Chapter 1

INTRODUCTION
The one trending and most prevalent notion of today’s world is to save energy, and
preserve furl for future generations. This notion is heard almost from everyone, from a
layman to an intellectual genius. Saving energy even of a slightest of size can be a big deal
considering the future. It is also considered to be a corporate responsibility to optimal
utilization of resources. With a growth of industries utilization of the natural resources is
increasing day by day. Most of this utilization is in an indirect form of power. Every industry
uses electrical power. India is a fast growing country in terms of industrial growth. Day by
day industries are piling up. With a considerable share of natural resources in the form of
minerals like copper, iron ore, manganese; basic metal industries and Alloy industries are
booming industries in India. Every year 5.15 million tons of ferro- alloys are produced which
include manganese alloys, ferro-silicon, chrome alloys and noble ferro-alloys. Most of these
plants employ conventional blast furnaces for the production, only a few alloy plants employ
electrical arc furnace for the process. In such process plants electrical power could be saved
by altering one or two process methods that presently employed, there by achieving
optimization of resource utilization and cost effective operating methodology. In the
following thesis our focus is on one of such ferro alloy industry named ABHIJEET ferro –
alloy ltd. This thesis intensely focuses on the cooling medium that is presently serving the
purpose for the industry and analyzing the merits and de merits and suggesting alternative
cooling medium that could overcome the mentioned demerits of existing one, when
incorporated into the existing cooling system, Also demonstration of its applicability and cost
effectiveness and performance. As, an experimental setup involves in huge costs of erecting
cooling system and physically applying to the real life scenario, the entire study and analysis
was done using CATIA and ANSYS FLUENT.

1.1 Background of the industry:

Abhijeet group is one of the largest producers of Manganese alloys in india producing Hi
Carbon Ferro Manganese (FeMn) and Hi Carbon Silico Manganese (SiMn) mainly for
European and south eastern markets. The group’s company , corporate ispat alloys limited
(CIAL) is presently operating a 36MVA manganese alloy plant of 0.074 MTPA capacity
backed up by 25 MW captive power plants , in Durgapur , west Bengal. Power is one of the

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major inputs required for ferro alloy production and thus power generation will make the
production highly cost competitive.

ABHIJEET FERRO TECH LIMITED, A group company has commissioned an 360 MVA
facility in Visakhapatnam, Andhra Pradesh in the year 2011. This is India’s largest Ferro
Alloy plant. The raw materials are ore and coke, will be imported from south Africa,
Australia and south America and finished alloys will be primarily exported in the European
and south east Asian markets.

1.2 INDUSTRY LAYOUT:

Unlike other conventional metal processing or alloy plants abhijeet ferro tech limited
employees a submerged electric arc furnace to serve its purpose of melting the metal. Thus it
minimizes the problem of flu gases that are released in conventional blast furnace. The
ttypical lay out of the plant consist of these major integrals

1. RAW MATERIAL FEEDING SYSTEM

2. SUBMERGED ELECTRIC ARC FURNACE
3. PIG CASTING MACHINE AND SLAG GRANUALATION PLANT
4. GAS CLEANING PLANT
5. PUMP HOUSE
6. POWER
7. EOT CRANES

Of all these our focus here is only on submerged electric arc furnace and its integral cooling
system and the cooling medium.

1.3 SUBMERGED ELECTRIC ARC FURNACE:

The submerged arc furnace that is employed in ABHIJEET FERRO TECH LIMITED
typically consists of the following integral parts:

1.3.1 SHELL:

Shell is one of the main parts of the furnace. it is made of boiler steel. The steel shell is fully
water cooled and is welded construction. There are 3 tap holes provided under the electrode
tips of the 3 electrode. Tap hole is the way to bring out metal and slag from the furnace. It is
pasted with tamping paste and lined with “silicon-carbide” bricks. Tap hole is opened by
oxygen lancing and it is closed with the help of plugs. The metal and slag from the furnace
goes to the buffer through the runner. The runner is also pasted with tamping paste.

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1.3.2 ELECTRODE COLUMN:

The electrode, which is the main part of the furnace, is submerged its tip into the
charge. Traditionally it is called SODERBERG SELF BAKING SEMIGRAPHITE FREELY
SUSPENDED SUBMERGED ELECTRODE. The arc produces at the tip ,will convert
electrical energy into the heat energy due to the conductive environment in the bath .The
required heat produced to smelt the charge is depends on the electrode position, reductants
content, type of raw material and Electrical parameters maintained.

fig1.1: Schematic diagram of electrode column

1. Pressure ring, 2.contact pads, 3. Supporting ring, 4. Hanger, 5.contact pad inlet and outlet pipes, 6.suspension link, 7.pressure ring inlet
pipe,8.pressure ring outlet pipe, 9. Protective shield, 10.bus tubes,11. Terminal blocks, 12. Flexible and hose pipes, 13. Bus bars,
14.Transformer, 15. Seal box blowers, 16.yoke, 17.hydraulic cylinders, 18. Star beams, 19.Upper clamp, 20.lower clamp, 21.slipping
cylinders, 22. Casing, 23. Electrode blowers, 24.Ribs, 25. Pockets, 26. Mantle, 27. Upper limit, 28. Lower limit

