Computational Fluid Dynamics Approach Research Articles

Research on particle migration in fractures driven by gas-liquid two-phase flow during deep energy storage and extraction

Particle-laden fluid flow in fracture encompasses various deep geo-energy projects, including but not limited to hydraulic fracturing, mud and water inrush, and sand production. The migration of particles under fluid flow seriously affects the stability of geo-energy engineering and understanding the mechanisms is of great importance. This study presents a numerical investigation of particle-laden fluid flow in rock fractures under two-phase flow. A coupled approach of resolved computational fluid dynamics (CFD) and discrete element method (DEM) is employed to capture the particle movements and variations in hydraulic properties, with the volume of fluid (VOF) method to reproduce the two-phase flow. The results indicate that the model with gas injection exhibits higher particles migration velocity compared to that without gas due to the increase in fluid velocity and fluctuation in drag force. Particles migration velocity presents an initial increase followed by a subsequent decrease as the gas fraction increases, which can be attributed to the initial rise followed by a subsequent decline in the drag force. In addition, the sensitive analysis shows that the particle migration velocity decreases with the increase of liquid viscosity and fracture roughness in the fluid, and further accelerates with the increase of particle size and hydraulic gradient. Our results have important implications for understanding the mechanisms of particle migration in rock fractures driven by the multiphase flow during deep energy storage and extraction.

Haemodynamic significance of extrinsic outflow graft stenoses during HeartMate 3™ therapy.

The HeartMate 3 (HM3) implantable left ventricular assist device connects the left ventricle apex to the aorta via an outflow graft. Extrinsic obstruction of the graft (eOGO) is associated with serious morbidity and mortality and recently led to a Food and Drug Administration Class 1 device recall of HM3. This study aimed to provide a better understanding of the haemodynamic impact of extrinsic stenoses. Computed tomography (CT) images of two retrospectively identified patients with eOGO (29 and 36% decrease in cross-sectional area, respectively, by radiological evaluation) were acquired with a novel photon-counting CT system. Numerical evaluations of haemodynamics were conducted using a high-fidelity 3D computational fluid dynamics approach on both the patient-specific graft geometries and in two virtually augmented stenotic severities and three device flows. Visual analysis identified increased velocity, pressure, and turbulent flow in the outer anterior curvature of the outflow graft; however, changes in graft pressure gradients were slight (1-9 mmHg) across the range of stenosis severities and flow rates tested. Evidence of eOGO during HM3 support and the recent device recall can provoke clinical apprehension and interventions. The haemodynamic impact of a stenosis detected visually or by quantification of cross-sectional area reduction may be difficult to predict and easily overestimated. This numerical study suggests that, for clinically encountered flow rates and stenosis severities below 61% in cross-sectional area decrease, eOGO may have low haemodynamic impact. This suggests that patients without symptoms or signs consistent with haemodynamically significant obstruction might be managed expectantly.

Analysis of the Drag-Reduction Ability of the Layout and Cross-Sectional Shapes of Subsea Structures in the Critical Flow Mode

Introduction. Slender structures of subsea energy production systems are under constant influence of currents and waves. Hydrodynamic loads result from the interaction of subsea pipelines, umbilicals, equipment supports with fluid flows, and lead to the vortex formation in the area behind the structures. Vortex-induced forces are the sources of the cyclic loading. They accelerate gradually the fatigue damage, which may result in a failure. One of the ways to reduce the loads on subsea structures is to alter the shape of a cross-section, taking into account the flow regime. Dependence of the resulting hydrodynamic loads on the cross-sectional shape and relative position of structures has not been studied in details for the uniform flow in the critical mode. The current work is aimed at filling this gap. The research objective is to consider the impact of the distance between the structures, and also, the presence of a D-shaped structure, placed upstream relative to the group of three cylinders of different cross-sectional shapes.Materials and Methods. The computational fluid dynamics approach was used in this work for numerical simulations of vortex-induced forces in the ANSYS Fluent software for cylinder with D = 0.3 m. Modelling was conducted with the Detached Eddy Simulation (DES) method, which combined advantages of the Reynolds-averaged Navier-Stokes equation (RANS) method and the Large Eddy Simulation (LES) method. The object of the research was the system of four structures in the 2D computational domain, which included the upstream D-shaped cylinder and the main group of three cylinders with the circular, squared and diamond shapes of the cross-section. The transient process was considered, where structures were under the influence of the uniform flow in the critical regime at Re = 2.5×10⁵.Results. Five sets of data were obtained in simulations for the time-dependent coefficients of the lift and drag forces: for the main system — of the D-shaped, circular, square and diamond structures, and also for the four systems — of only D-shaped, only circular, only square and only diamond shaped structures. Additional analysis was conducted for the effect of the distance between the structures on the amplitude of fluctuating hydrodynamic force coefficients. The obtained results are presented as time histories of coefficients of the lift and drag forces, frequency analysis and contours of velocity, pressure and vorticity fields. The results indicate a positive effect of the upstream D-shaped structure on reducing the drag force, acting on the central structure in the group of three cylinders located downstream.Discussion and Conclusion. The results of the performed studies facilitate the informed decisions regarding the arrangement of subsea structures in a group of four objects, depending on the cross-sectional shape and the distance between the structures. The upstream D-shaped structure provides reducing the hydrodynamic drag force acting on the central structure in the downstream group of three structures, thereby slowing the fatigue accumulation and increasing the time of safe operation.

