for Chemical Processing

Using a variety of advanced modeling techniques to study both continuous and particulate phases,with combination of Finite element method(FEA), DEM and CFD, we can handle simulation of particle included systems and their properties including following parameters: Particle flows, Cohesion, Material wear, Particle size distribution, Particle mechanics, Surface and morphology, Particle–particle interaction, Turbulence and dispersion, Geometry effects, Erosion, Particle attrition, Homogeneous and hydrogenous reactions, Particle flows, Electrostatic effects.

Filtration System Design and Engineering for Chemical Processing with CFD & Finite Element Method

CFD for separation and filtration includes modeling of transport of solid particle are used by diverse set of customers to understand and reduce erosion in solid separation and extraction devices. Enteknograte’s engineering simulation team has experience in using FEA and CFD for separation and filtration systems, give clients a clearer understanding of filtration optimization through in-depth studies of filter media, particle deposition and caking, pressure drop, throughput, back flushing, and mechanical design.

Chemical Processing Simulation and Design: Coupled CFD, FEA and 1D-System Modeling for Heat Transfer, Filtration & Mixer System , Reactor Design & Combustion Engineering

Enteknograte's engineering team CFD and FEA solutions for the Materials & Chemical Processing is helping companies to significant engineering improvement from equipment and processes to chemical and petrochemical refining to glass and metals manufacturing -  forming and casting -. Enteknograte's engineering team solution includes CFD for chemical process Industry, FEA for process industry and expand to cover electromagnetic and system design engineering concerns.


We pride ourselves on empowering each client to overcome the challenges of their most demanding projects.

By using Accurate reaction mechanisms that representing every class of reaction important for combustion analysis and combination of advanced computational fluid dynamics (CFD) combustion simulation tools such as Kiva, Ansys Fluent, Ansys Forte, AVL Fire, Converge CFD, Siemens Star-ccm+ , MSC Cradle and System Modeling software such as Matlab Simulink and GT-Suite enable Enteknograte engineering team to reduce chemistry analysis time by orders of magnitude, virtually eliminating the bottleneck that chemistry integration produces during the simulation process.



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Gas Turbine Combustion CFD Simulation: Detailed Chemistry

AVL Fire, Siemens Star-ccm+, Ansys Fluent and Converge
Gas turbine combustion can be a challenge to achieve accurate and reliable CFD simulation results. Computational efficiency requires appropriate mesh resolution and turbulence, spray, combustion, and emissions models that provide an appropriate level of detail. With using advanced and specilized CFD tools such as AVL Fire, Siemens Star-ccm+, Ansys Fluent and Converge, Enteknograte engineers can accurately predict important kinetically limited gas turbine phenomena such as ignition, flashback, and lean blow off. In addition, we can investigate the combined effects of chemistry and turbulence and optimize combustor performance parameters.

Fuel Injectors and Spray CFD Simulation

CFD software such as MSC Cradle, AVL Fire, Siemens Star-ccm+, Ansys Fluent and Converge is well equipped to simulate fuel injectors and spray processes including liquid atomization, drop breakup, collision and coalescence, turbulent dispersion, spray cavitation, drop-wall interaction, and drop evaporation.

Electromagnetic Multiphysics

Enteknograte Finite Element Electromagnetic Field simulation solution which uses the highly accurate finite element solvers and methods such as Ansys Maxwell, Simulia Opera, Simulia CST, JMAG, Cedrat FLUX, Siemens MAGNET and COMSOL to solve static, frequency-domain, and time-varying electromagnetic and electric fields includes a wide range of solution types for a complete design flow for your electromagnetic and electromechanical devices in different industries.

CFD Simulation of Reacting Flows and Combustion

Engine & Gas Turbine, Fuel Injector & Spray, Exhaust Aftertreatment with Detailed Chemistry
Knowledge of the underlying combustion chemistry and physics enables designers of gas turbines, boilers and internal combustion engines to increase energy efficiency and fuel flexibility, while reducing emissions. Combustion System couples multiphysics simulations incorporating accurate physical models with an advanced chemistry solver to provide a complete end-to-end combustion chemistry simulation capability to optimize products that involve reacting flow.

CFD Simulation of Engine Exhaust Aftertreatment

Aftertreatment systems are a critical component to ensure emissions from engines and power generation equipment comply with environmental standards. CFD (computational fluid dynamics) simulations can be used as part of a rapid prototyping process to design systems that reduce NOx, CO, and particulate matter emissions with minimal efficiency and maintenance costs. Two of the main challenges in aftertreatment system design are maximizing the uniformity of flows upstream of catalysts and eliminating areas at risk for urea deposition.

