01/03/24, 01:12 Static Mixer Tutorial - SimFlow CFD Software

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Static Mixer - CFD Simulation

SimFlow Tutorial

1. Introduction

In this tutorial, we demonstrate a feature called Passive Scalar.

Passive scalar adds an additional transport equation to the system
of governing equations. The passive scalar does not influence the
flow itself but only introduces a marker for tracing fluid transport.
This tutorial is used to track the mixing gases entering from 2
different inlets. The flow is still solved as a single phase and Passive
Scalar only tracks how fluid travels from one inlet and mixes with the
same fluid coming from different inlets. In some cases, this
technique can be used to track different fluids, as long as the
properties of the fluid are very close to each other (density,
viscosity). In postprocessing, you will learn how to create
Streamlines in ParaView.

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2. Download SimFlow

SimFlow is a general purpose CFD Software

To follow this tutorial, you will need SimFlow free version, you may
download it via the following link:
Download SimFlow

3. Create Case

Open SimFlow and create a new case named static_mixer

1 Go to New panel

2 Provide name static_mixer

3 Click Create Case

4. Import Geometry

Firstly we need to Download Geometry StaticMixer

1 Click Import Geometry

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2 Select geometry file staticMixer.stl

3 Click Open

5. Imported Geometry Units

The STL format does not contain the unit information which are
defined during the geometry export. If we do not know the exported
unit, we can estimate it based on the total size of the model. It is
displayed next to Geometry size label. In our case, the default unit
meter is correct.

1 To confirm default unit meter , press OK

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6. Geometry - Static Mixer

After importing geometry, it will appear in the 3D window.

1 Click Fit View to zoom in on the geometry.

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7. Meshing Parameters - Static Mixer

In order to create the mesh, we need to enable meshing for the

imported geometry.

1 Go to Hex Meshing panel

2 Select staticMixer geometry

3 Enable Mesh Geometry

8. Base Mesh - Domain

The imported geometry represents only the mixer blades. By using a

cylinder base mesh we will define the pipe housing.

1 Switch to Base tab

2 Choose base mesh type

Base Mesh Type Cylinder

3 Set the cylinder axis

Axis Z

4 Set the size of the cylinder base mesh:

Length [m] 0.12

Radius [m] 0.0154

5 6 7 Set the following parameters accordingly

Radial Division 12

Axial Division 100

Central Division 21

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9. Base Mesh - Boundaries

We need to assign individual names to each side of the base mesh.

This will allow us to apply different conditions to each side.

1 Choose boundary names accordingly

First Disk inlet
Second Disk outlet

Cylinder wall (double click on the name to type)

2 Choose boundary types accordingly

First Disk patch
Second Disk patch
Cylinder wall

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10. Material Point

Material Point tells the meshing algorithm on which side of the

geometry the mesh is to be retained. Since we are considering flow
inside the cylinder we need to place the material point outside the
blades.

1 Switch to Point tab

2 Specify the location of the material point inside

staticMixer
Material Point 0 0 0.1

You can specify the point location from the 3D view. Hold the
CTRL key and drag the arrows to the destination.

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11. Start Meshing

1 Go to Mesh tab

2 Start the meshing process with Mesh button

12. Mesh

After the meshing process is finished the mesh should appear in the
graphics window.

1 Click Fit View to zoom in the mesh

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13. Check Mesh

Check the mesh quality and cells statistics.

1 Expand the Options list next to default region

2 Select Check option

3 Checks summary will be displayed on the command

window. It also shows checking criteria.

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14. Create Geometry - Box

To provide two different fluids into the mixer, we need to split the
inlet boundary into two separate ones. We will use additional
geometry to mark the selection for the extraction.

1 Go to Geometry panel

2 Select Create Box

3 Set the origin and box dimensions

Origin [m] -0.02 0 -5e-03

Dimensions [m] 0.05 0.02 1e-02

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15. Inlet Boundary (I)

Now, using the new geometry we will extract a new boundary from
the original inlet.

