Coupled Computational Fluid Dynamics Research Articles

Shock Wave and Aeroelastic Coupling in Overexpanded Nozzle

The growing demand for increasing the engine power of a liquid rocket is driving the development of high-power De-Laval nozzles, which is primarily achieved by increasing the expansion ratio. A high-expansion-ratio for De-Laval nozzles can cause flow separation, resulting in unsteady, asymmetric forces that can limit nozzle life. To enhance nozzle performance, various separation control methods have been proposed, but no methods have been fully implemented thus far due to the uncertainties associated with simulating flow phenomena. A numerical study of a high-area-ratio rocket engine is performed to analyze the aeroelastic performance of its structure under flow separation conditions. Based on numerical methodology, the flow inside a rocket nozzle (the VOLVO S1) is analyzed, and different separation patterns are comprehensively discussed, including both free shock separation (FSS) and restricted shock separation (RSS). Since the location of the flow separation point strongly depends on the turbulence model, both the single transport equation and two-transport-equation turbulence models are simulated, and the findings are compared with the experimental results. Therefore, the Spalart–Allmaras (SA) turbulence model is the ideal choice for this rocket nozzle geometry. A wavelet is used to analyze the amplitude frequencies from 0 to 100 Hz under various pressure fluctuation conditions. Based on a clear understanding of the flow field, an aeroelastic coupling method is carried out with loosely coupled computational fluid dynamics (CFD)/computational structural dynamics (CSD). Some insights into the aeroelasticity of the nozzle under separated flow conditions are obtained. The simulation results show the significant impact of the structural response on the inherent pressure pulsation characteristics resulting from flow separation.

CFD–DEM comparison of slurry infiltration in laboratory column tests and in real-world tunnelling

Slurry infiltration and filter cake formation are critical for excavation surface stability in slurry shield tunnelling. Laboratory column tests are frequently adopted to study macroscopic infiltration. However, these tests, in a vertical orientation and confined by an impermeable cylindrical boundary, may not be a good representation of horizontal infiltration into an unbounded stratum in real-world tunnelling. In this paper, a more realistic slurry pressure balance (SPB) tunnelling model was created to overcome the limitations of simulated laboratory column tests. Coupled computational fluid dynamics (CFD)–discrete element method (DEM) numerical simulations were carried out to study the slurry infiltration into sand for this model and compare the results with the conventional laboratory column test model. Both models produced the same types of filter cakes. The SPB tunnelling model yielded larger infiltration distances and ranges, but a lower normalised permeability in the sand region in front of the tunnel face. The fluid pressure within this region dissipated much faster in the SPB tunnelling model, resulting in rapid velocity decreases and a faster infiltration process. Although the SPB tunnelling model is more representative of real-world tunnelling, the conventional laboratory column test is conservative, producing similar types of filter cakes over a longer timeframe.

Multi-region coupling computational fluid dynamics simulation of the underground compressed air energy storage process

Compressed air energy storage (CAES) in underground spaces is a common method for addressing the instability of renewable energy generation. As the construction and testing of CAES systems are often of high cost, the numerical simulation which offers a more efficient and low-cost research method can provide a better alternative to research the process. In this study, a numerical simulation model has been developed to describe the air movement within the CAES process. Specifically, the study focuses on two different types of motion: air compressible flow within the cavern and air porous flow in the surrounding rock. Using OpenFOAM, a multi-region coupling solver has been developed to address the different governing equations for these two types of motion, and couples pressure, velocity, and temperature at the boundaries. The developed solver is used to simulate a field test of a CAES system. The numerical simulation results closely match the experimental data, verifying the reliability of the solver. Moreover, the solver can achieve multi-region flow simulations that are previously unattainable, resulting in more accurate simulations. Simulations have also been conducted to analyze various working conditions, including different rock permeability, porosity, and air injection mass rates. The results show that different conditions significantly affect air pressure, leakage rate, temperature, and flow field changes within the cavern. These simulation results and the underlying mechanisms have been analyzed to provide reference and technical support for site selection, construction, and operational strategies of CAES systems in underground spaces.

