SINTEF

Proceedings of the 12th International Conference on PROCEEDINGS 2

Computational Fluid Dynamics in the Oil & Gas,
Metallurgical and Process Industries

Progress in Applied CFD –

CFD2017
 SINTEF Proceedings

Editors:
Jan Erik Olsen and Stein Tore Johansen

Progress in Applied CFD – CFD2017

Proceedings of the 12th International Conference on Computational Fluid Dynamics

in the Oil & Gas, Metallurgical and Process Industries

SINTEF Academic Press

SINTEF Proceedings no 2
Editors: Jan Erik Olsen and Stein Tore Johansen
Progress in Applied CFD – CFD2017
Selected papers from 10th International Conference on Computational Fluid
Dynamics in the Oil & Gas, Metallurgical and Process Industries

Key words:
CFD, Flow, Modelling

Cover, illustration: Arun Kamath

ISSN 2387-4295 (online)

ISBN 978-82-536-1544-8 (pdf)

© Copyright SINTEF Academic Press 2017

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SINTEF Proceedings
SINTEF Proceedings is a serial publication for peer-reviewed conference proceedings
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PREFACE
This book contains all manuscripts approved by the reviewers and the organizing committee of the
12th International Conference on Computational Fluid Dynamics in the Oil & Gas, Metallurgical and
Process Industries. The conference was hosted by SINTEF in Trondheim in May/June 2017 and is also
known as CFD2017 for short. The conference series was initiated by CSIRO and Phil Schwarz in 1997.
So far the conference has been alternating between CSIRO in Melbourne and SINTEF in Trondheim.
The conferences focuses on the application of CFD in the oil and gas industries, metal production,
mineral processing, power generation, chemicals and other process industries. In addition pragmatic
modelling concepts and bio‐mechanical applications have become an important part of the
conference. The papers in this book demonstrate the current progress in applied CFD.

The conference papers undergo a review process involving two experts. Only papers accepted by the
reviewers are included in the proceedings. 108 contributions were presented at the conference
together with six keynote presentations. A majority of these contributions are presented by their
manuscript in this collection (a few were granted to present without an accompanying manuscript).

The organizing committee would like to thank everyone who has helped with review of manuscripts,
all those who helped to promote the conference and all authors who have submitted scientific
contributions. We are also grateful for the support from the conference sponsors: ANSYS, SFI Metal
Production and NanoSim.

Stein Tore Johansen & Jan Erik Olsen

3
Organizing committee: Scientific committee:

Conference chairman: Prof. Stein Tore Johansen Stein Tore Johansen, SINTEF/NTNU
Conference coordinator: Dr. Jan Erik Olsen Bernhard Müller, NTNU
Dr. Bernhard Müller Phil Schwarz, CSIRO
Dr.Sigrid Karstad Dahl Akio Tomiyama, Kobe University
Dr.Shahriar Amini Hans Kuipers, Eindhoven University of Technology
Dr.Ernst Meese Jinghai Li, Chinese Academy of Science
Dr.Josip Zoric Markus Braun, Ansys
Dr.Jannike Solsvik Simon Lo, CD‐adapco
Dr.Peter Witt Patrick Segers, Universiteit Gent
Jiyuan Tu, RMIT
Jos Derksen, University of Aberdeen
Dmitry Eskin, Schlumberger‐Doll Research
Pär Jönsson, KTH
Stefan Pirker, Johannes Kepler University
Josip Zoric, SINTEF

4
CONTENTS

PRAGMATIC MODELLING ................................................................................................................ 9

On pragmatism in industrial modeling. Part III: Application to operational drilling ............................. 11
CFD modeling of dynamic emulsion stability ........................................................................................ 23
Modelling of interaction between turbines and terrain wakes using pragmatic approach ................. 29

FLUIDIZED BED .............................................................................................................................. 37

