AUSTRALIA SINGAPORE
This CFD simulation aimed to assess the thermal performance of a heat sink, ensuring uniform temperature distribution and verifying that it met the client's specifications for heat dissipation and overall thermal management. The goal was to prevent overheating under operational conditions by optimising airflow and heat transfer, ensuring effective cooling and maintaining system reliability.
The phase involved in this project was: air
This CFD simulation focused on optimising the design of a shell-and-tube heat exchanger by fine-tuning parameters such as the number of tubes, baffle arrangement, and turbulence levels to enhance heat transfer efficiency. The study specifically aimed at identifying and minimising dead zones while improving the internal layout to achieve a more uniform and effective heat distribution across the system. These adjustments ensured maximised thermal performance, supporting a more efficient and reliable heat exchange process.
The phase involved in this project was: liquid medium
This CFD simulation examined the behaviour of ammonia (NH₃) discharges from equipment installed on a building rooftop. The analysis focused on identifying the extent of short-circuiting in the discharges and assessed the impact of a plume with an initial ammonia concentration of 4,000 ppm on nearby structures. The study provided critical insights into plume dispersion dynamics and informed strategies to mitigate potential effects on surrounding buildings.
The phases involved in this project were: ammonia (NH₃) and air
The CFD simulation evaluated the performance of a pre-wetter unit designed to pre-wet solid powder with water. The study aimed to determine the effectiveness of the unit in achieving uniform wetting of the powder. The simulation provided insights into the interaction between the solid particles, water, and air phases, ensuring optimal mixing and wetting performance. The results highlighted areas for design optimisation, enabling improved functionality and efficiency of the pre-wetter unit in industrial processes.
The phases involved in this project were: solid powder, water and air
This CFD modelling and simulation aimed to assess the exhaust recirculation in cooling towers. The key objectives were to determine the extent of exhaust recirculation back into the cooling towers and analyse the temperature distribution in the surrounding area. By evaluating these factors, the study provided insights into improving cooling efficiency and minimising heat accumulation in the vicinity, leading to more efficient operation of the cooling towers.
The phases involved in this project were: liquid medium and air
As established advanced CFD consultants, we specialise in multiphase CFD analysis as a core service. Our simulation engineers deliver projects involving multiphase, multiphysics, multispecies, reaction chemistry, chemical processes, sliding mesh, combustion and energy production processes. We also excel in simulating large particles through Fluent and Rocky DEM coupling.
Despite the increase in computing power and an advancement in computational fluid dynamics (CFD) software, CFD is still a very difficult subject to master because it brings together fluid mechanics, numerical methods, thermodynamics, heat transfer and computer science. Each of this topic is already a difficult subject on its own. Thus, the combination of all these topics only makes CFD technology accessible to select few who have completed advance degrees in CFD and exposed to real-world projects. Despite this, many companies in the commercial world overcome this knowledge barrier by engaging engineering consultants that provide CFD simulation services.
Our CFD consultants use ANSYS Fluent that has well-validated physical modelling capabilities to deliver fast, accurate results across the widest range of CFD and multiphysics applications. As one of the specialised CFD consultancy firms providing CFD simulation services to clients based in Sydney, Melbourne, Brisbane, Perth, Canberra, Adelaide, Darwin, Hobart, Singapore and Jakarta, we have successfully delivered over 100 projects to clients in the chemical & petrochemical, food & beverage, marine and offshore, mining & mineral processing, oil & gas, pharmaceutical, renewable energy, semiconductor and water industries. With a combined CFD experience of over 50 years, Jimmy Lea P/L is considered as the leading engineering and simulation firm within Asia Pacific region.
Our advanced CFD services focus on modelling the following: multiphase, multiphysics, multispecies, reaction chemistry, chemical processes, sliding mesh, combustion and energy production processes.
Below are selected CFD real-world projects that we have successfully delivered to clients. Copyrights and all rights reserved - Jimmy Lea P/L.
This project involved an in-depth CFD analysis of an existing separator for particle sedimentation from water. The analysis aimed to assess the separator's effectiveness and pinpoint performance issues. Following this, a strategy was formulated to optimise the separator's performance, improving its efficiency in separating particles and enhancing water quality.