Coupled computational fluid dynamics and computational thermodynamics simulations for fission product retention and release: A molten salt fast reactor application

This study presents a computational capability for fission product retention and release in two-phase, multi-species systems representing Molten Salt Reactors (MSR) with coupled thermal-hydraulics and fuel coolant chemical behaviours. This is demonstrated through four simulated cases centred on the proposed Molten Salt Fast Reactor (MSFR). This is achieved by two-way coupling the Computational Fluid Dynamics (CFD) code OpenFOAM and the Computational Thermodynamics (CT) code Thermochimica, using the Joint Research Centre Molten Salt Database (JRCMSD). Local chemical equilibrium is assumed, implying that chemical kinetics are predominantly governed by mass transport. Four simulations address normal operating conditions, exploring: (i) dilution of fission products injected within the molten salt coolant, (ii) molten salt coolant evaporation rate, (iii) release of radioactive gaseous species, (iv) shifts in the UF4/UF3 ratio, and (v) comparison of vapour pressures of gaseous species. The influence of temperature-dependent viscosity on retaining fission products, compared to consistent values, is also discussed. The feasibility of integrating CFD with Thermochimica showed promising results, broadening insights into multiphysics systems and setting the stage for its application in more intricate scenarios.

The Role of Fully Coupled Computational Fluid Dynamics for Floating Wind Applications: A Review

Following the operational success of the Hywind Scotland, Kincardine, WindFloat Atlantic, and Hywind Tampen floating wind farms, the floating offshore wind industry is expected to play a critical role in the global clean energy transition. However, there is still significant work needed in optimizing the design and implementation of floating offshore wind turbines (FOWTs) to justify the widespread adoption of this technology and ensure that it is commercially viable compared to other more-established renewable energy technologies. The present review explores the application of fully coupled computational fluid dynamics (CFD) modeling approaches for achieving the cost reductions and design confidence necessary for floating wind to fully establish itself as a reliable and practical renewable energy technology. In particular, using these models to better understand and predict the highly nonlinear and integrated environmental loading on FOWT systems and the resulting dynamic responses prior to full-scale implementation is of increased importance.

Breakage characteristics of large mineral particles in pneumatic conveying

Pneumatic conveying of mineral particles is widely used in underground roadway material transportation and support. However, the breakage of large particles at bends is inevitable. Based on a coupled Computational Fluid Dynamics (CFD) and Discrete Element Method (DEM) method, the Euler-Lagrange equation was used to investigate the breakage of quartz particles (8 to 12 mm) during pneumatic conveying. By the Tavares UFRJ model, single large particle transport was simulated and the particle breakage was described as preliminary breakage and final breakage. The pneumatic conveying of multiple particles was simulated, and a detailed analysis was conducted on the effects of airflow velocity, particle size, and gravity direction on the particle breakage rate. The results indicated that the particle breakage rate increased with the rise in airflow velocity and particle size. The breakage rate was highest when the direction of gravity was in the negative x-direction and lowest in the negative y-direction.

Analysis of the effect of geometric and flow parameters on the separation efficiency of virtual impact separators: Optimization based on response surface methodology

Respiratory dust is the primary factor triggering pneumoconiosis. Accurately separating respiratory dust from total dust according to specific criteria are key aspects of respiratory dust monitoring and prevention technology. In this study, we numerically solve the gas-solid two-phase flow within a virtual impactor by coupling computational fluid dynamics (CFD) with the discrete element method (DEM). Here, we explored the air velocity and dust separation efficiency of each component of the virtual impactor to determine optimal structural scale parameters. Accurate 3D printing technology was employed to materialize the three-dimensional structure of the virtual impactor. The separation efficiency of the virtual impactor was evaluated and verified through simulated duct experiments. The results indicate that the weak flow ratio has the most significant effect on separation efficiency, followed by the effect of the ratio of separation chamber diameter to nozzle width (S/W), the ratio of the weak flow outlet size to nozzle width (D/W) aving the smallest degree of influence. When S/W is 1.8, D/W is 1.333, and the weak flow ratio is 0.1, the separation efficiency curves show optimal performance, as confirmed by experimental verification. The experimental verification matched the simulated separation efficiency data within a deviation range of 1.10–11.4 %.