Analyzing the thermal performance of walling systems in low-income housing through computational fluid dynamics approach

The thermal properties of wall materials have a direct impact on the thermal performance of the indoor environment, by also influencing the occupant’s well-being. Coupled with airflow dynamics, the thermal performance of wall materials influences the indoor air temperature distribution thereby impacting thermal comfort, particularly in naturally ventilated (NV) spaces. However, defining the relationships between the wall characteristics, airflow dynamics, and thermal comfort for selecting the appropriate wall material for low-income NV buildings is still not evident in the current literature. Therefore, this study proposes a simulation-based framework that considers the relationships between wall materials, airflow dynamics, and thermal comfort using a computational fluid dynamics (CFD) approach by spatially plotting the thermal comfort within the NV spaces.The study analyses locally accessible wall materials, subjecting them to different operating conditions within NV dwelling units of low-income housing in India. Out of the analyzed wall materials, aerated autoclaved blocks exhibited a significant indoor temperature reduction of 20.7 % compared to the compressed stabilized earth blocks, with constrained airflow exacerbating temperature fluctuations. The global implications of these findings are substantial for urban low-income dwellers experiencing excessive heat. Mass housing efforts worldwide can benefit from using thermally efficient materials in construction thereby improving living conditions, and mitigating the impact of climate change on thermal comfort and health.

Optimizing the Aerodynamic Efficiency of Electric Vehicles via Streamlined Design: A Computational Fluid Dynamics Approach

Optimizing the Aerodynamic Efficiency of Electric Vehicles via Streamlined Design: A Computational Fluid Dynamics Approach

Enhancing ammonia combustion performance using hydrogen peroxide-enriched air: A computational fluid dynamics analysis

The effect of H2O2 addition to the air on ammonia combustion was investigated in the current research using a computational fluid dynamics approach. The numerical simulation was conducted in a 10-kW laboratory-scale furnace. The oxidizer and fuel were injected into the furnace in a non-premixed mode. Furthermore, a kinetic study was carried out to analyze the sensitivity of NO production during combustion and to determine reaction pathways under various conditions. The findings indicate that the addition of H2O2 to the mixture increases flame temperature and NO levels, while decreasing N2O levels. Moreover, the study demonstrates that, with a maximum concentration of only 10 ppm, the amount of NO2 is very low under various percentages of H2O2 and different operating conditions. Furthermore, it is concluded that during ammonia/air combustion, lowering the oxidizer inlet temperature and increasing wall heat extraction may cause the combustion to become unstable. Under pure air oxidizer conditions, where Tin = 973 K and Twall = 1273 K, the combustion is stable. However, instability occurs when Twall falls to 1173 K. In this instance, adding merely 5 % H2O2 to the oxidizer is sufficient to provide self-sustaining and stable burning. More H2O2 must be introduced into the furnace to maintain stable combustion as Tin and Twall continue to decline. Interestingly, while adding H2O2 raises NO levels, decreasing the inlet and wall temperatures at higher H2O2 concentrations can help regulate NO emissions. These findings clearly indicate that introducing H2O2 into the fuel mixture could be a promising strategy for reducing the inlet temperature and enhancing heat extraction, which will both reduce energy consumption and increase system efficiency.