The phases involved in this project were: liquid medium and air
CFD simulation was performed to calculate and predict the concentration of toxic carbon monoxide (CO) gas emitted by motor vehicles in car park. The objective was to determine the minimum air supply required to dilute the carbon monoxide such that it complies with government statutory requirements.
The phases involved in this project were: carbon dioxide and air
This CFD simulation used a discrete phase model (DPM) to analyse a hot water tea leaf blancher, focusing on whether the turbulence generated by water circulation and air bubbles was sufficient to maintain optimal turbulence. The study aimed to ensure that the blancher operates efficiently, providing effective blanching and preserving tea leaf quality during processing.
The phases involved in this project were: liquid medium, air and solid particles
This CFD simulation investigated the rheological behaviour of time-independent fluids (pseudoplastic and dilatant) and time-dependent fluids (thixotropic and rheopectic). In one scenario, time-independent fluids were subjected to varying shear rates over a constant shearing duration. In another, time-dependent fluids were exposed to a constant shear rate with varying shearing durations. The study aimed to understand the fluid responses under different shear conditions, providing valuable insights into their mixing dynamics. [Click image to see animation].
The phases involved in this project were: liquid medium 1 and liquid medium 2
The project involved designing a heat dissipation system using CFD for a 12 MW turbine and alternator in an enclosure. Part 1 specified fan installation, using CFD to determine the minimum flowrate, optimal fan number, and placement for efficient cooling. Part 2 focused on designing a chimney stack to minimise hot air recirculation, determining its optimal location, height, and diameter. The report included qualitative and quantitative analyses, such as temperature and velocity profiles, to demonstrate system effectiveness.
The phase involved in this project was: air
This transient CFD simulation predicted the time needed for smoke to spread throughout a manufacturing facility in the event of a fire. The study analysed smoke concentration at various locations and estimated evacuation times to enhance safety planning. By understanding the smoke propagation dynamics, the simulation helped develop effective emergency response strategies, ensuring timely evacuation and minimising potential health hazards for personnel during fire incidents.
The phases involved in this project were: smoke and air
In deep-sea oil exploration at depths over 1000 metres, equipment faces extreme pressures and harsh conditions. A subsea pipe in the upstream oil and gas industry caused production streams to jet against the production casing, leading to wear. To address this, a modified pipe design redirected the flow upward upon exiting the holes, minimising impact. Multiphase CFD analyses, accounting for water, oil, gas, and sand, were conducted to optimise the design and reduce erosion.
The phases involved in this project were: water, oil, gas and sand
We successfully used CFD to optimise mixing, flow distribution, and reactor performance in a water and wastewater project. The simulation featured a multi-compartment reactor with baffles and mixers, with streamlines illustrating flow patterns and turbulence. This analysis ensured uniform flow distribution and effective chemical blending while identifying and resolving dead zones and inefficiencies. By enhancing reactor performance and energy efficiency, we improved water quality, reduced operational costs, and validated the design before implementation, eliminating the need for extensive trial-and-error.
The phases involved in this project were: air and fluid medium
This CFD analysis investigated cavitation within a vortex drop and its effects on structural integrity. The study identified areas prone to pipe lining delamination caused by pressure fluctuations and evaluated the air-core ratio within the vortex. Erosion modelling, incorporating fine suspended sand particles, was conducted to predict material loss in vulnerable regions. The findings offered critical insights into potential wear mechanisms, supporting maintenance strategies and design optimisation to enhance long-term durability and performance.
The phases involved in this project were: liquid medium, air and solid particles
This CFD performance study provided insights into open channel flow over a weir, focusing on understanding water dynamics to enhance flood prevention and water control. By analysing the complex interactions between water, air, and solid particles, the study enabled engineers to design and optimise the weir's geometry, achieving a precise flow rate that mitigated flooding risks. The results ensured that the weir structure functioned effectively within water management systems, offering a robust solution to control flow and maintain system reliability in diverse conditions.
The phases involved in this project were: liquid medium, air and solid particles
This transient multiphase CFD study simulated the impact of waves on concrete matting along a lagoon embankment to assess the erosion rate. The study aimed to predict how wave energy and particle impact would wear down the concrete over time. By modelling the interaction between the liquid medium, air and solid particles, it provided insights into the areas most susceptible to erosion, helping to improve the design and longevity of such structures in harsh environments.