Coupled building simulation and CFD for real-time window and HVAC control in sports space

Accurately predicting players’ thermal comfort in large sports spaces for real-time window and HVAC operations presents significant challenges due to non-uniform thermal distributions. Standalone building energy simulation (BES) typically assumes the entire targeted space as a uniform thermal zone, which fails to capture these variances. Conversely, Computational Fluid Dynamics (CFD) simulation can predict indoor thermal environments with precision but often struggles with determining accurate boundary conditions. This study introduces a coupled BES and CFD simulation method tailored for real-time window and HVAC control in sports spaces. A case study was conducted in a prototypical national fitness hall to evaluate the effectiveness of the proposed method. The thermal comfort and cooling energy results from the co-simulation-based control were compared with those from standalone EnergyPlus simulation-based control and fixed-schedule window and HVAC operations, which served as baselines. The results indicate that the proposed method enhanced thermal comfort by 68.5 % compared to constantly-scheduled window operations and achieved daily energy savings of up to 43.5 % versus constantly-scheduled HVAC operations. Furthermore, significant discrepancies in Average Predicted Mean Vote (PMV‾) or Average Adaptive Predicted Mean Vote (aPMV‾) as well as daily cooling energy consumption between the BES-CFD co-simulation and standalone EnergyPlus simulation were identified, ranging from -0.53 to 1.83 for PMV‾ (aPMV‾) and -2444.6 to 1266.5 kWh for cooling energy. This study contributes novel methods for real-time window and HVAC control in sports buildings towards thermally comfortable and energy-efficient sports environments.

Evaluating thermal sensation in outdoor environments - Different methods of coupling CFD and radiation modelling with a human body thermoregulation model

Thermal comfort is vital in outdoor spaces for social interaction and recreation. With increases in heat wave events and global warming, it becomes more essential to be able to assess heat stresses. Outdoor spaces have asymmetrical and transient environmental factors such as solar radiation, long-wave radiation and natural wind, which makes the thermal perception outdoors largely different from indoors. Traditional thermal comfort models have some limitations and less accuracy when applied to outdoor spaces. The current study focuses on developing a method to assess the human thermal interaction with the complex outdoor environment and the consequent thermal sensation. Computational Fluid Dynamics (CFD) and radiation modelling are coupled to the Joint System Thermoregulation (JOS-3) model to assess the skin temperature, based on which thermal sensation is predicted using the updated thermal comfort model developed by UC Berkeley. The proposed methodology is applied to assess the thermal sensation of human subjects standing in front of an outdoor radiant cooling hub. The important finding is that the one-way coupling, i.e., no skin temperature feedback to the CFD simulation, works reasonably well in the outdoor environment, and that convective heat transfer coefficients available from experimental studies can be coupled with CFD simulated environmental parameters to obtain more reliable convective heat exchange to avoid meshing the geometry of a human body in CFD and further reduce the computing cost.

Evaluation of a Coupled CFD and Multi-Body Motion Model for Ice-Structure Interaction Simulation

The interaction of water flow, ice, and structures is common in fluvial ice processes, particularly around Ice Control Structures (ICSs) that are used to manage and prevent ice jam floods. To evaluate the effectiveness of ICSs, it is essential to understand the complex interaction between water flow, ice and the structure. Numerical modeling is a valuable tool that can facilitate such understanding. Until now, classical Eulerian mesh-based methods have not been evaluated for the simulation of ice interaction with ICS. In this paper we evaluate the capability, accuracy, and efficiency of a coupled Computational Fluid Dynamic (CFD) and multi-body motion numerical model, based on the mesh-based FLOW-3D V.2023 R1 software for simulation of ice-structure interactions in several benchmark cases. The model’s performance was compared with results from meshless-based models (performed by others) for the same laboratory test cases that were used as a reference for the comparison. To this end, simulation results from a range of dam break laboratory experiments were analyzed, encompassing varying numbers of floating objects with distinct characteristics, both in the presence and absence of ICS, and under different downstream water levels. The results show that the overall accuracy of the FLOW-3D model under various experimental conditions resulted in a RMSE of 0.0534 as opposed to an overall RMSE of 0.0599 for the meshless methods. Instabilities were observed in the FLOW-3D model for more complex phenomena that involve open boundaries and a larger number of blocks. Although the FLOW-3D model exhibited a similar computational time to the GPU-accelerated meshless-based models, constraints on the processors speed and the number of cores available for use by the processors could limit the computational time.

