Start-up conditions in shell & tube heat exchangers involve strong thermal transients that directly influence temperature distribution, thermal stresses, and early-stage performance. In this study, the complete heat exchanger geometry was modeled using advanced CFD to accurately capture thermal mass effects and transient heat transfer behavior.
In reverse-air baghouses, uneven gas flow can directly impact filtration efficiency, pressure drop, and bag life. This case study applies CFD to analyze internal flow behavior within a compartmentalized bag filter system under operating conditions.
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Electrostatic Precipitators demand highly uniform gas flow to meet particulate emission limits and achieve stable collection performance. In this study, CFD was used to evaluate flue gas flow distribution across the ESP cross-section and identify regions of velocity maldistribution impacting collection efficiency and dust re-entrainment.
Crude oil blending is a critical refinery operation where improper mixer configuration can result in non-uniform blends and significant financial losses. This case study focuses on evaluating jet-mixer configurations inside blending tanks using Computational Fluid Dynamics.
Subsea pipelines are continuously subjected to complex hydrodynamic forces that impact their structural integrity over time. This case study focuses on developing CFD models to quantify static and dynamic external loads under different operating and environmental conditions.
Vapor horns play a crucial role in phase separation efficiency within process equipment. In this study, CFD modeling was carried out to analyze internal flow patterns and identify performance limitations affecting vapor separation efficiency.
Efficient air-oil separation is critical for the performance and reliability of mobile rotary compressors. In this case study, advanced CFD simulations were used to analyze velocity distribution, pressure drop, flow behavior, and oil droplet dynamics inside the air-oil filter assembly. By closely studying internal flow profiles and oil separation mechanisms, the design was optimized to improve sep...
Efficient grain drying is critical to maintaining grain quality, shelf life, and storage safety in large-scale silo operations. In this case study, Computational Fluid Dynamics (CFD) is used to model the drying behavior of grains inside a silo, providing detailed insight into airflow distribution, heat and mass transfer, and moisture removal across the grain bed.
Understanding the interaction between rollers and tubing is critical for efficient peristaltic pump operation. At Tridiagonal Solutions, we leveraged non-linear structural (FEA) and CFD simulations to capture tubing deformation, pinch points, and fluid flow behavior.
This multipurpose test facility is utilized to conduct a number of multiphase flow studies ranging from hydrate transport to liquid entrainment.
Corrosion, the gradual degradation of materials or metals due to chemical reactions with their environment, poses significant challenges in industries ranging from infrastructure and manufacturing to transportation and energy. To ensure the longevity and reliability of materials, it is essential to employ rigorous corrosion testing methods.
Heavy metals like mercury often migrate from natural sources—such as source rocks, metal-rich fluids, and oil-producing organisms—and accumulate within oil and gas pipelines, especially in complex terrains. This build-up poses serious challenges including corrosion, flow assurance risks, and environmental hazards. Our Liquid Metal Transportation Facility enables a deep dive into these issues throu...
Effective sand control is critical for ensuring long-term well performance and minimizing damage to production equipment. Tridiagonal Solutions offers high-fidelity sand retention testing (SRT) to evaluate and select the most suitable sand screens tailored to your specific reservoir conditions. Our advanced SRT setup replicates formation-specific particle size distributions (PSDs), enabling accura...
Sand production from weak reservoirs is a persistent challenge in the oil and gas industry. When sand becomes entrained in crude oil, it often settles at the bottom of the pipeline, forming stationary beds that lead to serious operational issues—ranging from reduced production rates and excessive pressure drops to equipment failure, erosion, and corrosion. Our Sand Transportation Facility is purpo...
TSPL's wax deposition flow loop is a hub of innovation, driving transformative research in multiphase flow dynamics. With advanced instrumentation and visualization capabilities, it provides crucial insights into wax removal mechanisms. Pioneering initiatives conducted within the loop, like self-pigging technology and wax inhibition proofs, lead to substantial cost savings and enhanced operational...
In complex process equipment, fluid-structure interaction can often lead to unexpected failures. Tridiagonal leveraged coupled CFD–FEA simulations to identify the root cause of repeated tube failures in an oxygen mixing device. The study revealed that fluid-induced vibrations from vortex shedding were exciting the natural frequency of sparger tubes, leading to structural resonance and eventual tub...
Efficient separation of materials by size is critical in industries such as mining, recycling, and food processing. The vibrating flip-flow screen (VFFS) offers a unique approach, using flexible screen mats that vibrate and flex to improve particle movement and sorting. To evaluate and enhance its performance, a Finite Element Analysis (FEA) was performed to accurately predict the motion of the sy...