Simulation of chemical looping combustion process in a double looping fluidized bed
reactor with cu‐based oxygen carriers .................................................................................................. 39
Extremely fast simulations of heat transfer in fluidized beds ............................................................... 47
Mass transfer phenomena in fluidized beds with horizontally immersed membranes ....................... 53
A Two‐Fluid model study of hydrogen production via water gas shift in fluidized bed
membrane reactors .............................................................................................................................. 63
Effect of lift force on dense gas‐fluidized beds of non‐spherical particles ........................................... 71
Experimental and numerical investigation of a bubbling dense gas‐solid fluidized bed ...................... 81
Direct numerical simulation of the effective drag in gas‐liquid‐solid systems ..................................... 89
A Lagrangian‐Eulerian hybrid model for the simulation of direct reduction of iron ore
in fluidized beds..................................................................................................................................... 97
High temperature fluidization ‐ influence of inter‐particle forces on fluidization behavior .............. 107
Verification of filtered two fluid models for reactive gas‐solid flows ................................................. 115

BIOMECHANICS ........................................................................................................................... 123

A computational framework involving CFD and data mining tools for analyzing disease in
cartoid artery ...................................................................................................................................... 125
Investigating the numerical parameter space for a stenosed patient‐specific internal
carotid artery model............................................................................................................................ 133
Velocity profiles in a 2D model of the left ventricular outflow tract, pathological
case study using PIV and CFD modeling .............................................................................................. 139
Oscillatory flow and mass transport in a coronary artery ................................................................... 147
Patient specific numerical simulation of flow in the human upper airways for assessing
the effect of nasal surgery................................................................................................................... 153
CFD simulations of turbulent flow in the human upper airways ........................................................ 163

OIL & GAS APPLICATIONS ............................................................................................................ 169

Estimation of flow rates and parameters in two‐phase stratified and slug flow by an
ensemble Kalman filter ....................................................................................................................... 171
Direct numerical simulation of proppant transport in a narrow channel for hydraulic
fracturing application .......................................................................................................................... 179
Multiphase direct numerical simulations (DNS) of oil‐water flows through
homogeneous porous rocks ................................................................................................................ 185
CFD erosion modelling of blind tees ................................................................................................... 191
Shape factors inclusion in a one‐dimensional, transient two‐fluid model for stratified
and slug flow simulations in pipes ...................................................................................................... 201
Gas‐liquid two‐phase flow behavior in terrain‐inclined pipelines for wet natural
gas transportation ............................................................................................................................... 207
NUMERICS, METHODS & CODE DEVELOPMENT ........................................................................... 213
Innovative computing for industrially‐relevant multiphase flows ...................................................... 215
Development of GPU parallel multiphase flow solver for turbulent slurry flows in cyclone .............. 223
Immersed boundary method for the compressible Navier–Stokes equations using
high order summation‐by‐parts difference operators ........................................................................ 233
Direct numerical simulation of coupled heat and mass transfer in fluid‐solid systems ..................... 243
A simulation concept for generic simulation of multi‐material flow,
using staggered Cartesian grids........................................................................................................... 253
A cartesian cut‐cell method, based on formal volume averaging of mass,
momentum equations ......................................................................................................................... 265
SOFT: a framework for semantic interoperability of scientific software ............................................ 273

POPULATION BALANCE ............................................................................................................... 279

Combined multifluid‐population balance method for polydisperse multiphase flows ...................... 281
A multifluid‐PBE model for a slurry bubble column with bubble size dependent
velocity, weight fractions and temperature ........................................................................................ 285
CFD simulation of the droplet size distribution of liquid‐liquid emulsions
in stirred tank reactors ........................................................................................................................ 295
Towards a CFD model for boiling flows: validation of QMOM predictions with
TOPFLOW experiments ....................................................................................................................... 301
Numerical simulations of turbulent liquid‐liquid dispersions with quadrature‐based
moment methods ................................................................................................................................ 309
Simulation of dispersion of immiscible fluids in a turbulent couette flow ......................................... 317
Simulation of gas‐liquid flows in separators ‐ a Lagrangian approach................................................ 325
CFD modelling to predict mass transfer in pulsed sieve plate extraction columns ............................ 335

BREAKUP & COALESCENCE .......................................................................................................... 343

Experimental and numerical study on single droplet breakage in turbulent flow ............................. 345
Improved collision modelling for liquid metal droplets in a copper slag cleaning process ................ 355
Modelling of bubble dynamics in slag during its hot stage engineering ............................................. 365
Controlled coalescence with local front reconstruction method ....................................................... 373