1 Go to MESH panel

2 Expand the Options list next to inlet boundary

3 Select Extract From option

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16. Inlet Boundary (II)

1 Check box_1

2 Click Extract

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17. Inlet Boundary (III)

1 Change the names accordingly

inlet → inlet_scalar0

inlet_in_box_1 → inlet_scalar1
(double click on the name to change it)

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18. Inlet Boundary (IV)

As the results of the extraction, we should receive two separate inlet

boundaries. Both boundaries can be distinguished by the different
colors.

1 Expand Graphics Objects List

2 Uncheck the icon next to the Geometries to hide all

geometry and press the Esc key

3 Check if the inlet boundaries are colored differently

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19. Domain Modification (I)

With SimFlow, the user can also modify the existing mesh domain.
We can extend the volume by extruding a specific boundary. For the
purpose of this tutorial, we will extend the mixer tube by extruding
the outflow face.

1 Select outlet boundary

2 Expand the Options list

3 Select Extrude option

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20. Domain Modification (II)

The outlet boundary will be extended by 5 cm and additional mesh

will be split into 37 cells in the extrusion direction.

1 Set the layer’s number accordingly

Number of Layers 37

2 Set the thickness accordingly

Thickness 0.05

3 Click Extrude

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21. Select Solver - PIMPLE

We want to analyze the incompressible turbulent flow. For this

purpose, we will use the PIMPLE (pimpleFoam) solver.

1 Go to SETUP panel

2 Filter the solvers by Incompressible flow

3 Pick PIMPLE (pimpleFoam) solver from the list

4 Select solver

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22. Turbulence

In this tutorial, we will consider a laminar flow.

1 Go to Turbulence panel

2 Make sure the Laminar model is selected

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23. Transport Properties

In order to define water properties, we go to the transport

properties panel. We will use predefined fluid properties from the
material database.

1 Go to Transport Properties panel

2 Click on Material Database

3 Select the water

4 Click Apply

24. Passive Scalar

We will use passive scalar to simulate the mixing of two different

fluids. Passive scalar adds an additional transport equation to the
system of governing equations. Note, the passive scalar does not
influence the flow itself but only introduces a marker for tracing fluid
transport. The scalar takes a value between 0 and 1 (0 represents
clear water, and 1 represents water with air dissolved in it). To control
scalar properties we can define either the Schmidt number or

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custom diffusivity. In our case, we will define custom diffusivity equal

2.0e-09 which corresponds to the water-air mixture.

1 Go to Passive Scalars panel

2 Press Add new passive scalar Equations button

3 Click on scalar1 to expand options list

4 Check the Custom Diffusivity

5 Set the diffusivity

Diffusivity 2
[m /s] 2e-09

25. Boundary Conditions - Inlet Scalar 0 (Flow)

We will define the constant inlet velocity for both inlets.

1 Go to Boundary Conditions panel

2 Select inlet_scalar0 boundary

3 Set the boundary character

inlet_scalar0 Velocity Inlet

4 Change the type and value of the velocity

U Type Fixed Value

U Value [m/s] 0 0 0.15

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26. Boundary Conditions - Inlet Scalar 1 (Flow)

Repeat these steps for the second inlet.

1 Select inlet_scalar1 boundary

2 Set the boundary character

inlet_scalar1 Velocity Inlet

3 Change the type and value of the velocity

U Type Fixed Value

U Value [m/s] 0 0 0.15

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27. Boundary Conditions - Inlet Scalar 1 (Scalars)

For the inlet_scalar1 boundary set the inflow phase value.

1 Switch to Scalars tab

2 Set the value of scalar1 to:

scalar1 Inlet Value [−] 1

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28. Initial Conditions

Before we start simulation we need to define the initial conditions.

We will specify a constant velocity equal to 0.15 m/s which
corresponds to the inlet velocity.

1 Go to Initial Conditions panel

2 Set the velocity

U 0 0 0.15

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29. Monitors - Create Slice (I)

During calculation, we can observe intermediate results on a section

plane. To add sampling data on a plane we need to define plane
properties and also select variables that will be sampled. Note that
runtime post-processing can only be defined before starting
calculations and can not be changed later on.

1 Go to Monitors panel

2 Switch to Sampling tab

3 Select Create Slice

4 Expand Fields list

5 Select all available options

Fields p U scalar1

6 Normal is defined along Z axis. Set the point to:

Point [m] 0 0 0.05

30. Monitors - Create Slice (II)

Create the next slice above the mixer.