Controlling emissions while maintaining product quality is a key challenge in rotary kiln operations. During the combustion process in the kiln and preheat zone, high levels of NOx emissions can be generated, requiring optimization of burner design to meet environmental regulations. Using CFD simulations, combustion flame behavior, temperature distribution, kiln wall heat flux, and exit flue gas p...
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In high-temperature boiler systems, headers serve as vital components for collecting and distributing steam and water, while stub headers act as crucial connecting channels to other boiler elements. These tubular structures are regularly exposed to cyclic thermal loading during cold, warm, and hot startups — making them vulnerable to thermal fatigue over time. To maintain long-term operational saf...
Enhancing the efficiency and durability of catalytic converters and combustion systems is critical for optimal plant performance. This case study showcases how Computational Fluid Dynamics (CFD) was used to improve flow distribution in catalytic converters, leading to better pollutant conversion. It also highlights the role of detailed combustion modeling in minimizing thermal stresses and prevent...
Asphaltene deposition is one of the most persistent flow assurance challenges in the oil and gas industry. When crude oil components interact with precipitants such as n-alkanes (e.g., n-heptane, n-pentane, propane), asphaltenes precipitate, agglomerate, and diffuse toward pipe walls—leading to deposits, clogging, and ultimately reduced production. This problem has cost the industry billions in lo...
As a consultant in the area of Computational Fluid Dynamics, it is important to review the journey of the technology over last two decades. At Tridiagonal, we have been a part of this journey since 2006 and its fascinating to see the adoption of technology, its spread across industry verticals, use of high performance computing with public and private clouds, use of open source platforms, attempts...
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Discover how advanced simulation helped eliminate wrinkles and tearing in complex sheet metal forming Stamping of sheet metal is a highly nonlinear and intricate process involving large deformations, contact interactions, and potential material failure. Ensuring proper die design and forming parameters is critical for optimal results. In this case study, Tridiagonal’s Finite Element Analysis (FEA)...
As LNG storage facilities grow in scale and strategic importance, their exposure to extreme external hazards like hurricane-borne missiles, debris impact, or blast loads has become a critical safety concern. Finite Element Analysis (FEA) offers a powerful solution to evaluate and enhance the structural integrity of large LNG tanks under rare but catastrophic scenarios and help assess the safety an...
Atul Dubey; R.J. Byron Smith; Damodaran Vedapuri
Praveen Kumar, Amarvir Chilka and Damodaran Vedapuri,
Welding-induced residual stresses in pressure vessels pose significant risks—compromising structural integrity and leading to potential cracking under fluctuating pressure and thermal loads. This makes post-weld heat treatment (PWHT) a critical step in ensuring long-term durability. At Tridiagonal Solutions, our simulation experts developed a Finite Element Analysis (FEA) model that precisely capt...
Industrial fluid systems, particularly those operating under high-velocity and abrasive conditions, place immense stress on essential components such as elbows, tees, reducers, and 3D pipe templates. Over time, this can result in significant erosion, jeopardizing equipment integrity, shortening component lifespan, and increasing operational risk. Tridiagonal Solutions offers a state-of-the-art Ero...
This case study presents the structural analysis of pressure vessels to ensure safe and reliable operation under varying process conditions. Using advanced simulation techniques, the vessels were evaluated for stress distribution, deformation, and safety factors against operating loads and pressure fluctuations. The analysis helped in identifying critical stress regions, validating design integrit...
Efficient operation of a three-phase separator tank depends largely on how well the phases are separated under gravity. One of the most critical design factors influencing this process is the position and configuration of baffles, which directly affect flow distribution and separation efficiency. In this study, CFD simulations were performed to evaluate the effect of baffle placement and particle ...
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Creating comfortable and healthy office spaces requires an HVAC design that balances air distribution with occupant load. Using Airpak simulations, airflow patterns and temperature distribution were analyzed to evaluate thermal comfort and indoor air quality in the workplace. The study provided insights into how air supply, circulation, and load variations impact comfort levels, helping identify d...
Managing flow behavior in cooling sumps is critical to avoid performance losses caused by eddies, vortices, and unwanted swirl formation. Using CFD simulations, the flow distribution and vortex locations inside a multi-chamber sump were analyzed to evaluate the limitations of the existing design.
CFD helps to determine Temperature & O2 distribution. Also to predict Residence time of the pollutants in high temperature & oxygen availability
Scaling up from a pilot reactor to a large-scale reactor often presents challenges in maintaining performance improvements. In this study, Computational Flow Modeling (CFD) was used to compare the flow behavior, mixing patterns, and overall performance of an existing pilot-scale test reactor with that of full-scale reactor designs.