BUBBLY FLOWS ........................................................................................................................... 381

Modelling of fluid dynamics, mass transfer and chemical reaction in bubbly flows .......................... 383
Stochastic DSMC model for large scale dense bubbly flows ............................................................... 391
On the surfacing mechanism of bubble plumes from subsea gas release .......................................... 399
Bubble generated turbulence in two fluid simulation of bubbly flow ................................................ 405

HEAT TRANSFER .......................................................................................................................... 413

CFD‐simulation of boiling in a heated pipe including flow pattern transitions
using a multi‐field concept .................................................................................................................. 415
The pear‐shaped fate of an ice melting front ..................................................................................... 423
Flow dynamics studies for flexible operation of continuous casters (flow flex cc)............................. 431
An Euler‐Euler model for gas‐liquid flows in a coil wound heat exchanger........................................ 441

NON‐NEWTONIAN FLOWS ........................................................................................................... 449

Viscoelastic flow simulations in disordered porous media ................................................................. 451
Tire rubber extrudate swell simulation and verification with experiments ....................................... 459
Front‐tracking simulations of bubbles rising in non‐Newtonian fluids ............................................... 469
A 2D sediment bed morphodynamics model for turbulent, non‐Newtonian,
particle‐loaded flows ........................................................................................................................... 479
METALLURGICAL APPLICATIONS .................................................................................................. 491
Experimental modelling of metallurgical processes ........................................................................... 493
State of the art: macroscopic modelling approaches for the description of multiphysics
phenomena within the electroslag remelting process ....................................................................... 499
LES‐VOF simulation of turbulent interfacial flow in the continuous casting mold ............................. 507
CFD‐DEM modelling of blast furnace tapping ..................................................................................... 515
Multiphase flow modelling of furnace tapholes ................................................................................. 521
Numerical predictions of the shape and size of the raceway zone in a blast furnace ........................ 531
Modelling and measurements in the aluminium industry ‐ Where are the obstacles? ..................... 541
Modelling of chemical reactions in metallurgical processes............................................................... 549
Using CFD analysis to optimise top submerged lance furnace geometries ........................................ 555
Numerical analysis of the temperature distribution in a martensic stainless steel
strip during hardening ......................................................................................................................... 565
Validation of a rapid slag viscosity measurement by CFD................................................................... 575
Solidification modeling with user defined function in ANSYS Fluent .................................................. 583
Cleaning of polycyclic aromatic hydrocarbons (PAH) obtained from ferroalloys plant ...................... 587
Granular flow described by fictitious fluids: a suitable methodology for process simulations .......... 593
A multiscale numerical approach of the dripping slag in the coke bed zone of a
pilot scale Si‐Mn furnace ..................................................................................................................... 599

INDUSTRIAL APPLICATIONS ......................................................................................................... 605

Use of CFD as a design tool for a phospheric acid plant cooling pond ............................................... 607
Numerical evaluation of co‐firing solid recovered fuel with petroleum coke in a
cement rotary kiln: Influence of fuel moisture ................................................................................... 613
Experimental and CFD investigation of fractal distributor on a novel plate and
frame ion‐exchanger ........................................................................................................................... 621

COMBUSTION ............................................................................................................................. 631

CFD modeling of a commercial‐size circle‐draft biomass gasifier ....................................................... 633
Numerical study of coal particle gasification up to Reynolds numbers of 1000 ................................. 641
Modelling combustion of pulverized coal and alternative carbon materials in the
blast furnace raceway ......................................................................................................................... 647
Combustion chamber scaling for energy recovery from furnace process gas:
waste to value ..................................................................................................................................... 657

PACKED BED ................................................................................................................................ 665

Comparison of particle‐resolved direct numerical simulation and 1D modelling
of catalytic reactions in a packed bed ................................................................................................. 667
Numerical investigation of particle types influence on packed bed adsorber behaviour .................. 675
CFD based study of dense medium drum separation processes ........................................................ 683
A multi‐domain 1D particle‐reactor model for packed bed reactor applications ............................... 689

SPECIES TRANSPORT & INTERFACES ............................................................................................ 699

