This study underscores fluid density's significance in CFD simulations for porous materials, addressing its impact on accuracy and computational efficiency. The paper proposes a tailored form of Navier-Stokes equations that accounts for fluid density's influence on CFD analyses of porous materials in industrial contexts, including cases where the solid phase is deformable. Numerical analyses demonstrate fluid density's significance (ρ≠constant) and explore the importance of the energy equation in governing equations. The energy equation is essential in setting up the governing equations, as it calculates thermal characteristic length based on cell temperatures. By examining various porous material samples, the study suggests a streamlined approach: employing a single coupled CFD-FEM simulation to directly determine each geometrical parameter. Additionally, the study investigates the capability to accurately simulate turbulent fluid motion at the pore scale and analyze the flow field characterization within porous media. Computational cost analyses underscore the advantages of coupled simulations, establishing their profitability over separate parameter-specific simulations.
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