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1.3.3 COOLING SYSTEM:

Every system of the furnace gets exposed to these high temperatures; therefore the need
of cooling these systems arises. For this purpose, two types of cooling systems are being
adopted.
1. Water cooling system
2. Air cooling system
1.3.3.1 Water cooling system: In submerged electric arc furnace, the water cooling is
necessary for the following equipment to withstand higher temperatures. The major
components of the cooling system are:

1. Contact clamps

2. Pressure ring

3. Protection shield

4. Lower mantle

5. Water jacket

6. Seal box

7. Hood

8. Shell and

9. Transformer

FLOW DIAGRAM OF WATER-COOLING SYSTEM

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 Reservoir

Salts addition

WSP (Water soften plant)

HDPE 6”ø (High density polyethylene pipe)

MS pipe line

400 m3 tank

Over flow

1000 m3 tank

Pump house motors (4 in use 2 in standby)

Header

f/c-1 inlet f/c-2 inlet f/c-3 inlet f/c-4 inlet

manifolds of f/c-1 manifolds of f/c-2 manifolds of f/c-3 manifolds of f/c-4

f/c-1 outlet f/c-2 outlet f/c-3 outlet f/c-4 outlet

Main out let

Cooling tower-1 Cooling tower-2 Cooling

tower-3

Galvanized iron pipes Galvanized iron pipes Galvanized iron

pipes

5 pvc white pipes 5 pvc white pipes 5 pvc white pipes

28 nozzels 28 nozzels 28 nozzels

Cooling hangers Cooling hangers Cooling hangers

V-splash V-splash V-splash

1000m3 tank

Fig 1.2: FLOW DIAGRAM OF WATER-COOLING SYSTEM

1.3.3.2 Air-cooling system:

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Air-cooling is given to electrode shell and furnace bottom by air blowers, as that element
does not affect severe to heat exposure. Every part of the furnace should be cooled to
withstand higher temperature. Hard water is used for cooling the equipments to expose the
higher temperature. Hence, we are using soft water, which will obtain from water softening
plant. Water fed into each water cooling system from a manifold is subsequently returned to
the heads for cooling and recirculation. Contact clamps are cooled in pairs are in series
system. Each pressure ring should be cooled independently. Air cooling systems are arranged
to electrode mantle and seal box

Pump House Motor:

KW 160

HP 220

rpm 1485

Amps 267

Cooling tower fan motor:

KW 37.5

HP 50

rpm 1470

Amps 65

1.4 Problem statement:

It is clearly evident that a part of the cooling system, which is employed for the purpose of
furnace cooling, uses water as coolant. The major setback of usage of water as coolant is its
low thermal conductivity when compared with certain fluids. Thus application of water has a
mediocre cooling effect, so that mass velocity (m/s) of the water required is more in order to
satiate the requirement. Thereby, increasing the pump work required. One more aspect of that
should be considered is that, the copper clamps which are employed for holding and
transmission electricity from the power source to the carbon electrode, shouldn’t be over
heated. If the temperature of the copper clamps is substantially increased it affects the
conductivity of the clamps, with an increase in its resistance. This literally affects the whole
process of submerged arc furnace as there were more resistance losses. Both these setbacks
can be substantially pared by introducing nano particles into the existing coolant viz. Water.

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In this thesis, there is a clean depiction of the effects and behavioural aspects of introducing
TiO2 as a nano particle additive to the water.

1.5. Organization of thesis

The thesis is organized in 10 chapters. The description of each chapter in brief is discussed
below
 Chapter 1 - ‘Introduction’ describes the motivation of the study, brief description of
overall back ground of organisation upon which the study is carried out, brief
introduction of the work which is carried out and also presents the problem statement
of the whole study.

 Chapter 2 - ‘Literature Review’ presents the various published works that are
studied and referred prior commencement of the work and also during the work for
facilitation of proper path for the whole study.
 Chapter 3 -‘Selection of nano fluids’ presents behavioural characteristics of
different nano particle additives and vivid analysis of the pliability of nano particle
additives and justification for selecting the subject fluid
 Chapter 4 - ‘Computational Fluid Dynamics’ it includes Computational fluid
dynamics procedures and methodologies employed are explained. It describes all the
optimal strategies used to solve the CFD problem. It gives the brief introduction to
CFD tools – ANSYS ICEM and ANSYS FLUENT

 Chapter 5 - ‘Modelling and analysis’ it discusses vividly about the virtual model of
the arc finance and components of study consideration which is generated in CATIA
V5. It also discuses briefly to define the model domain with all the flow field
boundary conditions. The grid generation and CFD simulations are developed in this
chapter and all the procedural steps involved in the CFD modelling & analysis are
outline.