The phases involved in this project were: liquid medium, air and solid particles
The image illustrated a CFD simulation of LNG vapour dispersion, showcasing how the gas spread and diluted over time. Colour gradients were used to represent varying concentrations, clearly highlighting high-risk areas where the potential for a vapour cloud explosion existed. The simulation also visualised flow patterns and turbulence as the LNG vapour dispersed into the surrounding environment. This provided critical insights into the behaviour of the gas and its associated hazards, supporting risk mitigation strategies and safety planning.
The phase involved in this project was: gas
This CFD assessment used transient simulations to calculate the drag coefficient of a boat’s hull and the thrust produced by its propellers. These results were combined to predict the boat's maximum speed, providing valuable insights for optimising the design and performance of the vessel.
The phases involved in this project were: liquid medium and air
This CFD heat transfer study aimed to determine the minimum flow rate required for a heating medium to avoid maldistribution in the manifold. The goal was to ensure uniform flow across the system, with no more than 5% variation between tubes. By optimising flow conditions, the study helped prevent inefficiencies or overheating in specific areas, ensuring consistent heat distribution throughout the system.
The phases involved in this project were: liquid medium and air
This CFD assessment analysed the heat dissipation from generators in a building housing data centres. The study aimed to understand the heat dispersion profile and evaluate whether the emitted heat was recirculating back into the building. The results provided insights into the effectiveness of the cooling system and highlighted potential areas for improvement in managing heat emissions to maintain optimal conditions inside the facility.
The phases involved in this project were: plume and air
This CFD simulation analysed plume emissions from an offshore oil platform to assess their impact on helicopter take-off and landing operations. The study offered crucial insights that guided the safe placement of the landing platform, ensuring it remained free from plume interference. This approach significantly enhanced the safety of helicopter operations by reducing potential risks associated with exhaust plume interactions, thereby improving the operational reliability of the platform’s aviation facilities.
The phases involved in this project were: plume and air
This CFD analysis evaluated erosion rates inside a steel pipe caused by solid particles in a liquid medium. It revealed that erosion occurred mainly at bends or areas where the fluid's direction changed sharply, as these regions experienced increased particle impact and turbulence. The study demonstrated how flow dynamics, including velocity and pressure changes, contributed to erosion, particularly in areas with higher wear due to directional shifts in fluid flow.
The phases involved in this project were: liquid medium, air and solid particles
Condensation inside a building is a severe issue since if it is not rectified, this ongoing condensation may lead to dampness-related problems to the walls, windows, fittings and fixtures. Problems may include buckling of fittings, staining, peeling of paints and the growth of mould. Prolonged exposure to mould is known to cause various health issues. Our consultants using CFD and by factoring the relative humidity, wall surface temperature and room temperature, predicted that condensation would occur at the ceiling of the building.
The phase involved in this project was: air
This multiphysics CFD analysis aimed to optimise the design of a UV photoreactor by examining critical parameters such as UV irradiation exposure, flow profile, turbulence; and the positioning of UV tubes, inlets, and outlets. The study focused on enhancing the efficiency of the reactor by ensuring uniform UV exposure and optimising flow dynamics to minimise dead zones and ensure effective irradiation of the fluid, improving overall performance and treatment efficiency.
The phases involved in this project were: liquid medium and air
This CFD simulation visualises the airflow inside a silo where hot air is injected through a hexagon-shaped diffuser to maintain a target macro temperature of 50°C for the stored polystyrene beads. The streamlines illustrate efficient circulation, ensuring uniform temperature distribution and preventing cold spots near the silo walls. This design helps stabilise the internal conditions, reducing temperature variations and enhancing the overall performance of the storage and handling process.
The phase involved in this project was: air
This project employed CFD simulations to analyse the accidental release of a highly flammable fluid from a major hazard facility (MHF). The simulations, validated by in-house chemical engineers, revealed that the evaporated fluid concentration ranged between the lower (LFL) and upper flammability limits (UFL), indicating the potential for a flammable atmosphere. The study provided critical data to assess explosion risks and improve safety measures for hazard management.
