At Zeta Dynamics, we leverage cutting-edge technology and proven methodologies to deliver accurate and efficient Computational Fluid Dynamics (CFD) simulations. Our process combines advanced software tools, expert knowledge, and a deep understanding of fluid dynamics to provide reliable solutions for your engineering challenges. Here's how we do it:

Step 1: Understanding Your Needs

Before diving into simulations, we make sure we fully understand the specific problem you need to solve. Whether you're dealing with heat transfer, fluid flow, or aerodynamics, we work closely with you to define the goals, constraints, and parameters of the project. This ensures that our simulations are tailored to your unique requirements, saving you time and resources.

Step 2: Data Collection and Preparation

Once the scope is defined, we begin collecting the necessary data to create an accurate simulation. This includes geometry, boundary conditions, material properties, and environmental factors. We ensure the quality and accuracy of the data, whether it comes from CAD files, physical testing, or operational data, to create a realistic representation of the system or product.

Step 3: Model Setup and Meshing

In this stage, we convert your real-world system into a digital model suitable for simulation. Using advanced meshing techniques, we break down the geometry into small, manageable elements that allow for accurate computation. The quality of the mesh directly influences the accuracy of the results, so we apply refined meshing strategies where necessary, particularly in areas with complex flows or high gradients.

Step 4: Simulation and Solver Configuration

Next, we configure the CFD solvers to replicate the fluid dynamics of your system under various conditions. Our team utilizes industry-leading software and algorithms to model fluid behaviour, turbulence, heat transfer, and other physical phenomena. We ensure the proper selection of models and solver settings to optimize for accuracy and computational efficiency.

Step 5: Results Interpretation and Validation

After running the simulations, we carefully analyze the results to extract meaningful insights. Using visualization tools like velocity fields, temperature contours, and pressure distributions, we provide a clear and understandable interpretation of the simulation data. If needed, we validate our findings through comparison with experimental data or industry benchmarks to ensure the credibility of the results.

Step 6: Optimization and Recommendations

With the results in hand, we identify areas for improvement or optimization. Whether it’s enhancing the design for better efficiency, reducing energy consumption, or improving product performance, we provide actionable recommendations based on our simulations. Our goal is to help you make data-driven decisions that lead to better outcomes, faster time-to-market, and reduced costs.

Step 7: Ongoing Support and Iteration

Our commitment doesn’t end with the final report. We offer ongoing support to ensure your project evolves with new insights and technological advancements. If your design or parameters change, we’re ready to re-simulate, iterate, and provide updated recommendations to ensure continued success.

Software’s we use for Simulations

We use the following software depending on the simulation requirements.

1. CAD Design and Simulation with SolidWorks

• Purpose: SolidWorks is a CAD (Computer-Aided Design) and CAE (Computer-Aided Engineering) software widely used for 3D modelling, design validation, and simulation.

• Key Features:

  • Parametric and direct 3D modelling.

  • Structural, thermal, and fluid dynamics simulations.

  • Motion analysis for dynamic systems.

  • Product lifecycle management (PLM) tools.

• Applications: Used in mechanical engineering, product design, and manufacturing industries to create and test prototypes virtually.

2. Expertise with CHEMCAD Simulation Software

• Purpose: CHEMCAD is a chemical process simulation software tailored for chemical engineers.

• Key Features:

  • Process flow simulation for steady-state and dynamic conditions.

  • Equipment sizing and optimization.

  • Thermodynamic property estimation.

  • Heat exchanger and distillation modelling.

• Applications: Commonly used for chemical plant design, troubleshooting, and optimization.

3. Modelling with ASPEN Simulation Software

• Purpose: Aspen Plus is a powerful process modelling software for optimizing chemical processes.

• Key Features:

  • Process flow diagram (PFD) modelling.

  • Thermodynamics and reaction kinetics library.

  • Mass and energy balance calculations.

  • Equipment sizing and economic analysis.

• Applications: Utilized in the design, optimization, and analysis of chemical processes, particularly in the oil & gas and petrochemical industries.

4. Modelling with HYSYS Simulation Software

• Purpose: Aspen HYSYS is a process simulation tool specifically for oil & gas and energy industries.