CFD modeling for hydrogen removal by a passive autocatalytic recombiner in oxygen-deficient conditions

This study aims to assess whether a computational fluid dynamics (CFD) approach effectively simulates hydrogen recombination characteristics by a passive autocatalytic recombiners (PAR) under oxygen-rich and lean conditions. Two PAR models were evaluated: one based on hydrogen recombination correlation provided by the manufacturer and another on hydrogen and oxygen mass diffusion rates. In the THAI-1 project, the experiments using an AECL PAR were performed to evaluate hydrogen recombination characteristics under oxygen-rich and lean conditions. In the CFD simulation of the HR18 test where oxygen was in surplus, both models predicted well the recombination rates. However, in simulations of the HR21 test under oxygen-starved conditions, the correlation-based PAR model significantly differed from experimental results. Conversely, the mass diffusion-based PAR model, incorporating oxygen diffusion to the catalytic surface, demonstrated greater accuracy than the correlation-based PAR model even with the recombination efficiency parameter used in the AREVA PAR correlation. These findings highlight the critical role of oxygen diffusion rates to catalytic surfaces in influencing hydrogen recombination rates, particularly in oxygen-starved conditions.

Computational fluid dynamics simulation on oxy-fuel combustion performance of a multiple-burner furnace firing coking dry gas

In heat production and power generation utilizing carbon-based fuels, oxy-fuel combustion is regarded as a potential method for carbon capture and sequestration. However, few studies, if any, have been performed on the impacts of exhaust dehydration efficiency and oxygen purity on the parameters of oxy-fuel combustion. In the current study, based on the experimental data, the oxy-fuel combustion characteristics of coking dry gas (CDG) in a gas-fired furnace were investigated using the computational fluid dynamics approach. The simulation results illustrate that the CO2 concentration in the flue gas could rise by nearly 14% as the dehydration efficiency increases from 0.60 to 0.95. The contents of CO2 elevate with the oxygen purity, while H2O and N2 show an opposite trend. Within the scope of the present study, an O2 content of 32% and an excess oxygen ratio of 1.1 are recommended given the combustion performance and economic issue. Due to the impacts of combustion performance, cost of ASU, CO2 enrichment, and so on, the selection of oxygen purity needs to be considered comprehensively. The content of N2 declines with the increase of the dehydration efficiency, which benefits the enrichment of CO2. The present work contributes to the clean and efficient utilization of combustible exhaust gas and provides further knowledge on green and low-carbon development.

A particle filter-based approach for real-time temperature estimation in a lithium-ion battery module during the cooling-down process

Temperature exerts a remarkable influence on the safety, performance, and lifespan of lithium-ion (Li-ion) batteries. Consequently, the real-time monitoring of this variable within battery cells emerges as both crucial and a significant challenge for battery thermal management systems. This paper introduces an approach for real-time temperature estimation in a Li-ion battery module during the cooling-down process by applying the particle filter (PF) technique. A battery module comprising fifteen cylindrical lithium cobalt oxide cells connected in series was employed for experimentation. The battery module was arranged into three rows, the PF employs real-time temperature measurements from the first cell of each string, based on a fractal-time model and an artificial evolution approach for parameter estimation, to estimate two unknown parameters and the temperature of the remaining twelve cells. Furthermore, the temperature measured on the surface of each cell in the module was compared both the PF and computational fluid dynamics (CFD) approach. The results exhibit a favorable agreement between the cell temperature estimates derived from the PF, the CFD simulations, and their respective experimental measurements. Finally, the proposed approach facilitates real-time temperature monitoring in battery modules with a reduced number of temperature sensors, thereby implying a cost reduction in the data acquisition system.

Numerical Analysis into the Improvement Performance of Ducted Propeller by using Fins: Case Studies on Types B4-70 and Ka4-70

Numerical analysis was conducted to assess the impact of fins on the B4-70 and Ka4-70 propeller performance. The study explored different fin variations, specifically bare fins, Propeller Boss Cap Fins (PBCF), and propeller nozzles, using computational fluid dynamics (CFD) simulations. To obtain the best results, the researchers utilized the explicit algebraic stress model (EASM) based on Reynolds-Averaged Navier-Stokes (RANS) equations and turbulence modelling. The primary goal of this study was to improve the energy efficiency of ships by examining various propeller configurations, both open and ducted. The overall conclusions indicated that the B4-70 PBCF convergent and Ka4-70 PBCF divergent with the addition of nozzle 19A exhibited the highest efficiency based on the EASM analysis. The CFD simulation results for both B4-70 and Ka4-70 propellers, utilizing a nozzle 19A with added boss cap fins, revealed several noteworthy phenomena. Firstly, for the B4-70 propeller, efficiency (η0) at J = 0.6 to J = 0.8 showed an increase of 1% to 2%. Secondly, concerning the Ka4-70 propeller, efficiency (η0) at J = 0.6 to J = 0.8 increased by 2% to 10%. These findings clearly demonstrate that the use of an ESD, such as the nozzle 19A with added boss cap fins, enhances the propulsion performance of the ship. It is evident that the CFD approach remains suitable and reliable for overall simulations.

