Using OpenFOAM to model of complex industrial...
Transcript of Using OpenFOAM to model of complex industrial...
Christophe Duwig 1, Henrik Hassing 2, Elisabeth Akoh Hove 2
1 R&D division - Haldor Topsøe A/S & 2 Force Technology
Using OpenFOAM to model of complex industrial devices
Outline of the talk� Shortly about Haldor Topsøe A/S
– What does CFD do for us
� Replacing commercial CFD with OpenFOAM
– OSFRI initiative in Denmark
� How does OpenFOAM fit in the context?
– LES with detailed chemistry: example of hydrogen auto-ignition
– LES of a swirling flow
Haldor Topsøe A/S – www.topsoe.com� Founded by Dr. Haldor Topsøe in 1940
– selling high quality catalyst since 1944
– selling high quality processes since 1957
� Business areas:– Syngas
� Hydrogen & gasification-based tech.
� Ammonia
� Methanol/ DME
– Refinery
– Environmental / gas cleaning
� deNox applications
� sulfuric acid (WSA)
� CatOx
� Automotive
CFD applications in HTAS
� Reforming (hydrogen, ammonia, …)– furnaces simulations
– Reformer simulation (air and oxygen rich flames)
– Turbulent heat transfer
� Environmental– Ammonia/ Urea mixing in SCR devices
– Heat transfer in sulfuric acid condensers
– Particle depositions in SCR catalysts
� Refinery– Multiphase flows
– Heat & Mass transfer
Traditional fields of applications for commercial codes
When did it start?�A DANSIS meeting in October 2007 on new trends in CFD and with a special focus on OpenFOAM revealed a strong interest – 110 participants!
What do we do?�Open Source CFD has a clear potential but also barriers and dangers…
�However the benefits and dangers are almost the same for all new users!
�So – why not create national competences, share knowledge, test cases, user guides and not do the same mistakes?
High energy of activation
Need of the same catalyst
Need a critical mass
Create the OSFRI consortium!
The need of funding
An application for public funding was tailored by H. Hassingat FORCE Technology.
� A a total budget of 7.4 mill. DKK including 3.4 mill. DKK in public funding (1.00 €=7.43895 DKK)
� The results should be made available to all interested Danish companies (and others!)
�FORCE Technology
�Grundfos Management
�Niro A/S
�MAN Diesel A/S
�Ødegaard & Danneskiold-Samsøe A/S
�Babcock & Wilcox Vølund A/S
�Haldor Topsøe A/S
�FLSmidth Airtech A/S
�FLSmidth A/S
�Aalborg University
�Technical University ofDenmark
What is the outcome?Between the primary participants, the expected outcome are more or less like:
� Organize training sessions
� Use Open Source for ‘standard’ cases
– Particles modeling
– Combustion modeling
– Swirling flow modeling
� Open Source will be used for 50-70% of the volume which will be increased drastically
However OpenFOAM also opens new avenues
Detailed modeling of state-of-the-art devices
� Application to flames
– about the physics
– an example
– what is new with OpenFOAM
� Application to Large Eddy Simulation
– about the physics
– an example
– what is new with OpenFOAM
� Even simple a Bunsen flame is complex as shown beside!
� There is a need of advanced investigation techniques (experimental and numerical), here laser based OH-PLIF
� Does it happen only in the lab. ??? … NO!
� But traditional CFD over-simplifies the story -> need to do better!!
OH PLIF from Buschmann et al., 26th Symp.
On Combustion, pp. 437-445, 1996
How does a flame front really look like? what we see and what we hear
How do we address these problems?
� Large Eddy Simulation
– Fine mesh
– Low dissipation numerical schemes
– Small time steps
– Large computers
� Advanced models for combustion
– Accurate thermo-chemistry description – realistic kinetics
� Reads ChemKin format!
– Turbulence/chemistry: ILES/EDC/ PaSR
� OpenFOAM is suitable because
– Open source = flexibility
– Fair choice of numerical schemes that can be used for LES/ I-LES
– Runs in // without additional costs!
Cabra’s lifted flame
T~305 KH
2 /N2
T~1045 K
H2 O
/O2 /N
2
T~1045 K
H2 O
/O2 /N
2
X
XIG
OBS: not on scale!
Cold high-speed H2 jet in Hot oxidant with 17% O2
Lift-off hight
Flame location
Large Eddy Simulation using OpenFOAM
Customized solver based on the OpenFOAM library solving filtered continuity and Navier-Stokes
low-Mach number & ideal gas assumptionpressure coupling is PISOSmagorinski SGS closuresecond order discretizationsolver CG with AMG-preconditioning for pressureNumerical grid of cell size in the jet region h~d/24 (~0.6 millions Hex)Costs: ~24h for one jet-flow-through on 8 procs.
Filtered specie- and enthalpy-equations:( ) ( )( ) ( ) hDhu
t
h
)Y(YSc
DYut
Y
h
jTiiii
∇
+⋅∇=⋅⋅∇+
∂∂
+
∇
+⋅∇=⋅⋅∇+
∂∂
∆
∆
∆
∆
~
Pr
~~~
~~~~~
υρρρ
ωυρρρILES :
We resolve the reaction layer in the
LES grid!!
Complex chemistry is
neededExample:
1. H2 oxidation by Juan Li et al., 2004; 9 species & 19 reactions
2. CH4, GRI3.0, 53 species
3. ….
Radical species : OH & HO2 fields
HO2 precedes OH: ignition precursor!!
Cold H2/N2 jet issuing into a hot coflow - Tcoflow=1045K – O2=17%
Example: incompressible swirling jet
0=⋅∇ u
( ) ( ) ( )upuuuuuut
u ∇⋅∇+∇−=−⋅∇+⋅∇+∂∂ ν
ρ1
Filtered continuity and Navier-Stokes
• Numerical methods (solver oodles)• spatial discretization: cubic limited• temporal discretization: 2nd order implicit
•Numerical grid• typical cell size in the shearlayer h=d/50• number of cells: 1.5 millions (hex)
•Costs: 3-4 days on 32 procs. For 50000 time steps
I-LES
Summary & future work� OSFRI initiative is a success
– Open-source CFD need catalysis to enter the industry
– Critical mass is needed
� OpenFOAM is suitable when dealing with complex turbulent flows and flames = industrial problems!
– Open source = flexibility
� Fit the code to the problem and not the other way around
– Massive parallel runs without additional costs!
� Future actions
– Development of new capabilities
� To the OpenFOAM community: thank you for your work
– Phase II for the OSFRI initiative