 Chapter 6 – ‘Results and Discussions’ includes results of CFD and discussion on in

change or effect on different functional parameters, with the change in coolant.
Comparison of results between two coolant, graphical representation of the substantial
changes

 Chapter 7 – ‘Conclusions and Recommendations’

 Chapter 8 – ‘Summary’

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 Chapter 2

LITERATURE REVIEW

The conceptual birth of nano technology can be dated back to the famous lecture of Richard P
Feynman, with a statement “there is plenty of room at the bottom” at Caltech December
29 , 1969.There are a lot of advancements in nano technology ever since. But nano fluids
were a result of experiments with an intension of enhancement of thermal conductivity of
liquids. The burth of nano fluids is attributed to revolutionary idea of adding solid particles
into heat transfer fluids (HFT) to increase its thermal conductivity, an innovative idea put
forth by Maxwell in 1873. From there the advancement in nano fluids were very rapid and
their applications were augmented every day. Many research works are published, in this
study few of literature works were studied for channelizing a proper path for the study.

2.1 Review on different pliable Nano Fluids:

Naveen Kumar Guptaa[1] in his work, Heat transfer mechanisms in heat pipes using
nanofluids – A review; vividly presented different nano fluids and their behaviour when
tested for thermal conductivity by studying their action on heat pipes in a controlled testing
environment. Nano fluids such as Al2O3 CuO, Cu, MgO, Fe2O3, SiO2, TiO2 and ZnO were
tested for their pliability as coolant and plots were presented for different concentrations
when combined with water.

Masoudeh Ahmadi, Gerold Willing has conducted a detailed study and carried out
experimentation on the pliability of nano fluids as coolants in their work, Heat transfer
measurement in water based nano fluids; experiment is carried out with dispersion of
CuO(40 nm) into water with different particle loading (0.25wt% and 1wt% ) and sending
them through hot pipes to calculate the heat transfer coefficient, the presented results were
quite promising with a substantial enhancement of heat transfer coefficient over water and
also reveals that the heat transfer coefficient resides on the relative distance of particle to the
wall and its relative movement.

Haitao Zhua and Canying Zhang in their research paper, Effects of nano particle clustering
and alignment on thermal conductivities of Fe 3O4 aqueous nano fluids; presented a
comprehensive synopsis on the thermal conductive properties of Fe3O4 , which are proven to
be quite high compared to other nano fluids , and indicatively pointing out TiO 2 to be pliable

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alternative. Also presented in detail about clustering phenomenon and its effects on thermal
conductivity

N. A. Usria, W. H. Azmia, Rizalman Mamata in their work, Thermal Conductivity

Enhancement of Al2O3 Nanofluid in Ethylene Glycol and Water Mixture; vividly
presented about the thermal conductivity of nano Al 2O3 when dispersed into water and EG
medium, the nano particle of size 13nm are dispersed into three different ratio of ethylene and
water. The thermal conductivity tests are done by using KD2 Pro Thermal Properties
Analyzer at working temperatures of 30 to 70 oC for volume concentration of 0.5 to 2.0 %,
which generates most credible results, which do indicate a tremendous enhancement of
thermal conductivity dependent on temperature and concentration, making it pliable nano
fluid for heat transfer medium.

Stephen U. S. Choi in his work ENHANCING THERMAL CONDUCTIVITY OF

FLUIDS WITH NANOPARTICLES; discussed in detailed about the merits of nano fluid
and sheer advantage of nano fluids over conventional coolants, also given a theoretical
evidence of the enhancement of thermal conductivity coefficient , which can be further
utilized to find the thermal enhancement coefficient of different nano fluids theoretically.

S.M.S Murshed and K.C. leong in their work, Enhanced thermal conductivity of TiO2 –
water based nano fluids; extensively discussed and presented vividly the enhancement of
thermal conductivity of TiO2 – water nano fluid over water. In this study nano particles of
cylindrical shape 15 nm diameter, were dispersed in de-ionized water and tested for its
thermal conductivity and obtained results are astonishing with an overall increase in
conductivity of 33 percent over water and also Presented the variation of thermal
conductivity ratio, to the particle volume fraction.

Min-Sheng Liu ,I-Te Huang and Chi-Chuan Wang in their combined research work ,
Enhancement of thermal conductivity with carbon nanotube for nanofluids ; presented a
detail report of their work on single walled and multi walled carbon nano tubes acting as
particle additives in base fluid to enhance its thermal conductivity. An intense experiment
based study has been conducted following way old hot tube method and the results shown in
the study was quite promising proving that CNT–ethylene glycol suspensions have noticeably
higher thermal conductivities than the ethylene glycol base fluid without CNT rand same with
CNT–synthetic engine oil suspensions.

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Jacek Fal [2] in his work, Experimental Investigation of Electrical Conductivity and
Permittivity of SC-TiO2-EG Nanofluids; a keen study was presented in a clear manner and
reliable results were offered for reference for future research scope. This study gives keen
insight of the dielectric properties of nano fluids such as SC, TiO 2, with an average particle
size of 15–40 nm of various mass concentrations. Both real part and imaginary part’s
dielectric permittivity, as a function of temperature and frequency were measured. Also,
dependence ac conductivity on frequency, temperature, and mass concentration were
investigated. This study provided a better understanding of electrical conductivity of the nano
fluids based on their particulate size and variation with temperature.

