SolutionsSimulation & virtual engineering
Pillar 2 · Solutions

Simulation & virtual engineering

For equipment not yet built, or a retrofit that still lacks a sound basis to proceed. Virtual testing compares the options on one validated model before any investment in hardware.

Core capability

CFD & multiphysics

In industrial projects, CFDWAYS applies the same classes of models the team has published in international journals.

Flow & heat transfer

Flow distribution, pressure loss, heat exchange, shape optimization of flow-guiding parts.

Multiphase & reacting flow

Gas–solid, gas–liquid, evaporation–condensation; combustion models and SOx/NOx removal reactions.

Multiphysics coupling

Flow coupled with thermal stress and structure where the deformation feeds back into the flow.

Electrostatic precipitator retrofit pilot: the flow uniformity index across the distribution screen rose from 0.73 to 0.88, and total pressure loss across the R.EP unit came to 229 Pa against a 300 Pa target — all settled on the model before installation.

Read the ESP retrofit case study → · The team's publications →

1D system simulation

CFD answers questions inside one piece of equipment. System simulation answers questions between them — when the problem is the balance of the whole plant rather than one combustion chamber.

  • Balance across the whole line: heat and mass for the entire process chain.
  • Dynamic response: how the system behaves under load changes, start-up and shutdown.
  • Piping networks, pumps, valves: operating points and the distribution of losses.
  • Coupling with detailed CFD: only where high resolution is genuinely needed.

Simcenter Amesim → · Flomaster →

Computational mesh and a chart validating the model against measurements
/image/hero-luoi-kiem-chung.svg4:3 ratio (landscape)
A model becomes a basis for decisions only after it is checked against design data or measurements.
When there are more options than can be run by hand

Design optimization & virtual testing

The computer searches for options and takes on most of the trial-and-error loop. Only the settled option goes to site.

Automated design optimization

  • Sensitivity study: which variables actually drive the result
  • Multi-objective optimization: shape and operating parameters at the same time
  • Trade-offs as numbers: efficiency, pressure loss and fabrication cost stated plainly
  • Tooling: Solid Edge / HEEDS sweeping the design space automatically

Virtual testing & commissioning

  • Sweeping operating scenarios: a far wider range of boundary conditions than the real equipment allows
  • Settling the layout before installation: injectors, flow guides, baffles
  • Back-validation after installation: measurements against prediction, the deviation used to recalibrate the model
  • Testing scenarios too hazardous for real operation
SNCR project for a 30 MW waste-to-energy plant: the injection layout was settled on the model before installation, with an 870–1100°C temperature window and no trial-and-error on site.

Read the SNCR case study →

Process

Four steps, with mandatory validation

The second step determines whether the model is reliable enough. Projects delivered so far typically take 4–8 weeks for one piece of equipment, including the verification round for the improvement options.

Collect the data

2D equipment drawings, piping ISO drawings, operating conditions. You provide them — CFDWAYS specifies exactly what is needed.

Build & validate the model

CAD → meshing → physics setup. Calibrated against design data or operating measurements before any analysis.

Analyze & diagnose

Velocity, temperature, pressure and phase distribution fields; bottlenecks located by quantitative criteria.

Propose & verify

Improvement options are re-run on the same model and KPIs compared before/after — the decision rests on numbers.

Talk to us about your equipmentSee the software portfolio

Have equipment that needs virtual testing?

Send the drawings and the operating conditions. CFDWAYS replies within 24 working hours on whether it can be solved by simulation, what data is required and the expected timeline.

Send project details