CFD & FEA Simulation
Computational fluid dynamics and finite element analysis to predict real-world flow, heat transfer and structural behaviour before you build — or to find out why existing equipment misbehaves.
Simulation that supports engineering decisions
Some questions are cheaper to answer on a computer than in steel. Computational fluid dynamics (CFD) shows how gases and liquids actually move through vessels, burners, scrubbers and distributors; finite element analysis (FEA) shows how equipment and structures respond to pressure, temperature and load.
We use simulation to validate designs, troubleshoot existing equipment and give engineering decisions a quantitative basis. Simulation is part of our Engineering Services and is used across process, mechanical, piping and environmental projects.
Types of CFD analysis
From single-phase pipe flow to reacting multiphase systems — CFD shows velocity, pressure, temperature and concentration everywhere in the domain.
Internal & external flow
Pressure loss, velocity and flow patterns in pipes, ducts, vessels and around structures.
Multiphase flow
Gas–liquid, liquid–liquid and particle-laden flows: separators, bubble columns, slurry and spray systems.
Heat transfer & conjugate heat transfer
Coupled conduction in solids and convection in fluids for exchangers, jackets and hot equipment.
Combustion & burners
Flame shape, heat release, temperature fields and emissions in furnaces, burners and incinerators.
Mixing & agitated vessels
Impeller selection, blend time, solids suspension and dead zones in agitated reactors and tanks.
Reacting flows
Species transport with chemical reaction for reactors, scrubbers and combustion chambers.
Dispersion & ventilation
Release and spread of gases, odours and heat in plant buildings and outdoor areas.
Scrubber, ESP & bag filter flow distribution
Uniform gas distribution across packing, collecting plates and filter bags for reliable emission control.
Column distributors & tray hydraulics
Vapour and liquid distribution in distillation and absorption columns, feed devices and tray decks.
Pumps, fans & turbomachinery
Performance, recirculation and losses in pumps, blowers and fans and their suction and discharge ducting.
HVAC & cleanroom airflow
Air change effectiveness, pressure cascades and particle paths in cleanrooms, control rooms and labs.
Fire & smoke
Smoke movement, visibility and temperature for fire scenarios in plant buildings and enclosures.
Types of FEA
Structural, thermal and dynamic analysis of pressure equipment, piping, skids and structures — with code checks where they apply.
Linear & nonlinear static
Stresses and deflections under pressure and mechanical loads, including material and contact nonlinearity.
Thermal & thermo-mechanical
Temperature fields and the thermal stresses they create in vessels, exchangers and piping.
Pressure vessels & nozzle loads
Design-by-analysis to ASME Section VIII Division 2, with stress linearisation and classification.
Piping stress
Sustained, expansion and occasional load cases with code checks and equipment nozzle loads.
Fatigue
Cyclic pressure and thermal loads assessed for crack initiation life.
Modal & vibration
Natural frequencies and mode shapes to avoid resonance in equipment, skids and piping.
Seismic & wind
Response of columns, stacks and structures to seismic and wind loads.
Buckling
Stability of thin shells, columns and frames under compressive and external pressure loads.
Transient dynamic
Time-dependent response to impact, water hammer, relief valve thrust and start-up events.
Skid & structural
Frames, lifting lugs, supports and platforms checked for transport, lifting and operation.
How a study runs
Define the question
Agree what decision the study must support and the acceptance criteria.
Geometry & mesh
Clean geometry and a mesh refined where gradients are steep.
Physics & boundary conditions
Models, materials and loads that represent real operating cases.
Solve & verify
Convergence, mesh-independence and sanity checks against hand calculations.
Validate
Comparison with plant data, test results or published correlations where available.
Report & recommend
Clear findings, design changes and their engineering justification.
What you receive
- Study scope and methodology note
- Assumptions and boundary-condition register
- Mesh and convergence evidence
- Contour plots, animations and key results tables
- Code compliance checks (where applicable)
- Design recommendations with quantified benefit
- Native models on request
- Review meeting with your project team
Tools chosen for the physics
We are not tied to one solver. Established commercial and open-source codes are selected to suit the physics, the accuracy required and the client's own standards.
Results are traceable: every report records the models, mesh statistics, convergence criteria and validation basis, so your team can review and reuse the work with confidence.
Industries
Why simulate first
Fewer surprises at start-up
Flow and stress problems are found on screen, not after commissioning.
Right-sized equipment
Margins based on evidence instead of rules of thumb.
Faster troubleshooting
See inside running equipment to find the root cause of maldistribution, vibration or hot spots.
Code-compliant designs
Design-by-analysis supports compliance where formula-based rules are too conservative or do not apply.
CFD & FEA questions
What is the difference between CFD and FEA?
CFD (computational fluid dynamics) predicts how fluids flow and transfer heat and mass. FEA (finite element analysis) predicts how solids and structures deform and carry stress under load. Many studies combine both — for example, CFD temperatures used as loads in a thermal stress FEA.
What information do you need to start a simulation study?
Geometry (drawings or 3D models), operating and design conditions, fluid or material properties, applicable codes and the question the study must answer. Plant or test data for validation is valuable whenever it exists.
Which software do you use?
We are software-agnostic: established commercial and open-source solvers are selected for the physics of each problem. What matters is a verified mesh, appropriate models and validation — not the brand of the solver.
How do you make sure results are reliable?
Every study includes mesh-independence and convergence checks, hand-calculation cross-checks and, where possible, validation against measurements or published correlations. Assumptions and limitations are stated in the report.
Can FEA be used for ASME pressure vessel compliance?
Yes. ASME Section VIII Division 2 Part 5 allows design-by-analysis, where FEA stresses are linearised and classified into membrane, bending and peak categories and checked against allowables, together with checks for collapse, local failure and fatigue as required.
How long does a typical study take?
It depends on geometry complexity and physics. A focused troubleshooting study can take days; a multi-case design validation takes longer. We agree scope, cases and schedule before starting.
Need a flow or stress question answered?
Share your process, capacity and site details — our engineers will respond with a clear scope and the right team.