Stabilization of SIMPLE-like RANS solvers for computing accurate gradients using the complex-step derivative method

The Reynolds-averaged Navier-Stokes (RANS) approach in Computational Fluid Dynamics (CFD) is increasingly vital for aerodynamic design across wind turbines, gas turbines, aircraft, and rotorcraft. Enhancing the process through CFD-based design optimization requires numerous design variables, favoring gradient-based methods for better scalability than gradient-free methods. This research uses numerical differentiation techniques, particularly the complex-step derivative method, to compute gradients. Challenges arise during aerodynamic shape optimization when unconventional shapes disrupt RANS solver assumptions, causing convergence failures. These failures undermine optimization, prompting the need to enhance solver convergence for robust optimization. The modified-Boostconv method is a residual recombination method bolstering unstable eigenvalues to stabilize convergence of iterative solvers for nonlinear systems of equations. This study extends the modified-Boostconv method to combine it with the complex-step derivative technique, creating robust optimizations via RANS-CFD with accurate gradients, even for these numerically unstable cases. The main issue encountered during the complexification of the modified-Boostconv method is how to correctly ensure that the model reduction leading to the least-squares problem satisfies the complex-step derivative method. We test whether the dot product operation involved in the model reduction should be a Hermitian or non-Hermitian inner product. The problem is first tested for a simple analytical case using the logistic equation in combination with the modified-Boostconv method. It shows that the non-Hermitian inner product should be used. This is also confirmed with a similar study using the RANS solver.

Validating low- and high-fidelity simulations of a yawed 8 MW wind turbine against measurements

This paper presents a comparison study of the aerodynamic behavior of an 8 MW wind turbine operating under yawed conditions using field measurements, Blade Element Momentum (BEM) theory and Computational Fluid Dynamics (CFD). Turbulent inflow wind field measurements are used to generate an IEC-compliant turbulence box upstream of the wind turbine that is used within the BEM tool MoWiT and the CFD tool chain by IWES in OpenFOAM. Both simulation approaches take into account blade flexibility using modal reduced, anisotropic beam elements in BEM and Geometrically Exact Beam Therory (GEBT) in CFD. While the focus is being set towards the CFD approach, turbine power output, blade root bending moments and blade tip deflections are analyzed. It is shown that both modeling approaches react differently towards the generated wind field.

Numerical simulation analysis of wind field above pavement surface in different landforms by computational fluid dynamics approach

The temperature and moisture of the pavement structure can be greatly influenced by the wind speed above pavement surface. The wind speed above pavement surface not only is dominated by the wind speed of atmosphere, but also it is highly related to the landform and buildings around road. However, currently there are no studies about the wind field above pavement surface in consideration of the effect of the landform and buildings. A simulation method, which is combined with geographic information system (GIS), wind data from meteorological observatory and computational fluid dynamics (CFD) software, is employed to study the effect of the landform and the wind speed of atmosphere on the wind field above pavement surface. Three cases are studied, including an urban road, a coastal road and a mountainous road. Furthermore, the wind field distribution above road surface in different wind directions was studied in our work. Results indicate that the wind field above pavement surface can be greatly affected by the landforms, buildings and wind direction. This simulation method can provide reliable results for the wind field above pavement surface. The maximum relative errors between simulated and measured wind speed can be less than 20% in the analysis of the three cases. It is recommended that the CFD simulation method is a good tool to accurately know the wind field above pavement surface.

Performance Optimization of Step-Like Divergence Plenum Air-Cooled Li-Ion Battery Thermal Management System Using Variable-Step-Height Configuration

Several studies on air-cooled battery thermal management systems (BTMSs) have shown that improvement can be achieved through redesign of the BTMSs. Recent studies have achieved improvements in managing the temperature in the system, but mostly with an increase in pressure drop. It is therefore imperative to carry out an extended study or redesign of the existing designs to overcome these challenges. In this work, a standard Z-type BTMS, which has a flat divergence plenum, was redesigned to have a step-like divergence plenum of variable step height. Computational Fluid Dynamics (CFD) approach was adopted to investigate the thermal and airflow performance of the BTMSs. The CFD methodology was validated by comparing its results with experimental data in the literature. Various step height configurations were considered for 3-step and 4-step models. Findings from the result revealed that the variable step height design enhances the cooling performance of the battery pack. For instance, a 3-step model with step heights of 3, 6, and 6 mm offered the least pressure drop and maximum temperature difference, and when compared with the model with a constant step height of 5, 5, and 5 mm, it yielded reductions of 3.4% and 21.6%, respectively. By increasing the inlet airflow velocity, the 4-step cases generally improved. The best cooling improvement was seen in case 26 at velocities over 3.7 m/s for maximum temperature and velocities over 4.8 m/s for maximum temperature difference. Doi: 10.28991/ESJ-2024-08-03-01 Full Text: PDF