1D/3D Coupled Simulation and Co-Simulation: Detailed Chemistry & Multiphase Flow Modeling with 1D Modeling

Enteknograte engineering team use advantage of CFD solver’s detailed chemistry, multiphase flow modeling, and other powerful features in coupling and co-simulation of CFD (Siemens Star-ccm+, AVL Fire, Ansys Fluent, Converge), 1D systems softwares (Matlab simulink, GT-Suite, Ricardo Wave allowing 1D/3D-coupled analyses to be performed effortlessly) and FEA software (Abaqus, Ansys, Nastran) for engine cylinder coupling, exhaust aftertreatment coupling, and fluid-structure interaction coupling simulation.

Integrated Artificial Intelligence (AI) & Machine Learning - Deep Learning with CFD & FEA Simulation

Machine learning is a method of data analysis that automates analytical model building. It is a branch of Artificial Intelligence based on the idea that systems can learn from data, identify patterns and make decisions with minimal human intervention. With Artificial Intelligence (AI) applications in CAE, that is Mechanical Engineering and FEA and CFD Simulations as design tools, our CAE engineers evaluate the possible changes (and limits) coming from Machine learning, whether Deep Learning (DL), or Support vector machine (SVM) or even Genetic algorithms to specify definitive influence in some optimization problems and the solution of complex systems.

Heat Transfer and Thermal Analysis: Fluid-Structure Interaction with Coupled CFD and Finite Element Based Simulation

We analyze system-level thermal management of vehicle component, including underhood, underbody and brake systems, and design for heat shields, electronics cooling, HVAC, hybrid systems and human thermal comfort. Our Finite Element (LS-Dyna, Ansys, Abaqus) and CFD simulation (Siemens Start-ccm+, Ansys Fluent , Ansys CFX and OpenFoam) for heat transfer analysis, thermal management, and virtual test process can save time and money in the design and development process, while also improving the thermal comfort and overall quality of the final product.

Acoustics and Vibration: FEA and CFD for AeroAcoustics, VibroAcoustics and NVH Analysis

Noise and vibration analysis is becoming increasingly important in virtually every industry. The need to reduce noise and vibration can arise because of government legislation, new lightweight constructions, use of lower cost materials, fatigue failure or increased competitive pressure. With deep knowledge in FEA, CFD and Acoustic simulation, advanced Acoustic solvers and numerical methods used by Enteknograte engineers to solve acoustics, vibro-acoustics, and aero-acoustics problems in automotive manufacturers and suppliers, aerospace companies, shipbuilding industries and consumer product manufacturers.

Simulation of Plasma Based Devices: Microwave Plasma and RF Plasma Analysis with Coupling Particle in Cell (PIC), MHD, CFD and FEA Solvers

Charged particles and their non-linear discharge characteristics have been especially difficult to model and simulate accurately. We provide consulting services for the modeling and simulation of plasma and other flow systems. Our consulting services utilize our specialized domain expertise in plasma, reactive flows and surface chemistry mechanism development and integration with multi-dimensional flow and plasma systems.

Finite Element Analysis of Durability and Fatigue Life

Vibration Fatigue, Creep, Welded Structures Fatigue, Elastomer and Composite Fatigue with Ansys Ncode, Simulia FE-Safe, MSC CAEFatigue, FEMFAT
Durability often dominates development agendas, and empirical evaluation is by its nature time-consuming and costly. Simulation provides a strategic approach to managing risk and cost by enabling design concepts or design changes to be studied before investment in physical evaluation. The industry-leading fatigue Simulation technology such as Simulia FE-SAFE, Ansys Ncode Design Life and FEMFAT used to calculate fatigue life of multiaxial, welds, short-fibre composite, vibration, crack growth, thermo-mechanical fatigue.

Multi-Phase Flows CFD Analysis

Multi-Phases flows involve combinations of solids, liquids and gases which interact. Computational Fluid Dynamics (CFD) is used to accurately predict the simultaneous interaction of more than one combination of phases that can be gases, solids or fluids. Typical applications involve sprays, solid particulate transport, boiling, cavitation, state-changes, free surface flows, dispersed multiphase flows, buoyancy problems and mixed species flows. For example, the risks from flow or process-induced vibration excitation of pipework are widely acknowledged in onshore process plants, offshore topsides and subsea facilities.