K.G. Kalpana Sarojini , Siva V. Manoj and Pawan K. Singha[3] in their paper on , Electrical
conductivity of ceramic and metallic nanofluids; provided with a very salutary
information about the electrical conductivity of most prevalent nano fluids containing
metallic and ceramic particles such as Cu, Al 2O3, and CuO, with an extensive
experimentation of nano fluids of both ethylene glycol (EG)based and water based, under
wide alteration parameters. The author acclaims that there is an increase in electrical
conductivity with concentration increase and decrease in the size of particle. It is shown that
there is a nearly linear rise in electrical conductivity of water- and EG-based nano fluids with
particle volume fraction.

2.2 Review on real applications of nano fluids:

Victor A. Primo , Daniel Pérez-Rosa , Belén García , conducted an extensive investigation

study on real life application of nano fluids in their work, Evaluation of the Stability of
Dielectric Nanofluids for Use in Transformers under Real Operating Conditions; an
experiment is concuted taking two base fluids of general use in transformers and adding
dielectric nano fluids and tested for their stability in real case unlike in cotrolled test
environment, this study evaluates the stability of several dielectric nanofluids under realistic
transformer operating conditions and the stability of dielectric nano fluids depends strongly
on the working temperature, on the materials applied to obtain the fluid, and on the
manufacturing procedure. This in turn suggests the viability of nano fluids in the real
industrial purposes

R.B. Ganvir in his work, Heat transfer characteristics in nanofluid—A review; presented
vividly various practical applications of nano fluids as working medium that are already in
use. This study is a comprehensive of practical application and pliable future applications of

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nano fluids. It implies that, the heat transfer characteristics of current fluids are tremendously
improved by suspending nano-sized solid particles with diameter below 100 nm and are
considered as prospective working fluids for the applications such as solar collectors, heat
pipes, nuclear reactors, electronic cooling systems, automobile radiators etc. The present
paper is a comprehensive of the current research in the nano fluid studies on convective heat
transfer performance, thermo-physical properties, effect of fluid temperature, inlet velocity,
use of surfactant for better stability of nanofluids, particle size, and volume concentration
effects and also possible channels for future developments

2.3 important conclusions of the literature review:

 Nano fluids have more thermal conductivity than conventional fluids

 Nano fluids thermal conductivity is dependent on temperature and their concentration
and also distance from the wall
 Nano fluids such as Al2O3 CuO, Cu, MgO, Fe2O3, SiO2, TiO2 and ZnO were tested and
declared to have enhanced thermal conductivity and were pliable as heat conductive
fluids.
 Fe3O4 emerged out to be more efficient thermal conducting fluid compared to others
with only hindrance of electrical conductivity
 TiO2 is the most pliable option as thermal conducting fluid having its thermal
conductivity coefficient close to Fe3O4 with negligible electrical conductivity
 Nano fluids were successfully tested for their validity as a heat transfer fluid in real
life applications and proven to be pliable

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 Chapter 3

SELECTION OF NANO FLUID

In this study the focus is entirely in the enhancement of functioning of the
organization with and enhanced performance of the submerged arc furnace with
an alteration in of working fluid in the cooling mechanism. As suggested in the
previous chapters of study the viable option of the alteration of the working
fluid is nano fluids. The main motto of this study is application of suitable
working fluid to the process and check for its applicability and also its
behaviour characteristic. In this study we tested this cause by virtual
development of replica model in CATIA V5 and testing simulation in ANSYS
Fluent. Although is virtual testing there involves a tedious process and time
consuming iteration for each fluid tested in different working parameters. Thus
a preliminary study is carried out on different nano fluids of their characteristics
such as thermal conductivity, electrical conductivity, ease of preparation, cheap
and ease of access, work stability etc. We have considered nano fluids such as
Al2O3 CuO, Cu, MgO, Fe2O3, SiO2, TiO2 and Fe3O4.

3.1 Thermal conductivity thermal conductivity is the most important and focus aspect of
present study, it is the property which determines the efficiency of the heat transfer fluid. It is
directly dependent on the volume fraction or concentration. The ratio of thermal conductivity
of nano fluid(keff) to the thermal conductivity of base fluid(k t) is termed as thermal
conductivity ratio, research works that are done on thermal conductivities of different

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prevalent nano fluids presented a plot between thermal conductivity ratio and volume fraction

Fig 3.1: plot of thermal conductivity ratio vs volume fraction %

From the fig 3.1,The plot clearly indicates that the thermal conductivity of TiO 2 clearly
occupies the top notch of the curving hindering all other nano fluids with aqueous base. This
makes TiO2 most suitable fluid for thermal conducting fluid or coolant in terms of thermal
conductivity

3.2 Electrical conductivity:

The objective of this study is to optimize the cooling system of the submerged arc furnace of
the subject organization, with an alteration of the cooling medium or working fluid. A
submerged arc furnace employs carbon electrodes for its functioning, electric power that is
passed through the carbon electrode smelts the metal with self consumption of electrode due
to the resistance of the electrode. These electrodes are supported by copper clamps which also
act as power transmission lines. The coolant or cooling medium is sent to cool these clamps.
If the working fluid is electrically conductive there will electric power losses, which would
clearly hinders the performance of the furnace. Thus the coolant or working fluid should be
dielectric in order to reduce the electrical losses that may occur with the electrical energy
conducted through the fluid to walls of the fluid channel; also this phenomenon can be lethal.

