INDUSTRIAL OPTIMIZATION

CONTENTS

• Who are we: ANALISIS-DSC?

• Design, optimization and analysis of elements orgeneric situations applications in a factory:

• Valves.

• Heat exchangers/Condensers/Evaporators.

• Pumps/Fans/Turbomachinery.

• Scrubbers.

• Pollutants dispersion.

• Incidents/accidents analysis .

• Contact.

Misión - VisiónANALISIS-DSC

Our Mission is:To be reference in the sectors: Fluid-dynamics and its interaction with structures.To be specialist in the modeling of Solid Particles.

Results reflected on:• Costs reduction• Quality improvement• Increasing production• Increasing profits

Design optimizationIndustrial processes optimizationEnergetic Eficiency AnalysisContingency Analysis

(incidents/accidents)Equipment Damages Analysis

WHAT CAN WE PROVIDE TO

OUR CLIENTS?

Aeronautical Mining

Naval Agriculture

Wind and thermal energy Pharmaceutical

Civil Engineering Others

Chemical

HVAC

Automotive

Enviromental

Turbomachinery

Steel

Defense

Fire Safety

TARGET SECTORS

VALVES: BALOON VALVE

2904184.4773.3126997117071.4407490

[pa][m/s][m/s][kg*m^-3][Pa][Pa]

Pressureloss

Velocityoutlet

Velocityinlet

Density(cte.)

P(total)(outlet)

P(total)(inlet) Fluid: Water

Temperature: 25ºC

VALVES: Declining valves, Gases

0.57847

kg*m^-3]

INLET DENSITY

958.526118.16070.575591101349101444

[pa][m/s][m/s][kg*m^-3][Pa][Pa]

PRESSURE LOSS

OUTLET VELOCITY

INLET VELOCITY

OUTLET DENSITY

P(total)(OUTLET)

P(total)(INLET)

Fluid: water vapour

Temperature: 380 k (106.85 ºC)

Inlet surface: 0.000379 m 2

STATIONARY VALUES

Streamlines for the gas used

VALVES : Declining valves, Gases

- Transversal cut showing thefluid velocities.

- Locating backwater points.

- Fluid dynamic forces ⇒⇒⇒⇒

structural dimensioning ofthe components.

VALVES : Declining valves, Gases

Turbulence kinetic energy:

• Pressure loss points.

• Points with bigger erosion.

• Compressive fluids analysis.

• State changes location.

2415754.7374.694997102555344130

[pa][m/s][m/s][kg*m -3][Pa][Pa]

Pressureloss

Outlet velocityInlet velocityDensity(constant)

P(total)(outlet)

P(total)(inlet) Fluid: Water

Temperature: 25ºC

STATIONARY VALUES (WITHOUT WATER HAMMER)

At any operating or working equipment there is the possibili ty of exceptionalsituations.

Pressure considering:

• Normal operating conditions.

• Incident or accident situations.

Butterfly valve with water hammerdownstream

VALVES : Butterfly valve with waterhammer

VALVES : Butterfly valve with waterhammer

We evaluate the resulting forceson the valve over time.

VALVES: Ponential projects andcapacities

• Operating curves development.• Cavitation and condensation prediction.• Accurate heat transfer.• Behaviour in adverse conditions (water hammer, fluids wi th particles,

etc.):– Design conditions.– Out of design conditions.

• Erosion and product life studies.• Noise studies.• Biphase flows dimensioning.

• Several tubes exchanger (water/ glycerol) withdeflectores.

• Fluid and solid heat transfer.• Heat loads and overpressure analysis.

HEAT EXCHANGERS

� Temperature in cooler. � Temperature on the methal.

HEAT EXCHANGERS

• Three plates interchanger (water/ air). • Heat transfer in fluids and solids.• Heat loads and overpressure analysis.

PLATE EXCHANGER

PLATE EXCHANGER

Changes in cooler temperatureas times goes by.

CONDENSERS &EVAPORATORS

�Microscopic analysis (Fins)�Including aerodynamics and thermal

�Macroscopic analysis(Complete Equipment)

�Including aerodynamics, thermal andphase change

Heat transfer atcondensator´s fins.

Loss of pressure on the finsof the evaporator.

CONDENSERS & EVAPORATORS (Fins)

Temperature distribution

Change of state

Velocitydistribution

CONDENSERS/ EVAPORATORS

HEAT EXCHANGERS

Hidraulic

Design

Mechanical

Design

Thermal

Design

Materials

Choosing

Efficiency optimizationCost savingsDecrease in number of prototypes required

� THERMAL DESIGN:�Energy balance�Transmission rate

�HIDRAULIC DESIGN:�Caudales�Load drops / pumping

�MECHANICAL DESIGN:�Overpressures�Thermal stress

�MATERIALS CHOOSING:�Chemical compatibility�Corrosion

ADVANTAGES

We consider the main advantages:

- Design support (NTU and MLTD methods):�Accurate estimation of transmission coefficients (fluid andstructure)�Efficiency curve.

- Dimensioning:�Heat exchange surfaces analysis�Tubes and housing particle deposition�Pressure upon tubes and housing

- Functioning analysis out of the design conditions:� In steady-state functioning� Transitories out of the design point.

ADVANTAGES

- Efficiency studies:� Enthropic Analysis of heat exchange� Pressure drop due to turbulent zones

- At local level:� Detection of low velocity zones� Local loads / fracture

- Parametric studies development.

FANS: Axial fan

Operating conditions:

• Speed: 1740 r. p. m.

