How to verify and optimize flow devices to meet strict customer requirements? A case study based on CFD analysis

Designing specialized process equipment for modernized industrial facilities is a common task in our clients’ projects. The need to meet the end-user’s stringent requirements while ensuring the equipment operates correctly requires the use of advanced engineering tools, such as CFD flow calculations.

In this case study, we describe how the CIM-mes team used CFD flow calculations to verify and optimize the design of steam water heaters to ensure the equipment operates correctly under actual process conditions.

The customer’s challenge: optimizing the design of the steam injection system and process parameters

The customer designed two compact steam water heaters to be integrated into the existing process line. The units had to ensure safe and proper operation, including shock-free and complete steam condensation, minimal pressure drops, and uniform temperature distribution at the outlet.

The main engineering challenges included:

• verifying that the heaters achieve the specified water heating parameters, ensure the lowest possible pressure drop, and provide uniform temperature distribution at the outlet across the cross-section,

• ensuring safe operation of the system, in particular shock-free operation and complete steam condensation inside the heater,

• optimizing the design, including selecting the diameter of the injector tube, determining the number and diameter of the outlet holes (nozzles), and the geometry of the stage mixing steam with water.

Solution implemented: two-stage CFD analysis and design optimization

Due to the complex physics of water vapor condensation, the CFD simulations were divided into two stages. The first stage covered the steam flow path and outlet and was used to determine the steam pressure drop characteristics as a function of flow rate, while the second stage focused on water flow through the heater and the degree of mixing based on the temperature distribution.

Step 1: Model Development and Flow Analysis

We created models of several design variants for each stage and performed analyses for varying flow parameters. A key aspect was determining, in consultation with the client, the design and manufacturing constraints for the production of certain components.

Step 2: Modifications and Optimization of the Steam Heater Design

Using precise simulations, we identified the design’s weakest points. We implemented a series of targeted changes:

• modified the number and size of the steam outlet holes,
• added and improved the water mixing system,
• defined the required process parameters,

A comparative analysis made it possible to select the most optimal solution that met all design and process requirements.

What did the client gain from CFD simulations?

Collaboration with CIM-mes and the use of CFD simulations yielded concrete, measurable results for the client in the steam water heater project.​

Key benefits included:​

• a thorough analysis of the design and simulation capabilities, covering both steam and water flow behavior under various operating conditions,

• confirmation that the heater’s design meets the required operating parameters and the end-user’s specifications,

• reduced design time thanks to the expertise of the CIM-mes engineering team, licensed software, and server infrastructure, which enabled a rapid transition from conceptual variants to the optimal solution.​

This case study is one of many projects in which CIM-mes has supported clients in the development and implementation of process equipment and designs requiring CFD calculations. The ISO 9001-certified quality management system ensures a consistent approach to planning, executing, and documenting analyses.

Are you unsure whether your design will meet the requirements? Have it verified by CIM-mes

Whether you’re working on a new flow device, upgrading an existing steam heater, or need an independent computational verification, the CIM-mes team can prepare a CFD flow analysis tailored to your design specifications. Based on the collected data and process requirements, we will prepare a free feasibility analysis and propose an action plan, taking into account potential optimization of the design and operating parameters.