Designing an efficient neutralization tank requires careful evaluation of mixing behavior and flow dynamics. In this project, a new impeller system along with optimized inlet and outlet configurations were developed and tested using CFD simulations. The focus was on studying flow patterns and assessing how acid mixing impacts key performance parameters.
Efficient gas cleaning is critical in many industrial applications, and cyclone separators are widely used to remove particulates from carrier gases. In this study, CFD simulations were carried out to evaluate cyclone separator performance under varying operating conditions. The analysis focused on how centrifugal forces drive particle separation and how different flow rates and loading conditions...
Ovalization of rotary cement kilns directly affects the structural integrity of the shell and the life of the refractory lining. Excessive ovality can cause premature refractory failure and impact overall kiln reliability. To address this, a Finite Element Analysis (FEA) was performed to evaluate the degree of ovalization in the kiln shell and benchmark it against allowable limits.
Efficient calcination is essential for stable kiln operation and product quality. The calciner, positioned in the riser duct between the kiln inlet and bottom stage cyclone, plays a critical role in distributing raw materials evenly to prevent accumulation and enhance residence time. Using CFD simulations, the combustion process was studied under conditions of kiln exhaust gas mixed with tertiary ...
Stents play a critical role in modern cardiovascular treatment by restoring blood flow in obstructed arteries without the need for invasive surgery. Once deployed, these tiny mesh tubes help keep the artery open, preventing future blockages. Understanding how blood behaves within these vessels is essential not just for mechanical performance, but also for improving drug delivery through drug-eluti...
This case study focuses on optimizing burner arrangements in a process heater using advanced simulations. By studying the behavior of velocity, pressure, and flue gas flow patterns, the analysis provided a clear understanding of how burner configuration influences heater performance and efficiency. The insights gained helped in identifying improved designs that enhance heat transfer, reduce energy...
In the fast-paced industrial landscape, the challenges faced by sectors such as oil and gas, crude refining, power generation, and cement manufacturing are immense. Tridiagonal has the key technological advancements that have revolutionized these sectors is the application of Fluid Structure Interaction (FSI) analysis.
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FCC(Fluid Catalytic Cracking ) is a conversion process used in petroleum refineries to convert the high-boiling point, high-molecular weight hydrocarbon fractions of crude oil into gasoline and other petroleum products. A major player in (FCC) process technology approached Tridiagonal to access structural integrity of the FCC unit.
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A critical concern for storage tank feed pipes is flow-induced vibration (FIV). This can occur when the liquid within the pipe rapidly vaporizes due to a pressure drop exceeding the liquid's vapor pressure.
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Corrosion, the gradual degradation of materials or metals due to chemical reactions with their environment, poses significant challenges in industries ranging from infrastructure and manufacturing to transportation and energy. To ensure the longevity and reliability of materials, it is essential to employ rigorous corrosion testing methods.
Inflow Control Devices (ICDs) and Automated Inflow Control Devices (AICDs) are critical in enhancing well performance, balancing reservoir inflow, and minimizing unwanted fluid production. Tridiagonal Solutions offers a fully equipped testing facility designed to rigorously evaluate these devices under realistic wellbore conditions. Our testing portfolio includes cavitation testing, flow performan...
This multipurpose test facility is utilized to conduct a number of multiphase flow studies ranging from hydrate transport to liquid entrainment. Hydrate mimic studies focus on understanding the impact of hydrate particles on flow regimes transitions and multiphase flow characteristics. Poly propylene particles are used as hydrate mimics. These particles float at the interface of oil and water. Liq...
Asphaltene deposition remains one of the most persistent flow assurance issues in oil and gas production. These complex, heavy organic molecules can quickly accumulate, clogging flowlines, damaging equipment, and significantly reducing production efficiency. The challenge? No single mitigation strategy works across all reservoirs or crude types. Asphaltene behavior is highly dependent on the oil's...
Designing a Directional Solidification System (DSS) involves addressing the complex interaction between fluid dynamics, heat transfer, and crystal growth. In this study, advanced simulations were applied to evaluate critical phenomena influencing system performance, including phase change, unsteady multi-component flows, heat transfer with radiation, natural convection, and mild turbulence over th...
Embark on a journey into the heart of our technological expertise, Mixing Facility. In the realm of the Chemical sector, optimizing tank configurations for increased yields is paramount. Challenges arise in determining the optimum configuration of mixing tanks, selecting the appropriate impeller type, impeller position, and impeller clearance to enhance yields through the mixing process without ge...
Understanding in situ gas volume fraction is critical for optimizing gas-liquid systems, especially in complex flow regimes. While overall gas holdup measurement is relatively simple, accurately capturing local gas holdup remains a significant challenge due to system opacity and noise interference.