Flow-induced erosion modelling of cohesive material with coupled CFD-DEM approach

Erosion is one of the continuous wear mechanisms in cohesive materials caused by the shear stress applied by the fluid flow at the liquid–solid interface. The erosion resistance of cohesive materials is significantly influenced by the strength of the cohesive bonds that hold the particles together, increasing the complexity of the mechanism. The erosion rate of cohesive materials depends on the critical shear stress (CSS) and the erodibility coefficient at the surface. The current understanding of the relationship among the inter-particle bond strength, CSS, erodibility coefficient, and their respective contributions to the flow-induced erosion process is still lacking; therefore, it cannot be adequately described mathematically. The present research offers a coupled computational fluid dynamics (CFD)–discrete element method (DEM) approach to visualize and quantitatively analyze the flow-induced erosion in cohesive materials. The capability and accuracy of the developed model were validated using experimental data available in the literature. A cohesion model was then employed to describe the strength of the cohesive bond, and the effects of the cohesion energy density (CED) on the CSS and erodibility coefficient were investigated. The analysis indicated that for cohesive materials, the non-dimensional CSS not only is affected by the particle Reynolds number but also strongly depends on CED. The simulation results indicated that by increasing the CED value from 500 to 900kJ/m3, the CSS increased by 25 %, and the erodibility coefficient decreased by 62 %. The proposed CFD–DEM approach can effectively estimate the erosion initiation and erosion rate of cohesive materials in different applications and geometries.

Investigation of the energy dissipation mechanism for centrifugal air compressor used for fuel cell based on CFD coupling with CIT

Effective evaluation indicator is the focus of air compressor structural optimization and development of control strategies, leaving to be further investigated from physical occurrence mechanism. Considering air expansion and compression, on the basis of coupling computational fluid dynamics (CFD) with classical irreversible thermodynamics (CIT), an extended entropy generation rate was established. Accordingly, various entropy generation rates for air compressor under wide operating conditions was investigated, aiming to what, where and how much the energy was dissipated. Results show that entropy generation rate related to air expansion and compression is always the largest contributor to the total entropy generation of the system under all operating conditions. A new dimensionless number R is defined to distinguish the fluid-related entropy generation rate and mechanical-related entropy generation rate. Furthermore, physical-based empirical models concerning the relationship of entropy generation rates, motor speeds and loads are proposed in this study, whose usage for guiding structural design was discussed. The work done in this paper can not only provide a new method for guiding the structural design of air compressors, but also providing a new idea for air compressor-fuel cell system’s optimal control.

Comprehensive analysis of the effect of structural parameters on erosion wear, structural stress, and deformation of high-pressure double-elbow in shale-gas fracturing

In field hydraulic fracturing operation of shale gas development, the high pressure and large displacement liquid-particle two-phase fracturing fluid can be forced to change direction many times through high-pressure double-elbow, and be transported from the outlet pipeline of the fracturing pump to the main pipeline. The high-pressure double-elbow is prone to be affected by erosion wear and Fluid-Structure Interaction (FSI), resulting in perforation and fracture, posing a potential safety threat to field operation. In this study, we conducted the erosion wear experiments on 35CrMo steel used for high-pressure double-elbow in shale-gas fracturing. The erosion rates under different impact angles and flow velocities were obtained, and proposed a novel model of erosion prediction for high-pressure double-elbow. Then the numerical investigation was employed to conduct a comprehensive analysis of erosion wear, structural stress and deformation by the coupling of Computational Fluid Dynamics (CFD) and Finite Element Analysis (FEA). The effects of structural parameters such as connection straight pipe length, pipe inner diameter and fluid turning direction were discussed. The results indicate that with the increase of connection straight pipe length, the flow erosion decreases first then varies little, and the deformation gradually increases. Slight erosion wear but large structural stress and deformation in major inner diameter pipe. And the minimum degree of erosion and flow-induced deformation present with the fluid turning direction of double-elbow as 0°. The study can provide references for the design, installation and detection of high-pressure double-elbow and ensure safety in the process of shale gas fracturing.

A fast and high-fidelity multi-parameter thermal-field prediction system based on CFD and POD coupling: Application to the RPV insulation structure

