Simulation solutions for the process industry is helping companies with significant engineering improvement in their asset- and process equipment efficiency and reliability. The required advancements can directly impact product and process performance, sustainable and green engineering, and ultimately corporate profitability.
From equipment and processes to chemical and petrochemical refining to glass and metals manufacturing, process-focused customers use ANSYS simulation solutions for the process industries to reduce overall costs, conserve energy, minimize environmental impacts, meet higher regulatory standards, and streamline product development and operations through a range of initiatives.
ANSYS solution set includes CFD for chemical process Industry, FEA for process industry and expand to cover electromagnetic and system design engineering concerns.
The Business Case for Material Intelligence
The impact of materials information on productivity, innovation, cost and risk in the engineering enterprise
Chemicals and Petrochemicals
Across the chemical and petrochemical industry, safety, process optimization, energy usage, emission reduction and new product innovation drive advanced engineering and technology development. ANSYS engineering software solutions and services can be used alongside experiments, testing and other process simulation tools. The advantages include detailed, high-fidelity design and analysis of equipment and processes.
Glass manufacturing is complex and resource-intensive — making it ideally suited to ongoing process improvements supported by engineering simulation. Software and simulation technologies from ANSYS can help glassmakers to model the many physical, chemical and thermal processes that occur during glass production and forming — enabling meaningful improvements in process efficiency, product quality and overall cost.
As worldwide demand for engineering materials has steadily increased, environmental pressures have intensified as well. To help address energy demands, process economics and other issues, engineering simulation via ANSYS technology is becoming a critical tool to help metals manufacturers balance time, price, sustainability and quality pressures.
Mining is an increasingly technology-driven industry, providing engineers with an opportunity to make significant improvements in established processes and equipment — while also creating a new generation of mining capabilities.
In the last few decades, polymers have emerged as a cost-effective, flexible solution for numerous applications in the materials and chemical processing industries. Because of their light weight, impact strength and processability at relatively low temperatures, plastic and rubber parts have experienced enormous growth in demand, despite surging oil prices and competition from alternatives such as metals and glass. At the same time, global competition continues to put pressure on profit margins and time to market, pushing manufacturers to constantly innovate in the areas of product performance and production efficiency.
Process equipment designers, manufacturers and operators are challenged daily to transfer, mix, separate, heat, distill, combust, react, store, package and extend the life of the nearly 70,000 products that the chemical and processing industries provide. By using large amounts of heat and energy to mechanically or chemically transform materials, these industries help to meet the world's most fundamental needs for food, shelter and health. The industry's ecosystem also creates products that are vital to computing, telecommunications and biotechnology.
Water and Wastewater
Water and wastewater companies face significant challenges as they seek engineering solutions to collect, drain, store, transport, treat, discharge and distribute water safely and effectively. These organizations rely upon a multitude of physical analyses — including computational fluid dynamics (CFD), hydraulics and mass transfer predictions — to model and verify the behavior and flows of water under a wide range of conditions.
Reaction and combustion systems generate heat as an essential part of many processes. Improving heat generation operations along with related emissions control and performance efficiency are continual challenges to combustion engineers. ANSYS computational fluid dynamic (CFD) solutions are used across a wide range of applications, from gas turbines to flares and coal combustion to flameless combustion and low-Nox burners to oxy-fuel combustors, gasifiers and biomass furnaces. By coupling CFD with ANSYS structural solutions, engineers have access to a unified environment for evaluating the entire combustion system — including thermal stresses, vibration and fatigue.
The performance and structural integrity of gas–liquid systems can be greatly enhanced using ANSYS solutions. Engineers trust ANSYS fluid mechanics software to model systems with or without heat and mass transfer/reaction in a broad range of applications in which fluid and gases are transported or processed.
Heat Generation and Heat Transfer Equipment
The generation and transfer of heat play a critical role in the materials and chemical processing industries. Chemical, petrochemical and refining engineers — as well as equipment designers — recognize that they need to understand and manage every BTU of available heat to maximize the performance of their processes. With the current emphasis on energy efficiency — and the growing pressure to improve margins in a difficult economy — heat generation and transfer are gaining more and more attention in process-based industries.
Measurement and Control
Engineers focusing on measurement and control systems — including valves, flow meters, sensors, filters and pumps — face special challenges: They are tasked to ensure a perfect level of accuracy while working with complex systems and multiple physical effects.
Advances in computational methods have brought science-based analysis to mixing design. Once considered more art than science, mixing today is an important unit process in many industries. Software from ANSYS can be applied as an integrated component of the computer-aided engineering process, helping process equipment designers and mixing engineers to understand, predict and improve the performance of mixing equipment in diverse mixing applications. The efforts combine to increase product and process quality, enhance vessel performance, reduce waste, and drive down operating costs, as well as improve overall performance and product uniformity.
Many flows in nature and industry involve multiphases. By making a sustained, substantial investment in advanced technology development — and focusing on reliable, fundamentally sound physical model development — ANSYS has developed an impressive range of multiphase flow modeling capabilities and the associated engineering experience to help researchers, process engineers and equipment designers to enhance the performance of complex multiphase systems. ANSYS provides an unparalleled depth of capabilities for modeling these systems, which include heat and mass transfer with or without reaction, including free surfaces, gas–liquid, gas–solid, boiling, cavitations, wet steams, flashing, slurries, and particulate systems.
Process industry companies, including metal and mining organizations, are driving energy reduction, sustainability and corporate profitability through innovation. Particulate systems are found in many applications involving physical and/or chemical transformations. Therefore, it is becoming more critical to understand how particles are produced and transported as well as how they move and interact with surrounding flows and equipment.
Emissions and pollution from industrial processes are areas of intense global focus. Engineers today work on innovative ways to reduce, capture and control many undesirable byproducts. Process industry companies face dual challenges: to reduce environmental impact while creating better products that use less energy. Topics such as green engineering, clean air and water, sustainable design, and carbon reduction have great environmental appeal — and they are at the heart of process engineering, as they drive process optimization and capital investment decisions.
Because they represent the heart of a chemical plant — in which high-value products are produced through chemical transformation — reactors are a crucial component, and their high performance must be ensured. Reaction engineers are concerned with each reactor’s specific yield, selectivity, safety, environment, quality and purity — as well as the degree to which reactors support overall plant economic viability and optimal operational conditions.
Separation, Filtration and Distillation
Separation, filtration and distillation technologies have a broad range of applications in the material, chemical and hydrocarbon processing and allied industries. Depending on the type and purpose of the process streams being treated, there are diverse devices and process strategies that can be considered. To help design and optimize separation equipment performance and increase device reliability, engineers around the world use ANSYS simulation software in gas separators; gas–solid, liquid–solid and liquid–liquid separations; membrane; and filtration and distillation equipment design applications.