Modelling and numerical simulation of surface active species transport
‐ reaction in welding processes ........................................................................................................... 701
Multiscale approach to fully resolved boundary layers using adaptive grids ..................................... 709
Implementation, demonstration and validation of a user‐defined wall function
for direct precipitation fouling in Ansys Fluent ................................................................................... 717
FREE SURFACE FLOW & WAVES ................................................................................................... 727
Unresolved CFD‐DEM in environmental engineering: submarine slope stability and
other applications................................................................................................................................ 729
Influence of the upstream cylinder and wave breaking point on the breaking wave
forces on the downstream cylinder .................................................................................................... 735
Recent developments for the computation of the necessary submergence of pump
intakes with free surfaces ................................................................................................................... 743
Parallel multiphase flow software for solving the Navier‐Stokes equations ...................................... 752

PARTICLE METHODS .................................................................................................................... 759

A numerical approach to model aggregate restructuring in shear flow using DEM in
Lattice‐Boltzmann simulations ............................................................................................................ 761
Adaptive coarse‐graining for large‐scale DEM simulations................................................................. 773
Novel efficient hybrid‐DEM collision integration scheme................................................................... 779
Implementing the kinetic theory of granular flows into the Lagrangian
dense discrete phase model................................................................................................................ 785
Importance of the different fluid forces on particle dispersion in fluid phase
resonance mixers ................................................................................................................................ 791
Large scale modelling of bubble formation and growth in a supersaturated liquid ........................... 798

FUNDAMENTAL FLUID DYNAMICS ............................................................................................... 807

Flow past a yawed cylinder of finite length using a fictitious domain method .................................. 809
A numerical evaluation of the effect of the electro‐magnetic force on bubble flow
in aluminium smelting process............................................................................................................ 819
A DNS study of droplet spreading and penetration on a porous medium.......................................... 825
From linear to nonlinear: Transient growth in confined magnetohydrodynamic flows ..................... 831
10
 SOLIDIFICATION MODELING WITH USER DEFINED FUNCTION IN ANSYS FLUENT
Moritz EICKHOFF1*, Antje RÜCKERT1, Herbert PFEIFER1
1 RWTH Aachen University, Department for Industrial Furnaces and Heat Engineering, Kopernikusstr. 10, 52074 Aa-
chen, GERMANY

* E-mail: [email protected]