An intense research is carried out in order to find and compare the electrical conductivity of
different prevalent nano fluids and presented.

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 Fig3.2: comparison of electrical conductivities without surfactant

Fig 3.3: comparison of electrical conductivities with 0.01wt% surfactant

Fig 3.4: comparission of water electrical conductivity with 0.01wt% and 0.02 wt% surfactant

From the fig 3.2, 3.3, 3.4 it’s pretty much clear that the electrical conductivity of TiO2 is less
compared to others and almost the value of pure water when considered without addition of
surfactant. Thus, it’s not a very difficult choice.

3.3 Pumping Work:

One other important factor that is to be considered before substituting or altering the coolant
is pumping work required. When compared with water the pumping work required would be

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more in a very small range, when same velocity (m/s) is to be achieved due to the additional
mass of the suspended particles. But due to thermal conductivity enhancement the velocity
(m/s) required is decreased in a notable range. Thus there is always an edge for nano fluids
over water or base fluid. The density variation between different nano fluids is compared in
the figure 3.4

Fig 3.4: comparison of various nano fluids and water for pumping work and volume fraction, mass velocity
(m/s)

From the comparison between different nano fluids almost every fluid have same amout of
required pump work thus this factor doesn’t have much influence on the selection,
considering previous factors we still consider TiO2 for the job

3.4 Ease of access:

Ease of access is an important criterion for the selection of nano fluid for any application. The
more ease you can lay your hands on, the cost effective the fluid application is. Ease of access
does mean availability and cheap in cost. Considering the cost a gm costs INR 300, which is
pretty much cheaper than other nano fluids, considering its working life.

3.5 characteristics of TiO2:

Considering all the above aspects we consider TiO 2 to be most viable nano fluid for our
application, one other important task is to select suitable concentration type of TiO 2, for this
behaviour characteristics of TiO2 are studied under our required operational conditions.

3.5.1 Particle size:

Particle size has prominent effect on its thermal conductivity, the thermal conductivity of
TiO2 with respect to the particle size is presented in the fig 3.5, with an excessive clustering
the thermal conductivity decreases with an increase in particle size , and without excessive

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clustering the thermal conductivity increases with increase in particle size. With further
research 50nm is the most suitable particle size for the present application

(a) (b)

Fig 3.5: variation of thermal conductivity of TiO 2 with respect to particle size (a) with no excessive
clustering (b) with excessive clustering

3.5.2 Particle concentration:

Particle concentration is nothing but the volumetric ratio of which particles are added to the
base fluid. From the fig 3.6 which vividly depicts the variation of electrical conductivity
enhancement variation with particle concentration. Thus the particle concentration effects the
electrical conductivity of nano fluid, which is most undesired phenomenon to avoid this the
particle concentration should be optimum, studies suggest that most optimum concentration is
0.05 gm per litre

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 Fig 3.6: variation of electrical conductivity enhancement with particle concentration

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 Chapter 4

COMPUTATIONAL FLUID DYNAMICS

Computers have been used to solve fluid flow problems for many years. Numerous
programs have been written to solve either specific problems, or specific classes of problems.
From the mid-1970’s, the complex mathematics required to generalise the algorithms began
to be uderstood, and general purpose CFD solvers were developed. These began to appear in
the early 1980’s and required what were then very powerful computers, as well as an in-depth
knowledge of fluid dynamics, and large amounts of time to set up simulations. Consequently,
CFD was a tool used almost exclusively in research. Recent advances in computing power,
ogether with powerful graphics and interactive 3-D manipulation of models have made the
process of creating a CFD model and analysing results much less labour intensive, reducing
time and, hence, cost. Advanced solvers contain algorithms which enable robust solutions of
the flow field in a reasonable time [19, 20].

As a result of these factors, Computational Fluid Dynamics is now an established

industrial design tool, helping to reduce design timescales and improve processes throughout
the engineering world. CFD provides a cost-effective and accurate alternative to scale model
testing, with variations on the simulation being performed quickly, offering obvious
advantages.

In this chapter an outline is given on purpose of ANSYS ICEM and numerical

methods used in CFD. Advantages, disadvantages and applications of CFD in various fields
of engineering and sciences are discussed and finally concluded the chapter by addressing
working methodology of CFD

4.1 Introduction to ANSYS ICEM

Meeting the requirement for integrated mesh generation and post processing tools
for today’s sophisticated analysis, ANSYS ICEM provides advanced geometry acquisition,
mesh generation and mesh optimization tools. Maintaining a close relationship with the
geometry during mesh generation and post-processing, ANSYS ICEM is used especially in
engineering applications such as computational fluid dynamics and structural analysis.

ANSYS ICEM provides a direct link between geometry and analysis. In ANSYS
ICEM, geometry can be input from just about any format, whether it is from a commercial

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CAD design package, 3rd party universal database, scan data or point data. Beginning with a
robust geometry module which supports the creation and modification of surfaces, curves and
points, ANSYS ICEM’s open geometry database offers the flexibility to combine geometric
information in various formats for mesh generation. The resulting structured or unstructured
meshes, topology, inter-domain connectivity and boundary conditions are then stored in a
database where they can easily be translated to input files formatted for a particular solver.