The phases involved in this project were: liquid medium and air
This CFD analysis focused on airflow and particle movement in a cleanroom environment with a perforated floor. The study characterised the airflow profile around a wafer box and table, simulating how particles behaved under different conditions. The results identified potential contamination risks and optimised cleanroom design to maintain a high standard of air quality, ensuring the integrity of sensitive manufacturing processes and reducing contamination-related defects.
The phases involved in this project were: air and solid particles
This CFD analysis focused on optimising sump pump design to reduce air entrainment and improve performance by eliminating vortex formation. Through detailed multiphase analysis, the study examined complex interactions between air and water within the sump, identifying conditions that led to air intake issues, inefficiencies and mechanical wear. By redesigning key aspects of the sump to prevent vortex formation, the optimised configuration enhanced pump reliability, minimised maintenance needs and ensured efficient operation in varying flow conditions.
The phases involved in this project were: liquid medium and air
This CFD study investigated the mechanics of coal particle erosion, focusing on tracking particle movement and impacts to evaluate erosion from coal piles. The analysis identified effective design strategies, such as implementing barriers, to minimise erosion and contain particles efficiently. The results provided valuable insights into optimising flow dynamics to reduce particle-induced wear and protect equipment and structures from erosion damage, supporting the development of more efficient and durable systems.
The phases involved in this project were: air and solid particles
Based on the attached CFD results, the simulation analysed the impact of a pipe explosion within a bunker, highlighting the propagation of pressure waves. The visualisation showcased velocity contours and pressure distribution, illustrating the high-energy interaction with the bunker walls. The results provided critical insights into potential structural vulnerabilities and air movement within confined spaces, enabling improved design strategies for blast mitigation and nearby personnel safety.
The phase involved in this project was: air
This CFD simulation evaluated the performance of a water-oil-gas separator unit, focusing on the separation efficiency of the three phases. The analysis assessed flow behaviour, phase distribution, and interface dynamics within the separator. The results demonstrated the unit's ability to effectively separate water, oil, and gas, ensuring optimal operational performance and reliability. Key insights from the study supported design enhancements to improve separation efficiency, minimise pressure drop, and maintain stable operation under varying flow conditions.
The phases involved in this project were: water, oil and gas
This CFD simulation assessed how much sand would be dispersed from a truck carrying a sand pile, the distance the sand travelled, and the amount deposited on neighbouring buildings. The study also identified residential areas most affected by this sand transport process. The results were used to develop strategies to mitigate sand dispersion and reduce its impact on surrounding environments and communities.
The phases involved in this project were: air and solid particles
This CFD analysis focused on characterising the water flow profile within a ground storage reservoir (GSR). It aimed to predict the residence time distribution (RTD), identify any potential plug flow conditions, and assess the presence and severity of cavitation at the suction side of the reservoir pumps. These insights were critical for optimising the reservoir's design and ensuring efficient operation.
The phases involved in this project were: liquid medium and air
The airport passengers reported feeling excessively hot and humid, prompting the airport authority to engage us to use CFD for troubleshooting. Our scope of work involved conducting a detailed thermal comfort simulation, which considered both temperature and humidity levels within the facility. The CFD analysis identified the underlying causes of the discomfort, and the final report provided recommendations to optimise the thermal environment, ensuring improved comfort for passengers while also balancing energy efficiency.
The phases involved in this project were: air and water
This CFD analysis evaluated the performance of a water clarifier in a wastewater treatment plant, focusing on design configurations that included the energy dissipating inlet (EDI), flow rates, capacity, and the properties of settling materials. The study assessed how effectively the clarifier handled suspended particles, managed flow dynamics, and enhanced sedimentation processes. The findings led to an optimised clarifier design, improved system efficiency, and ensured the treated water consistently met quality standards.
The phases involved in this project were: liquid medium, air and solid particles
This CFD design verification project was conducted to ensure the tank design performed effectively before fabrication. The tank was designed to handle multiple phases, including solid particles, a liquid medium, and air. Key objectives of the analysis included reducing turbulence levels, preventing particle agglomeration, and minimising or eliminating air entrainment into the outlet pipe. The study provided critical insights to validate and refine the design, ensuring optimal performance and efficiency in operation.
