FlowSim Pro™ CFD Suite
Advanced Computational Fluid Dynamics platform for industrial water system design
Development
24 months R&D
7 years of evolution
Team
28 engineers
CFD + Software specialists
Deployment
Major Petrochemical Complex
500 MLD cooling systems
The Engineering Challenge
Industrial water systems involve complex fluid dynamics with heat transfer, multi-phase flows, and chemical reactions. Traditional design approaches rely on empirical correlations and safety factors, often resulting in oversized equipment and suboptimal performance. The petrochemical facility's cooling tower system was experiencing thermal inefficiencies and uneven flow distribution, leading to 20% higher energy consumption and frequent hot spots requiring expensive retrofits.
FlowSim Pro™ Solution
We developed a comprehensive CFD simulation platform specifically designed for industrial water systems, featuring advanced turbulence models, multi-phase capabilities, and specialized water treatment modules for accurate design optimization and performance prediction.
CFD Simulation Capabilities
Advanced Numerical Solvers
Fluid Flow Solvers
SIMPLE/PISO algorithms for pressure-velocity coupling
Density-based solver for high-speed water jets
VOF, Eulerian, and DPM models for complex flows
Turbulence Models
Enhanced turbulence model for industrial applications
Superior near-wall treatment for complex geometries
High-fidelity simulations for critical design areas
Heat Transfer Models
Coupled fluid-solid heat transfer analysis
P1, DO, and S2S radiation models
Boiling, condensation, and solidification
Mass Transfer & Chemistry
Multi-component mass transfer with reactions
Finite rate and mixing-limited reactions
Corrosion and electrolysis simulations
Specialized Industrial Water Modules
Cooling Tower Design
Comprehensive modeling of cooling tower performance
Membrane Systems
RO, UF, and MF membrane module simulation
Heat Exchanger Networks
Shell-and-tube, plate heat exchanger optimization
Professional Software Features
User Interface & Workflow
Direct import from SolidWorks, CATIA, AutoCAD
Automatic mesh adaptation based on solution gradients
Convergence tracking with interactive residual plots
Automated design optimization with DOE methods
Advanced Computing Features
MPI-based scaling up to 1000+ cores
CUDA/OpenCL for 5-10x faster computations
AWS/Azure integration for large-scale simulations
Python/MATLAB integration for workflow automation
Validation & Industry Standards
Experimental Validation
Validated against 200+ experimental datasets
Industry Standards
Compliance with international standards
Quality Assurance
Rigorous testing and documentation
Major Petrochemical Complex Case Study
Design Optimization Results
- • Cooling tower efficiency improved by 18% through fill optimization
- • Heat exchanger surface area reduced by 12% with enhanced designs
- • Pressure drop reduced by 25% through optimized flow distribution
- • Energy consumption decreased by 22% (₹8.5 Cr annual savings)
Engineering Benefits
- • Design cycle time reduced from 8 weeks to 2 weeks
- • Eliminated need for physical prototyping (₹2.2 Cr savings)
- • 95% reduction in hot spots through flow optimization
- • Maintenance requirements reduced by 30% through better designs
Client Success Story
"FlowSim Pro has revolutionized our approach to industrial water system design. The detailed CFD analysis capabilities have enabled us to optimize our cooling systems with unprecedented accuracy. We've achieved significant energy savings and eliminated performance issues that plagued our previous designs. The software's specialized modules for industrial water applications and excellent technical support make it an indispensable tool for our engineering team."
Transform Your Engineering Design Process
Leverage cutting-edge CFD technology to optimize your industrial water systems. Reduce design time, improve performance, and achieve significant cost savings through advanced simulation.