ANSYS ICEM’s mesh generation tools offer the capability to parametrically create meshes
from geometry in numerous formats:

Multiblock structured
Unstructured Tetrahedral
Unstructured tetrahedral
Cartesian with H-grid refinement
Hybrid Meshes comprising Tetrahedral, tetrahedral,
Pyramidal and/or prismatic elements
Quadrilateral and triangular surface meshes

4.2 Introduction to Computational Fluid Dynamics (CFD)

Computational Fluid Dynamics (CFD) is a computer-based tool for simulating the

behaviour of systems involving fluid flow, heat transfer, and other related physical processes.
It works by solving the mathematical equations of fluid flow (in a special form) that govern
these processes using a numerical algorithm on a computer over a region of interest, with
specified (known) conditions on the boundary of that region. The technique is very powerful
and spans a wide range of industrial and non-industrial application areas. FLUENT provides
complete mesh flexibility, including the ability to solve flow problems using structured or
unstructured meshes that can be generated about complex geometries with relative ease.
Supported mesh types include 2D triangular/quadrilateral, 3Dtetrahedral / Tetrahedral /
pyramid / wedge, and mixed (hybrid) meshes. FLUENT is written in the C-computer
language. FLUENT uses a client/server architecture, which allows it to run as separate
simultaneous processes on client desktop workstations and powerful computer servers. All
functions required to compute a solution and display the results are accessible in FLUENT
through an interactive, menu-driven interface.

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4.2.1 The Mathematics of CFD
The set of equations which describe the processes of momentum, heat and mass
transfer are known as the Navier-Stokes equations. These partial differential equations were
derived in the early 19th century and have no known general analytical solution but can be
discretized and solved numerically[22,23]. Often, an approximating model is used to derive
these additional equations, turbulence models being a particularly important example.

There are a number of different solution methods which are used in CFD codes.
The most common, and the one on which ANSYS Fluent is based, is known as the finite
volume technique.

In this technique, the region of interest is divided into small sub-regions, called
control volumes. The equations are discretised and solved iteratively for each control volume.
As a result, an approximation of the value of each variable at specific points throughout the
domain can be obtained. In this way, one derives a full picture of the behaviour of the flow.

4.3 Numerical Methods in CFD

A numerical solution of a differential equation consists of a set of numbers from
which the distribution of the dependent variables 'Ф' can be constructed. In this sense, a
numerical method is a kin to a laboratory experiment, in which a set of instrument readings
enables us to establish the distribution of the measured quantity in the domain under
investigation [24].
There are three important methods in CFD
1. Finite difference Method (FDM)
2. Finite Volume Method (FVM)
3. Finite Element Method (FEM)

4.3.1 Finite Volume Method:

A number of weighted residuals equations can be generated by dividing the
calculation domain into sub-domain (or) control volume, and setting the weighting function
to be unity over one sub-domain at a time and zero everywhere else. This variant of the
method of weighted residuals is called the sub-domain method (or) finite volume method. It
implied that the integral of the residuals over each control volume must become zero. In the
control volume formulation, the calculation domain is divided into a number of non-
overlapping control volumes. The differential equation is integrated over each control
volume.

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 The appropriate form of the conservation statement for the control volume
(namely, that the time rate of increase of energy stored in the volume is equal to the net rate at
which energy is conducted into the volume) can be represented mathematically as,

∂T
∭ ρC ∂ t dR+∯ qnds=0
R S (4.1)

The 1st term in this equation, an integral over the control volume, represents the time rate of
increase in the energy stored in the volume. The 2 nd term, an integral over the surface of
volume, represents the net rate at which energy is conducted out through the surface of the
volume.

4.3.2 Simple Algorithm

The acronym SIMPLE stands for semi-implicit method for pressure-linked equations. The
algorithm was developed by PATNANKAR & SPALDING (1972) and is essentially a guess
and correct procedure for the calculation of pressure on the staggered grid arrangement [21].
The method can be explained by considering the two dimensional laminar steady flow
equations in Cartesian co-ordinates. To initiate the SIMPLE calculation process a pressure
field P* is guessed. Discretised momentum equations are solved using the guessed pressure
field to yield velocity components U* and V*. The correction P1 is the difference between the
P and P*, so that
P = P*+ P1 (4.2)
Similarly, Velocity corrections U1 and V1 to relate correct velocities U and V to the guessed
velocities U* and V* are given by
U=U*+U1 (4.3)
V=V*+V1 (4.4)
Substitution of the correct pressure field P into the momentum equations yields the correct
velocity field (u, v)

4.3.3 General Procedure for Algorithms

1. Guess the pressure (Po) at each grid point

2. Solve the momentum equations to find the velocity components (Uo, Vo).
3. Solve the pressure-correction equation to find 'p' at each grid point

4. Replace the previous intermediate values of pressure and velocity with the new

22 | P a g e
 corrected values and return to the original step. Repeat the step until the step
converges.