The phases involved in this project were: liquid medium, air and solid particles
This CFD simulation evaluated the performance of a cyclone separator by testing multiple design variants under different operating conditions. Each variant was simulated several times to assess the impact of key parameters on separation efficiency and pressure drop. The objective was to find a design that optimised performance and cost. After a comprehensive analysis, the most cost-effective design with the best separation efficiency was chosen for detailed design, ensuring the selected cyclone met performance criteria while minimising costs.
The phases involved in this project were: liquid medium and solid particles
This CFD simulation analysed the performance of a waste gas scrubber, focusing on the interaction between the liquid and gas phases. The study evaluated the scrubber's efficiency in removing contaminants from waste gases by examining flow patterns, droplet dispersion, and gas-liquid interactions within the scrubber. The results provided critical insights to optimise the scrubber design, ensuring maximum pollutant removal efficiency and operational reliability. Additionally, the analysis determined the concentration of gas exiting the scrubber, enabling precise performance evaluation and design improvements
The phases involved in this project were: liquid medium and gas pollutants
This project involved a comprehensive CFD analysis of the pressure drop across acid, solvent, and ammonia (NH₃) extraction HVAC ducts within a 4-storey manufacturing facility. The simulation provided detailed insights into the pressure levels, whether vacuum or positive, at critical points throughout the system. Using the results, various "what if" scenarios were simulated to evaluate potential operational adjustments and their effects on system performance.
The phase involved in this project was: air
A CFD study was conducted on a large water storage tank to evaluate the effectiveness of mixing using a recirculation pump. The primary objective was to prevent sedimentation and the accumulation of solid particles, which can compromise tank performance. The study identified dead zones and areas with stagnant flow that contributed to product stratification. By addressing these issues, the findings improved tank design and operational efficiency, ensuring better flow distribution and reducing the risk of sediment build-up.
The phases involved in this project was: air, water and solid particles
This CFD simulation characterised gas diffusers by analysing hole diameters, locations, numbers and diffuser tube length. Following this characterisation, the diffuser was optimised to enhance mass transfer rates while minimising gas flow rate, leading to more efficient gas diffusion in the system. This study provided valuable insights for improving the overall performance of the diffuser.
The phases involved in this project were: liquid medium and air
This CFD study analysed a multiphase mixing tank to optimise solid particle suspension and mixing efficiency. Key performance metrics included homogeneity, dead zones, flow patterns, power number and blending time. The investigation focused on variables such as baffle number and configuration, impeller count and diameter. The goal was to enhance flow efficiency, minimise stagnant zones and ensure effective mixing, providing insights into design improvements for optimal tank performance and reduced energy consumption. [Click image to see animation].
The phases involved in this project were: liquid medium, air and solid particles
This CFD study assessed the performance of a static mixer, focusing on its efficiency in mixing both Newtonian and non-Newtonian fluids. The objective was to evaluate the residence time distribution, ensuring uniform mixing and minimising dead zones. By analysing the flow behaviour and identifying potential areas for optimisation, the study aimed to improve the mixer's design for enhanced efficiency and reduced energy consumption, ultimately leading to a more effective and consistent mixing process.
The phases involved in this project were: liquid medium 1 and liquid medium 2
This CFD analysis evaluated a globe valve to assess erosion rates, flow profiles, and turbulence levels under various operational conditions. The study offered detailed insights into areas vulnerable to erosion, facilitating targeted design enhancements. These improvements boosted the valve’s durability by minimising material wear and ensuring consistent performance, even in challenging environments. The findings played a crucial role in extending the valve's operational lifespan and ensuring its reliability in critical systems.