The thermal performance of the reactor pressure vessel (RPV) insulation structure plays a crucial role in ensuring the operational safety of the reactor. In this study, a fast and high-fidelity prediction system is proposed, which is based on the snapshot ensemble generated by the computational fluid dynamics (CFD) method and incorporates proper orthogonal decomposition (POD) as its core component to predict the heat transfer performance of the RPV insulation structure. The proposed thermal-field prediction system is employed to examine the impacts of air inlet temperature, mass flow rate, and RPV outer wall temperature on the thermal performance parameters: average heat flux qout and temperature Tout of the RPV insulation outer wall, as well as the maximum local temperature Tmax of the concrete pit inner wall. The POD predictive results showcase that the maximum relative deviations of qout, Tout and Tmax for eight sets of off-design cases are 2.25 %, 3.04 %, and 2.37 %, respectively. Meanwhile, the maximum values of qout, Tout and Tmax are 90.13 W·m−2, 44.69 ℃, and 87.51 ℃, respectively. They are all less than their prescribed limits. The field distributions of heat flux and temperature in off-design cases exhibit consistency between the CFD and POD methods. Notably, in comparison to the CFD simulation method, the POD method capturing more than 99.9 % energy demonstrates significant computational time savings for 99.87 %. Moreover, a multivariate linear regression (MLR) model for thermal performance parameters is established based on the POD prediction datasets. The results indicate that the maximum relative deviations between the POD and MLR methods in predicting qout, Tout and Tmax for the 72 sets of test cases are 5.1 %, 7.9 % and 7.1 %, respectively. Meanwhile, 99.99 % CPU time is reduced for MLR model compared with CFD method. Obviously, the predictive system showcases excellent accuracy and efficiency in forecasting.

Coupled CFD-FEM modeling of fluid–thermal–structural interaction in a single-strand tundish

A mathematical model has been developed to study the fluid–thermal–structural interaction in a single-strand tundish based on a coupled computational fluid dynamics (CFD) and finite element method (FEM) approach. The flow pattern and temperature distribution of the molten steel were predicted by the CFD calculation. Heat transfer and thermal stress profiles in the solid layers were investigated by the FEM analysis. Case studies were carried out comparatively to investigate the effect of tundish preheating and thermal insulation. The results show that tundish preheating can maintain the desired temperature of the molten steel at the exit. The heating efficiency drops significantly after 3 h of preheating. Reducing the thermal conductivity of the insulation material will reduce the temperature of the tundish shell and increase the thermal stress on the working lining. The modeling results can be used to improve the reliability and lifetime of the tundish and reduce production costs.

Surrogate-based integrated design optimization for aerodynamic/stealth performance enhancements

The shape optimization considering both aerodynamic and radar stealth performances has been a considerable attention area for next-generation aircraft, with challenges involving balancing design contradictions and improving optimization efficiency. This paper develops a surrogate-based integrated design optimization method coupling Computational Fluid Dynamics (CFD) and Computational Electromagnetics (CEM) for aerodynamic/stealth performance enhancements. The topology-based 3D hexahedral mesh generation and 2D triangular mesh generation with adaptive refinement provide efficient preprocessing for CFD/CEM solvers. The surrogate-based optimization algorithm with parallel infill-sampling strategy and adaptive design space expansion is employed to search the global optimum and improve optimization efficiency while filtering out numerical noise. The Weighted Sum method is employed to address design contradictions in different disciplines. Optimizations considering aerodynamic, stealth, and aerodynamic/stealth performance of a flying wing aircraft are conducted to verify the effectiveness of the developed method. The optimization results indicate that exclusive consideration of a singular discipline leads to a significant deterioration in the performance of the other discipline. Balanced performance is achieved through coupling optimization. The numerical noise in the stealth discipline is markedly higher than in the aerodynamics discipline. The results demonstrate that the developed method is capable of addressing aerodynamic/stealth design optimization problems and significantly reducing the number of CFD/CEM evaluations while maintaining global optimization effectiveness.

GPU-powered CFD-DEM framework for modelling large-scale gas–solid reacting flows (GPU- rCFD-DEM) and an industry application

The coupling of CFD (computational fluid dynamics) and DEM (discrete element method) is extensively used for simulating gas–solid reacting flows in various industrial processes, while its high computational cost limits its industry applications, especially large-scale systems with a large number of particles and complex geometries. This paper reports a robust highly efficient GPU (graphics processing unit) − powered CFD-DEM coupling approach that is, for the first time, capable of simulating large-scale gas–solid reacting flow systems with complex geometries (GPU- rCFD-DEM). The fluid flow calculations are performed using CPU parallelization, while the particle flow simulations leverage GPU parallelization, and the coupling calculations between CFD and DEM are fully implemented on GPU. The model includes advanced coupling strategies to enhance numerical stability, especially when handling complex geometries with unstructured CFD meshes. The developed model is validated through experimental measurements and its computational performance is evaluated by comparison with previous GPU-based simulations. It shows good agreement with the experiments and superior performance compared to the traditional coupling method. The model is then applied to simulate raceway dynamics and coke combustion in an industrial-scale blast furnace, showcasing its effectiveness in handling complex geometries and a huge number of particles in gas–solid reacting flows. This work provides an efficient and robust solution for numerically simulating industrial applications of gas–solid reacting flow systems.