A critical insight into the most effective CFD settings to model atmospheric stability in wind energy applications

An accurate reconstruction of the Atmospheric Boundary Layer (ABL) is key for the estimation of energy production and loads in modern wind turbines since, at current rotor heights, the vertical structure of the ABL is heavily influenced by thermal stratification effects. The wind power community usually accounts for these effects by semi-empirical modifications to the neutral ABL profile obtained using linear solvers such as WAsP; this approach, however, may not be suitable for sites with complex terrain, time-dependent thermal effects, or dense canopies. In these applications, methods with higher fidelity, such as Computational Fluid Dynamics (CFD) approaches based on steady or unsteady Reynolds Averaged Navier-Stokes (RANS) equations are needed. While CFD is recognized as providing more accurate results for these realistic cases, its use is still not a common best practice. In the current study, the WindModeller CFD tool by Ansys was employed to assess the effect of various inlet boundary conditions on the predicted wind speed profiles in unstable and stable atmospheric conditions. The test case is a wind farm in North Dakota, USA, characterized by a simple terrain but strong atmospheric stability effects and temperature fluctuations. The comparison of CFD results with experimental measurements and WAsP-CFD simulations reveals a high level of agreement between CFD and experimental data in stable conditions. In the case of unstable conditions, despite the good representation of the wind field, a high sensitivity to inlet boundary conditions is highlighted.

Integration Approaches to Model Bioreactor Hydrodynamics and Cellular Kinetics for Advancing Bioprocess Optimisation.

Large-scale bioprocesses are increasing globally to cater to the larger market demands for biological products. As fermenter volumes increase, the efficiency of mixing decreases, and environmental gradients become more pronounced compared to smaller scales. Consequently, the cells experience gradients in process parameters, which in turn affects the efficiency and profitability of the process. Computational fluid dynamics (CFD) simulations are being widely embraced for their ability to simulate bioprocess performance, facilitate bioprocess upscaling, downsizing, and process optimisation. Recently, CFD approaches have been integrated with dynamic Cell reaction kinetic (CRK) modelling to generate valuable information about the cellular response to fluctuating hydrodynamic parameters inside large production processes. Such coupled approaches have the potential to facilitate informed decision-making in intelligent biomanufacturing, aligning with the principles of "Industry 4.0" concerning digitalisation and automation. In this review, we discuss the benefits of utilising integrated CFD-CRK models and the different approaches to integrating CFD-based bioreactor hydrodynamic models with cellular kinetic models. We also highlight the suitability of different coupling approaches for bioprocess modelling in the purview of associated computational loads.

Uncertainty quantification of the lattice Boltzmann method focussing on studies of human-scale vascular blood flow

Uncertainty quantification is becoming a key tool to ensure that numerical models can be sufficiently trusted to be used in domains such as medical device design. Demonstration of how input parameters impact the quantities of interest generated by any numerical model is essential to understanding the limits of its reliability. With the lattice Boltzmann method now a widely used approach for computational fluid dynamics, building greater understanding of its numerical uncertainty characteristics will support its further use in science and industry. In this study we apply an in-depth uncertainty quantification study of the lattice Boltzmann method in a canonical bifurcating geometry that is representative of the vascular junctions present in arterial and venous domains. These campaigns examine how quantities of interest—pressure and velocity along the central axes of the bifurcation—are influenced by the algorithmic parameters of the lattice Boltzmann method and the parameters controlling the values imposed at inlet velocity and outlet pressure boundary conditions. We also conduct a similar campaign on a set of personalised vessels to further illustrate the application of these techniques. Our work provides insights into how input parameters and boundary conditions impact the velocity and pressure distributions calculated in a simulation and can guide the choices of such values when applied to vascular studies of patient specific geometries. We observe that, from an algorithmic perspective, the number of time steps and the size of the grid spacing are the most influential parameters. When considering the influence of boundary conditions, we note that the magnitude of the inlet velocity and the mean pressure applied within sinusoidal pressure outlets have the greatest impact on output quantities of interest. We also observe that, when comparing the magnitude of variation imposed in the input parameters with that observed in the output quantities, this variability is particularly magnified when the input velocity is altered. This study also demonstrates how open-source toolkits for validation, verification and uncertainty quantification can be applied to numerical models deployed on high-performance computers without the need for modifying the simulation code itself. Such an ability is key to the more widespread adoption of the analysis of uncertainty in numerical models by significantly reducing the complexity of their execution and analysis.