The phase involved in this project was: liquid medium and solid particles
CREDIBILITY OF CFD SIMULATION RESULTS
Whilst the results from manual or traditional engineering calculations are relatively easier to check, unfortunately, due to the complexity involved in the iterations of non-linear partial differential equations, checking CFD calculations can be tedious whereas conducting physical validations to determine the accuracy of CFD results may be impractical and/or economically prohibitive. Consequently, users may have to rely on CFD results per se to make informed decisions which may involve safety consequences or pecuniary value in the magnitude of several hundred million of dollars. Obviously, having accurate CFD results will inspire confidence in the decision-making process. The accuracy of CFD results depend on six governing factors, namely:
- Boundary conditions (information to be provided by the client)
- Engineering knowledge of the subject matter
- Experience and track record of the firm in performing similar CFD projects
- Qualification and experience of the CFD specialist performing the simulation
- Quality control system
- Simulation software and hardware employed
One of the most important factors that determines the accuracy of any CFD result is the boundary conditions (BCs). Each of the mathematical equations requires meaningful values at the boundaries of the fluid domain for the calculations to generate reliable results. These numerical values are known as the boundary conditions and can be specified in several ways although in general the specification of multiphase phenomena or phenomena involving reactions is more complex than single phase phenomena. The use of wrong or inaccurate BCs will render the results inaccurate and must be prevented before modelling and simulation commence. We work closely with the clients and provide guidance to ensure that the BCs provided are meaningful, accurate and will lead to results that meet the objectives of the CFD studies. We have successfully delivered projects across many industries which exceeded client’s expectations both from the private and public sectors. The knowledge gained from an industry or project becomes part of the collective experience of the firm and is applied as when required to engineering problems emanating from other industries or projects. Thus, with a strong track record in delivering challenging engineering projects, we know exactly what to do, what directions to take and is strongly poised to provide the most appropriate recommendations to the clients.
All our simulation results are vetted by discipline engineers to ensure the results are realistic and the recommendations ensued are practical and implementable. We work closely with the clients to devise the most cost-effective solutions. At Jimmy Lea P/L, our discipline engineers consist of experienced chemical, civil, electrical and mechanical engineers. Clients are assured that our simulation results and the recommended solutions have been endorsed by our in-house discipline engineers.
Performing CFD simulations without proper knowledge may lead to misleading results. At Jimmy Lea P/L, only CFD consultants with a PhD qualification specialised and experienced in CFD are assigned to deliver CFD-related projects. We offer CFD consulting services substantiated by over 50 years of combined experience using ANSYS Fluent. Currently, our CFD specialists undertake complex projects related to aerodynamic, multiphase, multispecies, multiphysics, reaction chemistry, sliding mesh, combustion, energy and solidification-melting processes. With several PhDs specialised in CFD on-board, it is unsurprising that many clients consider us as a truly specialised engineering firm offering serious CFD consulting as one of its core services. To consistently deliver high quality reports, all projects are subjected to our stringent quality control system. Every stage is checked and reviewed to ensure the inputs or results are numerically accurate and make engineering-sense before being allowed to proceed to the next stage. This strategy prevents small errors emanating from each stage to snowball into a large error which ultimately affects the accuracy of the final results. Upon completion of all modelling and simulation iterations, the final results are independently reviewed by another PhD who has equivalent or more experienced in CFD-related projects. Eventually, all results and reports generated will be approved by our Engineering Director prior to submission to ensure a match between what the clients require and what is delivered.
Finally, we own ANSYS CFD perpetual licence with high performance computing (HPC) capability which enables parallel processing of the toughest, higher-fidelity models including more geometric details, larger systems and more complex physics. This provides a more accurate and detailed insight into the performance of a proposed design at a significantly shorter delivery time. In addition, by continually performing high fidelity simulations, we empower our clients to innovate new products or systems with a high degree of confidence that the accurate simulation results are predicting the actual performance of their products or systems under real-world conditions. ANSYS Fluent employs heavily validated models which provide assurance to stakeholders of high accuracy results. ANSYS fluid simulation solvers represent more than 1,000 person-years of R&D. This effort translates into the key benefits of fluid simulation software from ANSYS namely: experience, trust, depth and breadth. The CFD core solvers from ANSYS are trusted, used and relied upon by organisations worldwide.
The CFD simulation assessed heat dissipation in a transformer room to evaluate the time required to achieve steady-state temperature conditions. The study considered all heat sources and sinks, including the effects of heat conduction and flux through the walls. The transient analysis provided insights into temperature distribution and helped optimise cooling strategies, ensuring safe operation and preventing overheating of critical equipment in the transformer room.
The phase involved in this project was: air