• Mass flow rate: 1 kg/s

Pressure distribution at 0.5 span:

•Performance

•Noise level

•Others

• Axial fan:

• 9 blades

• Internal radius = 5.0 cm.

• External radius = 13.2 cm.

SPL or sound pressurelevels at differentpoints on the suctionarea.

Frequencies andharmónicos analysis.

FANS: Acoustics

Operating conditions:

• 890 r. p. m.

• Pressure drop = 300 Pa

Pressure levels Velocity distribution

FANS: Radial fan

1. Help on the design:

- Operating curves. Savings in prototypes and scales.

- Performance and power optimization.

- Achievement of specifications and with the authorities on n oiselevels.

- Competiveness as acoustic pollution is diminished.

2. At local level:- Vibrations.- Effect of the spaces between blades and the on the housing.

3. Behaviour out of the desing conditions:- Knowledge of operations in installations.- Operating on dirty atmospheres. Element erosion.

FANS: Case studies and capacities

Operating conditions:

• Speed: 3450 r. p. m.

• Pressure drop: 1 bar

Pressure distribution

PUMPS: Radial pump

Pressure curves and velocity inlet to oulet.

PUMPS: Radial pump

Cavitation areas

Pressure distribution, vectors and cavitation area

PUMPS: Cavitation

Operating conditions:

• Speed: 1000 r. p. m.

• Pressure drop: 5000 Pa

PUMPS: Axial pump

Span = 0.2 Span = 0.5 Span = 0.8

Inlet to outlet chart

PUMPS: Axial pump

Blade loading chart

1. Help on the design:– Real H-Q curves determination: savings in prototypes and

scaling problems.– NPSH curve.– Hydraulic and power performance.

2. At local level:– Recirculating and waterback locations: looking up

undesirable local effects.– Cavitation: cavitation area locations during operating

conditions.

3. Behaviour out of design conditions:– Optimal installation case by case for auto-hooving: pu mp

adapted to installation.– Starting up operating.

PUMPS Case studies and capacities

4. Coupled effects to the operating:– Non-Newtonian fluids: local determination of the pump/f luids

interaction.– Pressure loads on materials evaluation: local pressure f ields.– Heat loads.– Erosion.– Dirtyness and deposits.– Vibrations and noise.– Cooling and heating effects: optimization.– Lubrication.

PUMPS Case studies and capacities

SCRUBBER

• Objective: simulation to observe and study the relevant phenomena when the liquid injection volume of flow is changed.

• Scrubbers:

• Big importance for the chemical and process industry. Enviroment.

• Gas treatment: eliminate noxious fumes for the enviroment (SOx from combustion gases and others).

Typical design:• Height = 6.5 m

• Diametre = 2 m

• Injector phases = 2

Gases outlet

Filter (demister)

Liquid injector

Gases inlet

Liquid outlet (slurry)

SCRUBBER

• Results (Q1= 0,015 kg/s)

SCRUBBER

Drops path

Volumetric fraction

• Results (Q1= 0,015 kg/s)

SCRUBBER

Drops residence time

Gas residence time

773800Temperature [ºC]

0,0560,050H2O.mf

0,000630,001SO2.mf

OutletInlet

SCRUBBER

• Improving design/starting up (Q1= 0,015 kg/s):

• Flow homogeneization baffles:

• Avoid backwater areas.

• Avoid preffered ways.

• More number / better distribution of injectors:

• Bigger contact area gas/liquid.

• Land: 3,6 X 5,2 km.

Town

Chemical industry (leak of 50 kg/s ofethane and chloro)

Wind with velocity profile. 2 m/s at 10 m height

• Ideal gas air

• Cl2 (chlorine)

• C2H6 (ethane)

Ethane explosion riskChlorine toxic cloud

POLLUTANTS DISPERSION

Exposure time = 15 min.

POLLUTANTS DISPERSION• Results: Vulnerability: death probability (PROBIT method)

1. Security projects. Emergency and evacuation plans desi gn:- Vulnerability for toxics or radiations PROBIT analysis.

2. Risk analysis. Leak risks evaluation.- Immediately Dangerous to Life or Health risk.

3. Emergency plans.

4. Toxic clouds dispersion coupled to complex orographies analysis.

5. Explosion risk analysis (explosive mixtures coming up ).

6. Study of spills in rivers and ports.

POLLUTANTS DISPERSION Case studies and capacities

Industrial plantsWhat can we provide?

- Development of projects of different equipments at an indus trial plant:

- Design / optimization.

- Behaviour detailled evaluation:

- Normal operating conditions.

- Transitories out of the operating conditions.

- Damages on equipments analysis.

- The same kind of projects can be applied to other equipment s like:

- Boilers.

- Refrigerating towers.

- Others.

Industrial plantsWhat can we provide?

- It can also be applied to elements like:

- Reactors (including kinetics of the reaction)/scrubbers/ etc...

- Incidents or accidents evaluations:

-Pollutants dispersion.

- Damages evaluation.- Operating analysis of any equipment in which a fluid int ervenes. - Locating and solving bottle necks in plants.- Diminishing and 0 pollutants systems.- Leak or scape risk analysis.

Contact

���� www.analisis-dsc.com, click on the top right part for the English version.

���� info@analisis-dsc.com

� +34 914614071 or +34 914284802

���� ANALISIS-DSCC/ Nuestra Señora de la Luz, 21 local Izq. 28025 Madrid (SPAIN)

If You are interested in a technical meeting or in getti ng more informationabout our products and services, do not hesitate to contac t us.