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Dr. Markus Stephan
STAR Global Conference 2013
the optimization company the optimization company
Flow design development of a
dual stream Diesel Oxidation
Catalyst (DOC) using topology
optimization
Markus Stephan, Björn Butz
(FE-DESIGN GmbH, Karlsruhe, Germany)
Volker Schaika
(Albonair GmbH, Dortmund, Germany)
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Dr. Markus Stephan
STAR Global Conference 2013
Overview
1. Introduction: Topology Optimization for
Fluid Flow
2. Application Case: Diesel Oxidation
Catalyst
► Introduction
► Flow Analysis Actual Design
► Topology Optimization
► Flow Analysis Optimized Design
► Final Design
3. Summary
4/10/2013 Slide 2 |
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Dr. Markus Stephan
STAR Global Conference 2013
FE-DESIGN
Business activities
► TOSCA Structure and TOSCA Fluid
► Customization and specific solutions on customer demand
► Excellent expertise and service in the CAE field for different industries
► Projects led with personal commitment and high reliability
► Worldwide consulting and support by FE-DESIGN and its resellers
► Support of the selection process of CAE tools to efficiently meet company needs
► Basic and advanced seminars on TOSCA Structure and TOSCA Fluid
► Onsite trainings
4/10/2013
ENGINEERING SERVICES
TRAINING, SUPPORT AND CONSULTING
SOFTWARE-DEVELOPMENT
Slide 3 |
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Dr. Markus Stephan
STAR Global Conference 2013
Distribution partners of FE-DESIGN
4/10/2013
Americas
FE-DESIGN Optimization Inc.
Germany/Austria/Switzerland
FE-DESIGN & Partner
Belgium, Netherlands, Luxemburg
4RealSim USA/Canada
SimuTech Group
Brazil
VirtualCAE
Russia
OOO MES
Czech/Slovakia
T.S.E.
India
Enphiniti
South-East Asia
Dazztech
Turkey
CAE Solutions, FIGES
Japan
CD-adapco, VINAS
Korea
SAMWON, CAE-CUBE, CD-adapco
Taiwan
Simutech
China
Kingswell, FEAonline,
FLYOND, PERA, Sili-Tech, Soyotec
UK
Wilde Analysis
Scandinavia
FE-DESIGN
Slide 4 |
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Dr. Markus Stephan
STAR Global Conference 2013
Existing
design
Topology optimization for CFD
Example: HVAC duct
4/10/2013
Optimization process
CAD redesign
and verification
Implementation
Design space
Existing
design
Optimization result
Slide 5 |
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Dr. Markus Stephan
STAR Global Conference 2013
Topology optimization with TOSCA Fluid: Step by step
► Define the design space (e.g. CAD)
► Meshing “as usual”
► Define boundary conditions
► Run the optimization
4/10/2013
Design space
Outflow 1
Outflow 2
Inflow
Slide 6 |
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Dr. Markus Stephan
STAR Global Conference 2013
Topology optimization with TOSCA Fluid: Step by step
4/10/2013
Outflow 2
Optimized channel
shape
Prevented flow
Free flow
Transition area
(defining new channel shape)
Inflow
Outflow 1
Design space
Slide 7 |
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Dr. Markus Stephan
STAR Global Conference 2013
Diesel oxidation catalyst (DOC)
Introduction (1)
► CO + ½ O2 → CO2
► {CnHm} + {O2} → CO2 + H2O
4/10/2013 Slide 8 |
Source: Tognum: MTU & MTU Onsite Energy
Source: Wikipedia
CO + ½ O2 → CO2
{CnHm} + {O2} → CO2 + H2O
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Dr. Markus Stephan
STAR Global Conference 2013
Diesel oxidation catalyst (DOC)
New design concept
4/10/2013 Slide 11 |
IN OUT
Monolith 1
Monolith 2
Flow Split
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Dr. Markus Stephan
STAR Global Conference 2013
Diesel oxidation catalyst (DOC)
Flow analysis results (actual design)
4/10/2013 Slide 13 |
Contours of total pressure Pathlines (coloured by velocity magnitude)
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Dr. Markus Stephan
STAR Global Conference 2013
Diesel oxidation catalyst (DOC)
Total pressure loss (actual design)
4/10/2013 Slide 14 |
A
B
A
B
To
tal p
ressu
re, P
a
Flow path length →
► Overall total pressure drop 7920 pa
► Ex. monolith total pressure drop: 3150 pa
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Dr. Markus Stephan
STAR Global Conference 2013
Diesel oxidation catalyst (DOC)
Flow uniformity and split ratio (actual design)
4/10/2013 Slide 15 |
A
B 1
2 IN OUT
g = 0,925 g = 0,996 ► Flow A: 47,5 %
► Flow B: 52,5 %