4.4 Advantages, Disadvantages and Applications of CFD

a) Advantages of Computational Methods

In the computational approach a limited number of assumptions are used, a high-
speed digital computer is used to solve the resulting governing fluid dynamic equations [23].
The development of numerical methods and the availability of high end computer hold the
promise that the implications of a mathematical model can be worked out for almost any
practical problem. Several advantages are listed as follows
 No restriction to linearity.
 Complicated physics can be treated.
 Time evaluation of flow can be obtained.
 It has the potential of providing information not available by other means.
 Computational investigation can be performed with remarkable speed. Designer can
study the implications of hundreds of different configurations in minimum time and
choose the optimum design.
 It gives detailed and complete information. It can provide the values of all the relevant
variables (pressure, velocity, temp, concentration, turbulence) throughout the domain
of interest.
b) Disadvantages of Computational Methods
 Truncation errors.
 Computer storage & speed.
c) Applications of CFD
CFD is used by engineers and scientists in a wide range of fields. Typical applications
include:
Process industry: Mixing vessels, chemical reactors
Building services: Ventilation of buildings, such as atria
Health and safety: Investigating the effects of fire and smoke
Motor industry: Combustion modelling, car aerodynamics
Environmental: Dispersion of pollutants in air or water, Weather
prediction
Power and energy: Optimisation of combustion processes

23 | P a g e
 Aviation: Aerodynamics of aircraft & Space vehicles: lift & drag.
Turbo machinery: Flows inside rotating passages, diffusers.
Biomedical engineering: Blood flows through arteries and veins.
Marine engineering: Loads on off-shore structures, Hydrodynamics
of ships.
Electrical and electronic engineering: Heat transfer within and around circuit
boards, cooling of equipments including micro-circuits.

CFD provides a good example of the many areas that a scientific computing
project can touch on, and its relationship to computer science. Fluid flows are modeled by a
set of PDE, the Navier-stokes equations. On the discretised mesh the Navier-stokes equations
take the form of large system of non-linear equations going from continuous to discrete set of
equations that combines both physics and numerical analysis [21]. CFD problems are at the
limits of computational power. Solving a particular problem generally involves first
discretising the physical domain that the flow occurs in, such as the interior of turbine engine
or the radiator system of a car. This discretisation is straight forward for very simple
geometries such as rectangles or circles, but difficult for more complicated objects. Currently
automatic "mesh generators" are simply not adequate, requiring extensive investment of time
on the part of the designer.

4.5 Working of CFD Methodology

CFD may be used to determine the performance of a component at the design stage, or it can
be used to analyse difficulties with an existing component and lead to its improved design.
The process of performing a CFD simulation is split into four components. They are as
follows [23],
1. Geometry/Mesh (first pre-processing stage) 3. Solver
2. Physics Definition (second pre-processing stage) 4. Post-processor

1. Pre Processor
It transfers the input of a flow problem to CFD program by means of an operator friendly
interface and the subsequent transformation of this input into a suitable format, which can be
used by solver. It includes:

a. Geometry/Mesh (first pre-processing stage)

This interactive process is the first pre-processing stage. The objective is to produce a mesh
for input to the physics pre-processor. Before a mesh can be produced, a closed geometric

24 | P a g e
solid is required. The geometry and mesh can be created in CAD/Mesh or any of the other
geometry/mesh creation tools. The basic steps involve:
 Defining the geometry of the region of interest i.e. the computational domain.
 Creating regions of fluid flow, solid regions and surface boundary names.
 Setting properties for the mesh (Grid generation or mesh generation - subdivision of the
computational domain into small segments, which are called as cells, control volumes).

This pre-processing stage is now highly automated. In ANSYS Fluent, geometry can be
imported from most major CAD packages using native format, and the mesh of control
volumes is generated automatically.

b. Physics Definition (second pre-processing stage)

This interactive process is the second pre-processing stage and is used to create input required
by the Solver. The mesh files are loaded into the physics pre-processor. The physical models
that are to be included in the simulation are selected. The solution to a flow problem
(pressure, velocity, temperature etc.) is defined at 'nodes', corners of each cell. The number of
the cells in the grid governs the accuracy of a CFD solution. In general, the larger number of
cells the better the solution accuracy, but increases the time required for solution.
Fluid properties and boundary conditions are specified.
1. Selection of the physical phenomena that need to be modelled.
2. Specification of appropriate boundary conditions at cells, which coincide with or
touch the domain boundary.

2. Solver
The component that solves the CFD problem is called the Solver. It produces the required
results in a non-interactive/batch process. It CFD problem is solved as follows:
1. The partial differential equations are integrated over all the control volumes in the
region of interest. This is equivalent to applying a basic conservation law (e.g., for
mass or momentum) to each control volume.
2. These integral equations are converted to a system of algebraic equations by
generating a set of approximations for the terms in the integral equations.
3. The algebraic equations are solved iteratively.
- An iterative approach is required because of the non-linear nature of the equations, and as
the solution approaches the exact solution, it is said to converge. For each iteration, an error,
or residual, is reported as a measure of the overall conservation of the flow properties.

25 | P a g e
- How close the final solution is to the exact solution depends on a number of factors,
including the size and shape of the control volumes and the size of the final residuals.
Complex physical processes, such as combustion and turbulence, are often modelled using
empirical relationships.