Gas and powder flow characteristics of packed bed: A two-way coupled CFD-DEM study

A two-way coupled Computational Fluid Dynamics (CFD) and Discrete Element Method (DEM) calculation was performed to numerically investigate the gas and powder flow characteristics within a packed bed. The analysis and discussion focused on the effects of gas phase velocity, particle shape, and size on the flow behavior of the powders. The results revealed that the average absolute velocity of the powder increased with an increase in the inlet gas flow rate. Conversely, the average dimensionless velocity exhibited the opposite trend. Particle shape significantly impacted the flowability of the powders. A critical value of sphericity equal to 0.96 was observed. For powders with sphericity less than 0.96, the average velocity fluctuated around a progressively decreasing value over time, and the powders tended to accumulate in the inlet region. In contrast, powders with a sphericity greater than 0.96 exhibited average velocities fluctuating around a constant value throughout the simulation. Additionally, a smaller number of these particles remained within the fluid domain, indicating a higher flow rate through the packed bed and ultimately exiting the fluid domain. Regarding the influence of particle size, the flowability reached a minimum value at a radius of 0.14 mm, with the average powder velocity mirroring this trend. Powders with a radius exceeding 0.14 mm demonstrated increasing flowability and average velocity. The observed impact on flowability was likely due to a combination of mechanisms. The findings presented in this paper offer valuable insights into the dynamics of powders within a packed bed. This knowledge can be instrumental in the design and analysis of packed bed reactors.

CFD–DEM method is used to study the multi-phase coupling slag discharge flow field of gas-lift reverse circulation in drilling shaft sinking

To elucidate the distribution law of the multiphase coupling slag discharge flow field in gas-lift reverse circulation during drilling shaft sinking, a numerical analysis model of gas–liquid–solid multiphase coupling slag discharge was established by CFD–DEM (Coupling of computational fluid dynamics and discrete element method) method, taking the drilling of North Wind well in Taohutu Coal Mine as an example. This model presented the distribution of the multiphase flow field in the slag discharge pipe and at the bottom hole, and was validated through experimentation and theoretical analysis. Finally, the impact of factors, including bit rotation speed, gas injection rate, air duct submergence ratio, and mud viscosity on the slag discharge flow field was clarified. The results indicated that the migration of rock slag at the bottom of the well was characterized by “slip, convergence, suspension, adsorption, and lifting”. The slag flow in the discharge pipe exhibited the states of “high density, low flow rate” and “low density, high flow rate”, respectively. The multiphase fluid flow patterns in the well bottom and slag discharge pipe were horizontal and axial flows, respectively. The model test of the gas lift reversed circulation slag discharge and the theoretical model of the bottom hole fluid velocity distribution confirmed the accuracy of the multiphase coupling slag discharge flow field distribution model. The rotation speed of the drill bit had the most significant impact on the bottom hole flow field. Increasing the rotation speed of the drill bit can significantly enhance the tangential velocity of the bottom hole fluid, increase the pressure difference between the bottom hole and annular mud column, and improve the adsorption capacity of the slag suction port. These findings can provide valuable insights for gas lift reverse circulation well washing in western drilling shaft sinking.

Multiphase Numerical CFD Simulation of the Hydrothermal Liquefaction Process (HTL) of Sewage Sludge in a Tubular Reactor

This article presents multiphase numerical computational fluid dynamics (CFD) for simulating hydrothermal liquefaction of sewage sludge in a continuous plug-flow reactor. The discrete particle method (DPM) was used to analyze the solid particles’ interaction in liquid–solid high shear flows to investigate coupling computational fluid dynamics (CFD). Increasing solid particles’ interactions were observed with the increasing liquid velocity. The study examined the influence of parameters such as flow rate, temperature, and residence time on the efficiency of bio-oil production. An increase in temperature from 500 to 800 K caused an increase in the amount of biocrude oil produced from 12.4 to 32.9% within 60 min. In turn, an increase in the flow rate of the suspension from 10 to 60 mL/min caused a decrease in the amount of biocrude oil produced from 38.9 to 12.9%. This study offers insights into optimizing the flow channel of tubular reactors to enhance the HTL conversion efficiency of sewage sludge into biocrude oil. A parametric study was performed to investigate the effect of the slurry flow rate, temperature, and the external heat transfer coefficient on the biocrude oil production performance. The simulation data will be used in the future to design and scale up a large-scale HTL reactor.