The recent CAEXPERTS webinar highlighted how simulation using Simcenter STAR-CCM+ is transforming the design and operation of agitated tanks. The integrated approach to engineering digitalization was a key focus, highlighting how to predict and optimize the behavior of complex processes, reduce costs and increase operational efficiency.
1. Why is Agitated Tank Simulation Necessary Today?
With the growing demand for efficiency and innovation, agitated tank simulation is becoming a tool for industrial process design. Simcenter STAR-CCM+ allows you to explore multiple design variants and operating conditions, reducing the need for expensive experimental testing and increasing visualization of phenomena that only complex sensors can measure. In this way, companies can improve mixing quality, reduce energy consumption and increase productivity, creating more sustainable and competitive solutions.
2. Complex Geometry Manipulation and Multiphysics Modeling
Simcenter STAR-CCM+ stands out for its ability to manipulate complex geometries, enabling the creation, modification and repair of CAD models directly in the software. With a flexible and robust mesh, the tool accurately captures geometric features, ensuring detailed and realistic results. Multiphysics modeling allows the simulation of complex interactions between different phases, such as gas-liquid or solid-liquid, and the prediction of the conversion and yield of chemical reactions.
3. Design Exploration and Workflow Automation with Admixtus
Workflow automation with the Admixtus tool accelerates the configuration and simulation of mixing tanks. This approach facilitates the configuration of geometries, generation of meshes and definition of the physics involved in an automated manner based on best practices. The tool also facilitates the post-processing of results, generating reports and graphs in an integrated and customizable manner, ideal for exploring different design scenarios and operational conditions.
4. What Can Be Calculated Using Simulation?
Simcenter STAR-CCM+ allows you to calculate a wide range of critical parameters for the optimization of agitated tanks, such as pumping and circulation rate, mixing time, flow field, shear rate, impeller torque, energy consumption, among others. These simulations are capable of predicting the performance of complex systems and adjusting design variables to achieve the best results.
5. Case Studies and Practical Impact
Several case studies show the practical application of simulation. One of the highlights was the exploration of impeller positioning and rotation to minimize mixing time and reduce energy consumption in mixing tanks, resulting in significant process savings. Another study focused on the optimization of impellers and baffles, showing improvements in energy efficiency and mixing quality.
6. Challenges and Solutions for Agitated Tanks
Key challenges addressed include energy efficiency, bubble and particle size distribution, and prediction of mixing quality in multiphase systems. Simulation helps minimize these challenges by enabling adjustments that improve process efficiency, reduce energy consumption, and increase design flexibility. The tool also facilitates the evaluation of new raw materials and process intensification, contributing to sustainability and cost management.
7. Solutions for Non-Newtonian Fluids
During the webinar, we also addressed the challenges of mixing non-Newtonian fluids, such as polyacrylamide. Simulation with STAR-CCM+ allows for careful adjustment of the agitation speed and agitator design to avoid problems such as lump formation and inefficiency in the flocculation process. This type of analysis is essential to ensure the quality and homogeneity of the mixture, even under complex conditions.
8. Multiphase Models and Their Applications
Simcenter STAR-CCM+ offers a comprehensive set of multiphase models, such as Discrete Element Method (DEM) and Volume of Fluid (VOF), which are used to capture the complexity of phase interactions. The Eulerian Multiphase (EMP) model is particularly useful for simulating the mixing of miscible fluids and predicting phenomena such as coalescence and break-up, essential for processes such as fermentation and polymerization. The ability to capture these complex effects is critical for simulating industrial processes involving multiple phases, such as gas-liquid or solid-liquid systems.
9. Heat and Mass Transfer, and Chemical Reactions
The ability to simulate heat and mass transfer between different phases is essential for predicting the efficiency of chemical reactions in stirred tanks. STAR-CCM+ allows you to analyze everything from the dissolution of substances to heat transfer in complex systems, such as those involving heating or cooling coils. With dedicated models, it is possible to simulate reactions both within a phase and at the interface between phases.
10. Intelligent Design Optimization and Exploration
The tool also stands out for its intelligent design exploration, combining multiple optimization strategies to find the best design configurations in fewer iterations. This includes performing Design of Experiments (DoE) and optimizing multiple objectives, such as minimizing mixing time and power requirements while maximizing yield and productivity.
11. Economic Impact and Return on Investment
Finally, the economic impact of simulation is discussed, highlighting how reducing the number of experimental tests and optimizing the design can lead to significant savings. Simulation allows for accurate prediction of tank performance, reducing yield losses and scale -up costs , as well as accelerating the development time of new products with greater reliability and much lower investments.
12. The Future of Simulation and the Redefining of Engineering
The use of advanced tools such as STAR-CCM+ is redefining the way engineering is conducted. Digitizing processes allows for digital exploration and physical confirmation, minimizing the time and costs associated with physical testing. Using simulation, companies of all sizes can explore new designs and improve products more quickly and efficiently, while remaining competitive in an increasingly demanding market.
The CAEXPERTS webinar showed that agitated tank simulation with Simcenter STAR-CCM+ goes beyond simple analysis; it is an essential tool for innovation, efficiency, and competitiveness in today’s market. By adopting integrated digital simulation, companies can explore new design possibilities, reduce costs, and increase productivity in a sustainable way.
Want to know how this technology can transform your processes? Schedule a meeting with us and find out how we can help your company optimize operations, reduce costs and increase competitiveness.
WhatsApp: +55 (48) 988144798
E-mail: contato@caexperts.com.br
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