Sub/superscripts
ABSTRACT eff Effective (molecular + turbulent).
The modelling of solidification processes in combination with ESR Electro slag remelting.
fluid flow is one main application of ANSYS Fluent. The solid- ϵ Turbulent dissipation rate.
ification is modelled with the enthalpy porosity technique. k Turbulent kinetic energy.
Therefor the fluid flow is damped like a flow through a porous liq Liquidus / liquid.
media of dendrites. In case of materials with large solidification p Pulling (movement of the solid).
ranges, like the nickel based superalloy 718, the adjustment
sol Solidus.
possibilities of ANSYS Fluent are often not adequate. The pro-
gram postulates a linear dependency between liquid fraction UDF User-defined function.
and temperature. To improve the simulation, the solidification UDM User-defined memory.
was implemented by a user defined function (UDF). The prin- VAR Vacuum arc remelting.
cipal modelling of fluid flow is based on the theory of AN- x X-direction.
SYS Fluent, but it is now possible to adjust the liquid fraction y Y-direction.
in fine temperature steps. 𝑧 Z-direction.
Keywords: Rheology, Interphases, Casting and solidifica-
tion, Process metallurgy, Alloy 718.
INTRODUCTION
Metallurgical processes are often modeled to obtain de-
NOMENCLATURE tails of the inner fluid flow or temperature distribution,
due to the difficult observation possibilities with classical
Greek Symbols measurement methods. The modelling of solidification
𝜖 Turbulent dissipation rate, [-]. processes is in focus of research since the 1970s (Erick-
𝜆 Thermal conductivity, [W/(m K)]. son, 1975).
𝜇𝐷 Dynamic viscosity, [kg/(m s)]. One of the common simulation programs ANSYS Fluent
∇ Divergence operator, [-]. uses the enthalpy-porosity approach (ANSYS Inc.,
Release 14.5, 2012) which was introduced by Poirier
ρ Density, [kg/m³].
(1987). ANSYS Fluent uses the assumption that the liq-
τ Shear stress tensor, [N/m²].
uid fraction is proportional to the temperature in the so-
lidification range. For many standard steels, this assump-
Latin Symbols
tion will be an appropriate approach. In case of some
𝐴𝑚𝑢𝑠ℎ Mushy zone constant, [kg/(m³ s)].
nickel based superalloys, like alloy 718, the supposition
𝑒 Internal energy, [J].
is far-out the real material behavior.
𝑓 Fraction, [-].
Therefore, user-defined functions implement the solidifi-
𝐹 Force against fluid flow per volume, [N/m³].
cation to reproduce the real material behavior.
𝑔 Gravity, [m/s²].
𝑘 Turbulent kinetic energy, [-].
SOLIDIFICATION PHENOMENA
𝐾 Permeability, [m²].
𝑙 Small number, [-]. Important for the simulation of solidification processes
𝑝 Pressure, [Pa]. are the damping of the fluid flow in the mushy region and
𝑄𝑒 volumetric energy source, [J/m³]. the solidification enthalpy. The damping is adjustable
𝑆 Momentum sink for turbulence, [kg/(m³ s)]. with the material specific mushy zone constant (Voller et
𝑣 Velocity, [m/s]. al., 1990) and considers the liquid fraction also.
t Time, [s]. Figure 1 shows the liquid fraction of an alloy 718 in re-
spect to the temperature in the solidification range calcu-
T Temperature, [K].
lated by JMatPro. Obviously, the linear approximation
made by ANSYS Fluent is not appropriate for this mate-
rial. After a cooling of 25 % of the temperature range the
liquid fraction is not 75 % but only 40 %. Therefore, the

583
damping of the fluid flow is underestimated by AN- BUILT-IN SOLIDIFICATION IN ANSYS FLUENT
SYS Fluent. The solidification module from ANSYS Inc. (Release
14.5, 2012) uses the enthalpy-porosity approach to im-
plement the damping of the fluid flow in the mushy re-
gion. Poirier (1987) shows, that the inter dendritic flow
follows Darcy’s law (Darcy, 1856):

Darcy’s law
𝜇𝐷
∇𝑝 = − ∙𝐯 (1)
𝐾

Voller and Prakash (1987) implemented the awareness of

Poirier (1987) in the fluid flow modeling. Later, a mushy
zone constant was introduced to replace the dynamic vis-
cosity µD and the unknown permeability K (Voller et al.,
1990). The liquid fraction fliq represents the change in
permeability, whereas the mushy zone constant Amush im-
plements the different material behavior (2). The small
number ε is equal 0.001 to avoid a division by zero (AN-
SYS Inc., Release 14.5, 2012).
Figure 1: Liquid fraction of alloy 718 (Giesselmann et
al., 2015) in comparison to ANSYS Fluent 𝜇𝐷 (1 − 𝑓𝑙𝑖𝑞 )
2

= ∙ 𝐴𝑚𝑢𝑠ℎ (2)
The deviation of the liquid fraction from alloy 718 results 𝐾 3
𝑓𝑙𝑖𝑞 −𝑙
in a nonlinear behavior of the enthalpy in the solidifica-
tion range, because the solidification enthalpy is depend- The ratio between viscosity and permeability (see for-
ent on the liquid fraction. mula (2)) is then inserted in the equations (3) and (4) to
Figure 2 shows the comparison of solidification en- formulate the force F against the fluid flow v as well as
thalpies in respect to the temperature in the solidification the momentum S against the turbulence quantities Φ.
range. The grey line shows the linear implementation of
ANSYS Fluent. Obviously, the change in enthalpy of the 2
(1 − 𝑓𝑙𝑖𝑞 )
mild steel (Koric and Thomas, 2008) is close to the ap- 𝐅= ∙ 𝐴𝑚𝑢𝑠ℎ ∙ (𝐯 − 𝐯𝐩 ) (3)
3
proximation from ANSYS Fluent. Whereas, the red line, 𝑓𝑙𝑖𝑞 −𝜖
representing Alloy 718 (Overfelt et al., 1994), shows a (𝟏 − 𝒇𝒍𝒊𝒒 )
𝟐

considerably different behavior. 𝑆= ∙ 𝑨𝒎𝒖𝒔𝒉 ∙ 𝛷 (4)