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In the realm of multiphase flow dynamics, understanding the intricate behavior of foams is essential for numerous industrial applications, particularly in the oil and gas sector. Tridiagonal's Foam Transport Facility stands at the forefront of this research, providing a state-of-the-art platform designed to delve into the complexities of foam generation and breaking mechanisms. This facility featu...
Aeration and foaming during the bottle filling process can lead to significant product losses, underfilling, and operational inefficiencies. This case study presents experimental investigations conducted to understand the fundamental mechanics of aeration and foaming under various liquid properties and operating conditions.
Project aimed to create an efficient drying process that would not burn the coffee beans. To achieve this, Tridiagonal created a computational fluid dynamics (CFD) model and conducted a pilot plant proof of concept at TRL-3.
Paraffin wax deposition in pipelines is a persistent challenge in crude oil transport, affecting flow efficiency and increasing maintenance costs. This case study explores the effectiveness of paraffin wax stripping under various operational conditions using a full-scale experimental pipeline setup.
Effective sand management is critical to ensuring the longevity and performance of oil and gas wells. Uncontrolled sand production can cause severe erosion in downhole equipment, leading to increased OPEX/CAPEX and reduced well productivity. This case study focuses on evaluating the erosion resistance and flow performance of sand control screens—key to retaining formation particles while enabling ...
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Understanding sand transport behavior in oil and gas wells is essential for designing effective sand management strategies. This case study presents a pilot-scale experimental loop designed to replicate wellbore conditions using tubular test sections with the same diameter as actual well designs, albeit at shorter lengths. The setup allows for both single-phase and multiphase flow studies to evalu...
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Mercury contamination in oil and gas pipelines poses serious challenges—leading to pipeline corrosion and environmental hazards due to biomagnification in marine ecosystems. This case study investigates the gas-assisted transport of liquid heavy metals, like mercury, to enable effective removal from pipelines.
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Erosion-corrosion experiments are pivotal for understanding the degradation processes in larger pipelines like 4-inch diameters, offering insights into the combined effects of both erosion and corrosion under real-world conditions. These insights are crucial for predicting and mitigating pipeline failures, guiding the development of robust materials and coatings, and optimizing maintenance strateg...
Tridiagonal Organization specializes in providing innovative solutions for various industries, including Oil & Gas, Pet Chemicals, Pharma, Food, Metals & Mining, Cement, etc. In these industries, equipment such as SS elbows, tees, reducers, and 3D templates are subjected to harsh operating conditions, including high velocities of abrasive fluids, which can lead to erosion. Erosion is a cri...
In most oil well production, that comprises over more than one reservoir, the major problem encounters is the gas and water that also gets produced with oil. AICD plays an important role in oil production and injection by restricting the flow of unwanted fluids.
Static mixers (SMX) are compact and efficient devices, but they often face challenges such as ensuring uninterrupted mixing of viscous liquids, achieving uniform blending, and maintaining effective heat and mass transfer. To address these, CFD simulations were carried out to evaluate flow patterns and particle distribution in SMX mixers.
This case study demonstrates how Computational Fluid Dynamics (CFD) was applied to analyze the performance of an esterification reactor under its existing configuration. The simulations provided detailed insights into fluid flow patterns, particle trajectories, mixing efficiency, and circulation behavior within the reactor. Special attention was given to evaluating circulation time distribution (C...
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This case study focuses on the simulation and evaluation of impeller designs in a polymerization reactor to improve overall performance. The existing impeller was modeled, and several alternative designs were developed and analyzed to understand their impact on mixing dynamics. Detailed plots of strain rate distribution and Particle Size Distribution (PSD) were generated to compare performance acr...
This case study highlights how CFD simulations were applied to improve the manufacturing process of ion exchange resins involving poly-dispersed bead sizes. The team analyzed the reactor’s operating conditions to understand how particle size distribution (PSD) affects strain rate distribution and mixing behavior. By simulating multiple design scenarios, it became possible to visualize performance ...
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The performance of a dry powder asthma inhaler was evaluated using advanced CFD simulations. The study focused on an inhaler design that included an inner obstruction and a filter near the mouthpiece—two critical features influencing airflow and particle dynamics. By simulating real operating conditions, the analysis provided a detailed understanding of how these design elements impact overall inh...
A steady-state CFD simulation of a pharmaceutical batch reactor equipped with two 45° Pitched Blade Turbines (PBT) and a six-disk turbine was performed to evaluate power number and fluid phase mixing characteristics. The study provided insights into mixing efficiency, hydrodynamics, and energy requirements—helping optimize reactor performance for pharmaceutical applications. Download the full case...
