Process Modeling

Process simulation and other types of modeling are key tools in understanding value propositions and troubleshooting operating problems.  C12 Solutions utilizes a variety of industry leading software to provide the necessary data that leads to informed decisions.

Computational Fluid Dynamics: CFD is a branch of fluid mechanics that uses numerical analysis and algorithms to analyze aspects of fluid flow.

Computers are used to perform the millions of calculations required to simulate the interaction of liquids and gases with surfaces defined by boundary conditions. We have worked on a large variety of problems including: high temperature turbulent combustion, multi-phase fluidized beds and combustion, liquid sloshing, super and sub-sonic flows, catalytic reactors, pipe flow and valve placements, gas mixing and a multitude of air flow simulations (as depicted in the accompanying figure).

In order to perform the calculation, the domain to be simulated is broken down into a large number of blocks, termed cells.  Within each cell, the corresponding differential equations governing flow, turbulence, conservation of mass and momentum are solved.  Using sophisticated software and visualization techniques, it is possible to view the overall solution of a flow field by solving and viewing the collective cells defining the problem.

C12 Solutions has over 20 years using CFD software and we have successfully utilized the technique to provide rapid answers to real-world engineering issues saving our clients thousands of dollars in process performance enhancements.

Process Modeling: Where CFD helps answers some of the questions associated with equipment design, process modeling focuses on addressing overall operational parameters.

It’s used to help clients understand the implications of making process modifications or to optimize new process designs.  Our expertise in reaction kinetics enables us to define the chemistry occurring within unit operations that may normally be modeled using an approach to equilibrium technique.  Process simulation enables us to examine different operating conditions and to perform optimization studies.  The ability to test financial assumptions or help generate the necessary data for further financial modeling proves invaluable when dealing with new processes that may require investment funding.  C12 Solutions is also able to provide a rapid turnaround process evaluation as typically associated with an investment due-diligence process.

Chemical Reaction Modeling: Many industrial processes are simulated using equilibrium or approach to equilibrium methods.  Although this is a valid technique for certain processes, the ability to simulate the kinetic constraints of a system can prove exceedingly useful.  C12 Solutions uses sophisticated reaction modeling techniques to examine complex reaction mechanisms.  The output of this modeling might be a reaction rate or series of reaction rates for use in a process of CFD model or it might be to better understand how the kinetic system is operating in order to generate improvements to the reaction system – this is particularly the case for catalytic systems.   Our expertise in chemical kinetic modeling includes: defining detailed reaction mechanisms for both homogeneous and heterogeneous systems, and reducing complex mechanisms to simpler forms.  We have expertise in generating catalytic surface reaction mechanisms which are proving especially useful in the development of monolith catalytic reactor processes.

MATLAB and other tools: In today’s ‘quick fix’ society, we are sometimes asked to provide CFD or process modeling services to provide answers to problems that might be solvable by other techniques.  These may include creating spreadsheet based solutions or developing solver algorithms in powerful packages such as MATLAB.  Whatever the situation, we pride ourselves on selecting the most appropriate technique that gets the problem solved as quickly and as effectively as possible.