Hemodynamics and wall shear metrics in a pulmonary autograft: Comparing a fluid-structure interaction and computational fluid dynamics approach

ObjectiveIn young patients, aortic valve disease is often treated by placement of a pulmonary autograft (PA) which adapts to its new environment through growth and remodeling. To better understand the hemodynamic forces acting on the highly distensible PA in the acute phase after surgery, we developed a fluid-structure interaction (FSI) framework and comprehensively compared hemodynamics and wall shear-stress (WSS) metrics with a computational fluid dynamic (CFD) simulation. MethodsThe FSI framework couples a prestressed non-linear hyperelastic arterial tissue model with a fluid model using the in-house coupling code CoCoNuT. Geometry, material parameters and boundary conditions are based on in-vivo measurements. Hemodynamics, time-averaged WSS (TAWSS), oscillatory shear index (OSI) and topological shear variation index (TSVI) are evaluated qualitatively and quantitatively for 3 different sheeps. ResultsDespite systolic-to-diastolic volumetric changes of the PA in the order of 20 %, the point-by-point correlation of TAWSS and OSI obtained through CFD and FSI remains high (r > 0.9, p < 0.01) for TAWSS and (r > 0.8, p < 0.01) for OSI). Instantaneous WSS divergence patterns qualitatively preserve similarities, but large deformations of the PA leads to a decrease of the correlation between FSI and CFD resolved TSVI (r < 0.7, p < 0.01). Moderate co-localization between FSI and CFD is observed for low thresholds of TAWSS and high thresholds of OSI and TSVI. ConclusionFSI might be warranted if we were to use the TSVI as a mechano-biological driver for growth and remodeling of PA due to varying intra-vascular flow structures and near wall hemodynamics because of the large expansion of the PA.

Investigation of the Impact Load Characteristics during Water Entry of Airdropped Underwater Gliders

Underwater gliders have emerged as effective tools for long-term ocean exploration. Employing aircraft for launching underwater gliders could significantly expand their application. Compared to slender underwater vehicles, the distinctive wing structure of underwater gliders may endure huge impact forces when entering water, leading to more intricate impact load characteristics and potential wing damage. This paper employs a computational fluid dynamics approach to analyze the water entry event of an airdropped underwater glider and its impact load behavior. The results indicate that the glider impact load is enhanced prominently by the wing, and that the extent of enhancement is influenced by the entry attitude. At an entry angle of 80°, the glider exhibits the maximum impact load during different water entry angles. In addition, a larger attack angle indicates a higher glider impact load. Our present study holds significant importance for both the hydrodynamic shape design and water entry strategy control of airdropped underwater gliders.

Comparison of thermo-hydraulic performance among different 3D printed periodic open cellular structures

As additive manufacturing of periodic open cellular structures (POCS) is gaining interest in structured catalytic reactor research, this work seeks to thermohydraulically compare the well-known Kelvin lattice structure with the lesser-researched BCC and gyroid lattice structures. Using a combined CFD (Computational Fluid Dynamic) and experimental approach, the selected POCS are fabricated through Laser Powder Bed Fusion (LPBF), characterized, and subsequently subjected to numerical analysis. From the manufacturability point of view, the 3D printed samples closely matched their CAD designs, showing a maximum porosity deviation of 15% below design values. A CFD model, validated through pressure drop experiment, was employed to compare the POCS designs on shared geometric attributes such as specific surface area and porosity. While all structures exhibited comparable performance in term of heat and momentum transfer, our findings suggest that the Gyroid lattice may provide the optimal balance between momentum and heat transfer rates in low-velocity region. Conversely, the BCC configuration may be more favourable at higher velocity. An Ergun-like correlation was also developed and validated for each lattice type, with a Mean Absolute Percentage Error (MAPE) below 10%. Our pressure drop results align quite well with existing literature correlations, showing a MAPE under 20%. Concerning heat transfer, the values forecasted in this research show a reasonable alignment with literature’s results, though they tend to be on the lower spectrum.