𝒇𝟑𝒍𝒊𝒒 − 𝝐

The necessary turbulence quantities depend on the used

turbulence model. Equation (4) is equal for all quantities
like turbulent dissipation rate ε, turbulent kinetic en-
ergy k, specific dissipation ω and so on (ANSYS Inc.,
Release 14.5, 2012).
To show the implementation of the formula above, the
momentum equation of the solver (5) is given below. The
damping force F of the fluid flow (Equation (4)) is in-
serted in the last term.

𝜕
(𝜌 ⋅ 𝒗) + ∇ ⋅ (𝜌 ⋅ 𝒗 ⋅ 𝒗)
𝜕𝑡 (5)
= −∇𝑝 + ∇ ⋅ (𝝉) + 𝜌 ⋅ 𝒈 + 𝑭

As mentioned in the previous chapter, the solidification

enthalpy is distributed linear over the temperature range
of solidification and implemented as source term Sm in
the energy equation (6).

𝜕
(𝜌 ⋅ 𝑒) + ∇ ⋅ (𝒗 ⋅ (𝜌 ⋅ 𝑒 + 𝑝))
Figure 2: Comparison of solidification en- 𝜕𝑡 (6)
thalpies (Overfelt et al., 1994, Koric and Thomas, 2008) = ∇ ⋅ (𝜆𝑒𝑓𝑓 ⋅ ∇𝑇 + 𝝉𝒆𝒇𝒇 ⋅ 𝒗) + 𝑄𝑒

