Researchers at CSIRO are using computational fluid dynamics (CFD) modelling to optimise processes, plant and equipment, and assist scale-up, quickly and cost effectively.
CSIRO Minerals' computational fluid dynamics (CFD) team has been studying different processes and systems related to the mineral processing, metal production, petroleum and power generation industries for over 20 years.
CFD uses advanced computer software to model the flow of fluids through a processing facility. The fluid may be in liquid, gas, or loose particle form, or a combination of these.
CFD is a cost-effective way of carrying out equipment and process design and optimisation, and can reduce risk in equipment modification and process scale-up.
Finite volume method
The team uses general purpose commercial packages, such as ANSYS/CFX, to model a wide range of applications. These packages, based on the finite volume method, are suitable for modelling most types of flows. The team extend these packages to model new applications by:
The simulations developed using this approach are used to develop, test and refine a wide range of variations in physical design and operational parameters, until a solution is identified which gives optimum performance.
The Minerals' CFD team extend commercial packages to model new applications for minerals processing.
Optimising processes and equipment
The broad application of CFD to new and existing plant in the mineral processing, metal production and energy industries has the potential to save companies many millions of dollars per year.
CSIRO researchers have successfully used CFD modelling to enhance operations of equipment and processes including:
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cyclones, particle separation and coal processing
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gas-liquid and liquid-liquid systems
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rotary dryers, boilers, kilns and ovens
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buildings
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risers and gasifiers
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flow through and over solid media
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flash and bath smelting
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burners.
To support current projects, researchers are developing models of:
Current research
Computer simulation of mineral processing is leading to more cost-effective plant designs and improved operating conditions, without the need for expensive real-world trials.
CSIRO expertise in computational fluid dynamics is delivering improved mineral and energy processing, more efficient manufacturing processes, and more realistic computer animation.
An independent evaluation reveals that this CSIRO-led project on improving gravity thickeners has delivered benefits of at least A$295 million to the minerals processing industry, with the prospect of future benefits of another A$250 million.
This video looks at the work of the CSIRO's Improving Thickener Technology Team, for which they received the 2004 CSIRO Business Excellence Award. (3:00)
CSIRO’s laser flow diagnostics laboratory offers a world-class measurement and model validation facility with capabilities that are unique in Australia.
Scientists have developed a computational fluid dynamics model that determines the effect of cell design and operation conditions on flotation performance.
Changes spurred by advanced computer modelling work on its regenerator are saving BP Bulwer Island Refinery millions of dollars each year in operating costs. Article from Process October 2007.
Researchers using computational fluid dynamics (CFD) have identified a large recirculating vortex as the cause of performance variations in precipitation tanks being used at an alumina refinery. Article from Process October 2007.
A mixture of computational and physical modelling techniques is helping the aluminium industry conserve energy by improving slotted anode designs, making aluminium reduction cells more efficient. Article taken from Process October 2007.
Modelling is helping researchers develop a better understanding of the copper and zinc electrowinning process.
A better understanding of the physiochemical workings at play in the often murky depths of a thickener’s feedwell has helped one of the world’s leading thickener suppliers make what could be the first significant design change to these crucial units in more than a decade.
Computational fluid dynamics (CFD) modelling has helped identify the cause of a 'puffing' problem at a nickel smelter.
Find out more about the work of
CSIRO Process Science and Engineering.
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