• Key Features:

  • Dynamic process simulation.

  • Process optimization and troubleshooting.

  • Multiphase flow modelling.

  • Gas processing and LNG simulation.

• Applications: Focused on energy systems, refinery operations, and natural gas processing.

5. Modelling with ANSYS Simulation Software

• Purpose: ANSYS is a multiphysics simulation software for engineering analysis and design.

• Key Features:

  • Finite Element Analysis (FEA) for structural and thermal problems.

  • Computational Fluid Dynamics (CFD) for fluid flow and heat transfer.

  • Electromagnetic and acoustics simulations.

  • Fatigue, failure, and optimization analysis.

• Applications: Used in aerospace, automotive, and mechanical engineering for detailed system modelling and validation.

6. Modelling with OLI Simulation Software

• Purpose: OLI Studio focuses on electrolyte and water chemistry simulations.

• Key Features:

  • Thermodynamic modelling of electrolytes.

  • Corrosion prediction.

  • Scale formation and solubility analysis.

  • Process simulation for aqueous and brine systems.

• Applications: Critical in industries like water treatment, oil & gas, and mining for chemical process optimization.

7. Detailed Mass & Energy Balance Analysis

• Purpose: Involves calculating and validating the input-output balances of materials and energy in a process.

• Key Features:

  • Identifying inefficiencies in process design.

  • Ensuring conservation laws (mass and energy) are followed.

  • Supporting process scaling and optimization.

• Applications: Used in chemical, mechanical, and environmental engineering to design efficient systems.

8. Aspen Exchanger Design and Rating (EDR) Software for Heat Exchangers

• Purpose: Aspen EDR is a specialized tool for designing and rating heat exchangers.

• Key Features:

  • Thermal and mechanical design of heat exchangers.

  • Customizable simulation models for shell-and-tube, plate, and air-cooled heat exchangers.

  • Performance analysis and optimization.

• Applications: Common in energy systems, petrochemical processes, and HVAC industries.

9. System Hydraulics Analysis

• Purpose: Analysing fluid flow and pressure drops within a hydraulic or piping system.

• Key Features:

  • Calculation of flow rates and pump requirements.

  • Pressure drop analysis and flow distribution.

  • Optimization of pipeline and equipment design.

• Applications: Vital for the design of piping networks, process plants, and fluid transport systems.

10. User-Friendly Simulation Spreadsheet Interfaces

• Purpose: Creating simulation tools in spreadsheet software (e.g., Microsoft Excel) for ease of use and accessibility.

• Key Features:

  • Pre-programmed formulas for process calculations.

  • Integration with VBA (Visual Basic for Applications) for automation.

  • Visual dashboards for results interpretation.

• Applications: Used by engineers to simplify complex calculations and share results.

11. Computational Fluid Dynamics (CFD) Modelling of Processes

• Purpose: Simulating fluid flow, heat transfer, and associated phenomena using CFD software.

• Key Features:

  • Detailed analysis of turbulence, heat transfer, and chemical reactions.

  • Meshing tools for complex geometries.

  • Time-dependent or steady-state analysis.

• Applications: Critical for designing efficient fluid systems, such as mixing vessels, reactors, and HVAC systems.

Let me know if you'd like to dive deeper into any of these topics or software!

Modelling we do in ANSYS Fluent 

•                     Turbulence Modelling

•                     Combustion Modelling

•                     Multiphase Modelling

•                     Heat Transfer Modelling

•                     Acoustics Modelling

•                     Species Transport Modelling

•                     Discrete Phase Modelling (DPM)

•                     Mesh Deformation Modelling (Dynamic Mesh)

•                     Moving Mesh Modelling

•                     Particle Tracking Modelling

•                     Discrete Element Modelling

•                     Fluid Structure Interaction Modelling (FSI)

•                     Optimization Modelling (RBF Morph)

•                     Design of Experiments Modelling (DOE)

•                     Automation Modelling

•                     User Defined Functions Modelling (UDF)

•                     Turbomachinery Modelling

•                     Radiation Modelling

•                     Thermal FSI Modelling

•                     Large Eddy Simulation Modelling (LES)

•                     Solidification and Melting Modelling

•                     Fan Modelling