1 Expand Options list next to the slice_1

2 Click Duplicate

3 Click on slice_2 to expand options list

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4 Change the point coordinate

Point [m] 0 0 0.1

31. Monitors - Create Slice (III)

Duplicate the slice once again and move it to the vicinity of the
outlet.

1 Expand Options list next to the slice_2

2 Click Duplicate

3 Click on slice_3 to expand options list

4 Change the point coordinate

Point [m] 0 0 0.15

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32. Run - Time Controls

Before running computations adjust the time controls in order to

capture appropriate time scales of the flow features.

1 Go to RUN panel

2 Set the simulation time

Simulation Time [s] 3

3 Set the time stepping

Time Stepping Δt[s] 1e-03

33. Run - Output

We can control how often results should be saved on the hard drive.
We will write the results at the interval of ` 0.1 ` seconds. Note, that
only saved data will be available during postprocessing.

1 Switch to Output tab

2 Set the write control interval

Write Control Interval [s] 0.1

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34. Run - CPU

Search Docs... Overview Installation Tutorials How To Panels Solvers Validation FAQ

To speed up the calculation process increase the number of CPUs

basing on your PC capability. The free version allows you to use
only 2 processors in parallel mode. To get the full version, you can Start

use the contact form to Request 30-day Trial Geometry

Mesh
Estimated computation time for 2 processors: 20 minutes
Setup
Boundary
Conditions
1 Switch to CPU tab
Monitors
2 Use parallel mode
Run

3 Increase number of CPUs for the computation Postprocessing

Number of processors 2 35. Results -
Slice
36.
4 Click Run Simulation button Postprocessing
- ParaView
37. ParaView -
Load Results
38. ParaView -
Streamline (I)
39. ParaView -
Streamline (II)
40. Advanced
Postprocessing
with ParaView

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35. Results - Slice

Slices tab appears next to Residuals. Under this tab, we can preview
results on the defined slice planes. The results preview is available
during the calculation and we can track it on a regular basis. The
newly calculated time step will be actualized automatically as long
as the time selector points to the latest time step.
We want to check if the fluids are mixed at the end of the mixer. We
will display scalar1 contribution at each slice in the mixer.

1 Change tab to Slice

2 Changed displayed results by selecting scalar1

3 To adjust color range to actually displayed data click

Adjust range to data

4 Play with animation buttons to view the results of the

analysis.

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36. Postprocessing - ParaView

After computations are finished we can do complex visualization of

our results with ParaView.

1 Go to POSTPROCESSING panel

2 Click on Run ParaView

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37. ParaView - Load Results

Load the results into the program.

1 Select static_mixer.foam

2 Click Apply to load results into ParaView

3 After loading results they will be shown in the 3D graphic

window

4 Click on a Load a colour palette from the top menu

and select White Background

38. ParaView - Streamline (I)

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We can visualize the flow by displaying the streamlines.

1 Select Stream Tracer from top menu

2 Set the maximum streamline length

Maximum Streamline Length 0.3

3 Change a seed type

Seed Type Point Source

4 Type the center coordinate and radius of the sphere:

Center 0 0 0

Radius 0.016

5 Uncheck the Show Sphere

6 Increase the number of points

Number of Points 200

7 Click Apply

8 Select the scalar1 from the list

9 Play with animation buttons to track the results of the

analysis.

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39. ParaView - Streamline (II)

To show the geometry together with the streamlines we will follow

below steps:

1 Click on the eye next to static_mixer.foam

2 Select Solid Color from the list

3 Change the opacity

Opacity 0.3

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40. Advanced Postprocessing with ParaView

This concludes the tutorial, covering all the aspects we intended to

showcase. For a finely tuned presentation of the results, you may
take advantage of the more advanced features.

In ParaView, you can display streamlines, contour plots, vector fields,

line or time plots, calculating volume or surface integrals and create
animations.

To familiarize yourself with the ParaView capabilities, it’s worth

checking out our video tutorial, Paraview CFD Tutorial - Advanced
Postprocessing in ParaView, in which we demonstrate some of the
most commonly used post-processing techniques.

Paraview CFD Tutorial - Advanced Postprocessing in ParaView

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