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Dr. Markus Stephan
STAR Global Conference 2013
Diesel oxidation catalyst (DOC)
Topology optimization : Objectives and constraints
Objective
► Find a modified design proposal with low total
pressure drop
Constraints
► The new design may not exceed the existing
design (maximum available design space)
► Inlet and outlet connecting ducts as well as the
monolithic blocks have to be kept unchanged
(“frozen zones”)
► Keep or enhance flow uniformity and flow split
ratio
4/10/2013 Slide 16 |
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Dr. Markus Stephan
STAR Global Conference 2013
Diesel oxidation catalyst (DOC)
Topology optimization setup (1)
4/10/2013 Slide 17 |
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Dr. Markus Stephan
STAR Global Conference 2013
Diesel oxidation catalyst (DOC)
Topology optimization setup (2)
4/10/2013 Slide 18 |
1
p
v
v
3 p v
2 v
4
v p
v
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Dr. Markus Stephan
STAR Global Conference 2013
Diesel oxidation catalyst (DOC)
Topology optimization run
► 4 individual optimization runs with TOSCA
Fluid Ver 2.1
► Convergence achieved after approx. 10.000
Iterations
► Wall clock run time approx. 12 h / 1 CPU
(serial) / run
4/10/2013 Slide 19 |
Sedimentation
“pseudo Pressure drop”
TOSCA Fluid optimization progress
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Dr. Markus Stephan
STAR Global Conference 2013
Diesel oxidation catalyst (DOC)
Derived designs
4/10/2013 Slide 22 |
1
2
3
4
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Dr. Markus Stephan
STAR Global Conference 2013
Diesel oxidation catalyst (DOC)
Comparison of designs
4/10/2013 Slide 23 |
Actual design Optimized design
A
B Monolith 1
Monolith 2
A
B Monolith 1
Monolith 2
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Dr. Markus Stephan
STAR Global Conference 2013
Diesel oxidation catalyst (DOC)
Flow analysis results (comparison of designs)
4/10/2013 Slide 26 |
Actual design Optimized design
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Dr. Markus Stephan
STAR Global Conference 2013
Diesel oxidation catalyst (DOC)
Design comparison (total pressure loss)
4/10/2013 Slide 27 |
A
B Total pressure
drop reduction
approx.
2000 Pa
To
tal p
ressu
re, P
a
Flow path length →
Actual design
Optimized design
- 60%
© F
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Dr. Markus Stephan
STAR Global Conference 2013
Diesel oxidation catalyst (DOC)
Flow uniformity and split ratio (optimized design)
4/10/2013 Slide 28 |
A
B 1
2 IN OUT
Flow A: 49,2 %
Flow B: 50,8 %
g = 0,939 g = 0,982
(g = 0,925) (g = 0,996)
(47,5 %)
(52,5 %)
© F
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Dr. Markus Stephan
STAR Global Conference 2013
Diesel oxidation catalyst (DOC)
Final design
4/10/2013 Slide 29 |
Redesign by consideration of manufacturing constraints
© F
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Dr. Markus Stephan
STAR Global Conference 2013
Diesel oxidation catalyst (DOC)
Summary: Flow performance
4/10/2013 Slide 31 |
Actual design Optimized design
Total pressure drop, pa 7920 pa 6000 pa (- 24.2 %)
Total pressure drop (ex. Monolithes), pa 3150 pa 1238 pa (- 60.7 %)
Total pressure drop monolith A, pa 4140 pa 4650 pa
Total pressure drop monolith B, pa 5330 pa 4870 pa
Flow ratio A, % 47.5 % 49.2 %
Flow ratio B, % 52.5 % 50.8 %
Uniformity A 0.996 0.982
Uniformity B 0.925 0.939
© F
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Dr. Markus Stephan
STAR Global Conference 2013
Diesel oxidation catalyst (DOC)
Summary
► CFD analysis and optimization of a new, two-way DOC concept
► Topology optimization helped to find a significant improved design variant using a first,
rough design as the available design space
► The raw optimization results need to be reconstructed
► The achieved total pressure drop reduction compared to the actual design is 60%
(relative to the optimizable sections) resp. 25% (over all)
► Flow split ratio and the individual flow uniformities at the monolithic inlet section have
been improved resp. homogenized
► Based on the results of the topology optimization, a totally new, innovative,
manufacturable and highly efficient design proposal could be found
► Total process time was approx. 1 to 2 weeks
4/10/2013 Slide 32 |