584
 2
USER-DEFINED SOLIDIFICATION MODEL (1 − 𝑓𝑙𝑖𝑞 )
To reconstruct the real material behavior of alloy 718 an 𝑆𝜖 = − 3 ∙ 𝐴𝑚𝑢𝑠ℎ ∙ 𝜖 (11)
𝑓𝑙𝑖𝑞 − 𝜖
in-house developed solidification model based on UDFs
is used for several process models, like electro slag re-
The five source terms have to be included for the corre-
melting (ESR) and vacuum arc remelting (VAR).
sponding values in the ANSYS Fluent interface. The pro-
Approach gram implements the source terms in the momentum
The aim of the modified solidification model is to imple- equation (5) as well as the turbulence model.
ment the nonlinear behavior of the liquid fraction in re- Solidification enthalpy
spect to the temperature. The curve progression can be
To implement the nonlinear behavior of the solidification
received for example from a Scheil-Gulliver approach
enthalpy (see Figure 2) the enthalpy is included in the
like in Figure 1 or other calculation programs for thermo-
heat capacity of the material (see Figure 3). Therefore, it
physical data.
is not necessary to modify the energy equation (6) of the
The idea was to reconstruct the solidification model of
solver.
ANSYS Fluent by user-defined functions. Therefore, the
main equations ((3) and (4)) for the damping are also
used.
The solidification enthalpy is included in the heat capac-
ity of the material.
Implementation
The implementation of the modified solidification model
is based on a DEFINE_ADJUST function for the liquid
fraction and several DEFINE_SOURCE functions for the
damping. A modified heat capacity includes the change
in enthalpy.
The liquid fraction should be adjusted very detailed to
represent the real fluid flow. Therefore, liquid fraction
and solidification enthalpy out of the thermophysical da-
tabase are divided in 1 K steps.
Damping of the fluid flow
Figure 3: Heat capacity of alloy 718 including the so-
A DEFINE_ADJUST UDF loops over all the cells in the lidification enthalpy (Giesselmann, 2014)
fluid regions to get the temperature of the cells. A look-
up function searches the corresponding liquid fraction for Obviously, most of the solidification enthalpy is needed
these temperatures out of the tabulated liquid fractions. or set free near to the liquidus temperature. This refers to
The liquid fraction is saved in a user-defined the steep slope of the liquidus fraction in this area (com-
memory (UDM) for post processing. pare Figure 1).
Analog to the calculation procedure in ANSYS Fluent Another possibility to implement the enthalpy of solidi-
the ratio between viscosity and permeability is calculated fication would be a DEFINE_SOURCE UDF. The ad-
with equation (2) and saved in another UDM. This ratio vantage of the presented solution is the reversible char-
is the damping term of velocities and turbulence quanti- acter of the heat capacity. Because some parts of the sim-
ties (see equation (3) and (4)). ulated region maybe melt on again, the solution with
The damping force and momentum values are calculated source term would be more elaborate. Whereas the heat
in several DEFINE_SOURCE UDFs. One UDF for each capacity offers directly the possibility for change of sign
velocity direction and the turbulence quantities, typical in the temperature derivation.
turbulent dissipation rate ε and turbulent kinetic en-
ergy k. The source value is the negative product of the COMPARISON OF THE MODELS
damping term with the velocity or turbulence value (See To compare the built-in solidification of ANSYS Fluent
equations (7) to (11)). If a pull velocity vp moves the solid with the UDF based solidification model a test case was
region, it has to be subtracted from the fluid velocity, here set up. Figure 4 and Figure 5 show the flow of hot metal
in the x direction: through a cooled pipe. The left face is a velocity inlet of
hot liquid metal. The top wall is at constant temperature,
2
(1 − 𝑓𝑙𝑖𝑞 ) which is lower than the solidus temperature. At the right
𝐹𝑥 = − 3 ∙ 𝐴𝑚𝑢𝑠ℎ ∙ (vx − vp ) (7) side, the boundary is an outflow. The contour plot visu-
𝑓𝑙𝑖𝑞 − 𝜖
2
alizes the liquid fraction from one (white) to zero (black).
(1 − 𝑓𝑙𝑖𝑞 ) The black line symbolizes the position of 1 % solid frac-
𝐹𝑦 = − 3 ∙ 𝐴𝑚𝑢𝑠ℎ ∙ 𝑣𝑦 (8)
𝑓𝑙𝑖𝑞 − 𝜖 tion. The vectors and their lengths show the velocity.
2 In Figure 4 the solidification model of ANSYS Fluent
(1 − 𝑓𝑙𝑖𝑞 ) was used. Therefore, the liquid fraction increases uni-
𝐹𝑧 = − 3 ∙ 𝐴𝑚𝑢𝑠ℎ ∙ 𝑣𝑧 (9)
𝑓𝑙𝑖𝑞 − 𝜖 formly over the whole solidification range.
2
(1 − 𝑓𝑙𝑖𝑞 )
𝑆𝑘 = − 3 ∙ 𝐴𝑚𝑢𝑠ℎ ∙ 𝑘 (10)
𝑓𝑙𝑖𝑞 − 𝜖

585
 The solidification model of ANSYS Fluent was modified
and calculated in a user-defined function to adjust the liq-
uid fraction concerning the cell temperature properly.
The damping of the motion values is then implemented
by source terms for velocities and turbulence quantities.
The solidification enthalpy is included in the heat capac-
ity of the material. Therefore, the enthalpy can be fitted
very detailed.
A test case shows the similarities and differences of the
two models. The modified solidification implements a
more abrupt damping of the fluid flow.
The modified solidification model is able to replicate the
material behavior more detailed than the built-in solidifi-
cation module of ANSYS Fluent.

Figure 4: Test case: Built-in Fluent solidification model REFERENCES

ANSYS INC., (Release 14.5, 2012), "ANSYS®
Figure 5 shows the same test case simulation as Figure 4
Academic Research Help System".
with the UDF based solidification model. Obviously, the
DARCY, H.P.G., (1856), "Dètermination des lois
shape of the solidified area is slightly different, but more
d'ècoulement de l'eau à travers le sable".
interesting is the case that there is sharp edge in the mid-
ERICKSON, W.C., (1975), "Use of a general-
dle of the gray scale. Therefore, the fluid flow is damped
purpose heat-transfer code for casting simulation",
at this position abruptly.
United States.
GIESSELMANN, N., (2014), "Numerische
Untersuchungen des Elektroschlacke-
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