- The solution process requires no user interaction and is, therefore, usually carried out as a
batch process. The solver produces a results file which is then passed to the post-processor.

There are three distinct of numerical solution techniques: finite difference, finite
element and finite volume method. The outlines of the numerical method that form the basis
of the solver perform the following sequence steps:
1. Approximation of the unknown flow variables by means of simple function.
2. Discretisation by substitution of the approximation into the governing equations and
subsequent mathematical manipulation.
3. Solution of the algebraic equation through an interactive process.

3. Post Processor
The post-processor is the component used to analyse, visualise and present the
results interactively. Post-processing includes anything from obtaining point values to
complex animated sequences. As in pre-processing, a huge amount of development work has
recently taken place in the post-processing field. Owing to the increased popularity of
engineering workstations, many of which have outstanding graphics capabilities, the leading
CFD package are now equipped with versatile data visualization tools [24].
Examples of some important features of post-processors are:
• Visualisation of the geometry and control volumes
• Vector plots showing the direction and magnitude of the flow
• Visualisation of the variation of scalar variables (variables which have only
magnitude, not direction, such as temperature, pressure and speed) through the
domain
• Quantitative numerical calculations
• Animation
• Charts showing graphical plots of variables and vector plots
• Hardcopy output
• Domain geometry and grid display.
• Line and shaded contour plots.
• 2d and 3D surface plots.

26 | P a g e
 • Particle tracking.
• View manipulation (translation, rotation, etc.)
• Colour postscript

ANSYS Fluent is capable of modelling:

• Steady-state and transient flows
• Laminar and turbulent flows
• Subsonic, transonic and supersonic flows
• Heat transfer and thermal radiation
• Buoyancy
• Non-Newtonian flows
• Transport of non-reacting scalar components
• Multiphase flows
• Combustion
• Flows in multiple frames of reference
• Particle tracking

4.5.1 Description of finite volume solver settings (FLUENT)

The FLUENT serial solver manages file input and output, data storage, and flow
field calculations using a single solver process on a single computer. FLUENT also uses a
utility called cortex that manages FLUENT's user interface and basic graphical functions.
FLUENT's parallel solver compute a solution using multiple processes that may be executing
on the same computer, or on different computers in a network. FLUENT can read the file in
the .msh or .cas format only. It facilitates to define data like units, turbulent models, material
properties, operating conditions and boundary condition. At the time of running the
tool(fluent) for monitoring purpose FLUENT can print and plots the graphs like iteration
verse residuals (like continuity, velocity victors and k etc.,) in one window and iterations
verse Co-efficient of drag(for convergence) in another window, fluent can also print and plot
the results like forces and moments.

This solution-adaptive grid capability is particularly useful for accurately

predicting flow fields in regions with large gradients, such as free shear layers and boundary
layers. In comparison to solutions on structured or block-structured grids, this feature
significantly reduces the time required to generate a high quality grid. Solution adaptive
refinement makes it easier to perform grid refinement studies and reduces the computational

27 | P a g e
effort required to achieve a desired level of accuracy, since mesh refinement is limited to
those regions where greater mesh resolution is needed.

4.5.2 Overall Process: The generic working process involves the following

Open / Create Project

Create / Import Geometry

Geometry Manipulation / Clean up

Set parts
Create Mesh Blocking
Auto Sizing (Quad / Tetra)

Set Mesh Sizes, Methods and Types

View / Edit
Auto Volume Mesh Premesh
Shell Mesh

View / Edit Mesh

Solver Setup

Output to Solver
Run
Solver

Post process

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 Chapter 5

MODELLING AND ANALYSIS

In the virtue of analysing the behavioral characteristics of TiO 2, when used as coolant as
proposed in the previous chapters, we attempt in finding it by testing on virtual model created
by using CATIA V5 software and analysing it in ANSYS fluent with an aid of ICEM CFD
for meshing process. This chapter describes in detail how the virtual model is created by
using CATIA V5 and also the process or methodology that are adapted to carry on the study
or analysis in ANSYS. The model is created in the form of individual components and
assembled although there is a possibility of analysing the whole clamp and pressure ring
assembly, the iteration are time consuming and tedious. There is a close and almost similar
result, when single clamp is tested with an internal fluid flow and the results were multiplied
to the total number of clamps.

5.1 Modelling
Copper Clamp

The modelling was done using CATIA V5, firstly part modelling is selected and then
the plane was selected in this and the top view of the clamp was drawn according to the
dimensions and the pad command was used to extrude the two dimensional top view of the
clamp according to the given dimensions.

Fig5.1: modelling of the copper clamp

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Now the clamp is created as a solid block but the coolant channel section should be cut
inside, the solid clamp. For this process the central plane should be selected and the central
axis of the channel is to be drawn, with curves that the channel should possess as pre
determined. Now the top of the clamp is selected and a datum plane is added and at the end of
previously drawn curve a circle with required channel diameter is drawn and a slot command
is selected and applied. The channel is created. The final 3D modelling of a single clamp with
internal channel for coolant is shown in fig 5.1.

The Geometry is saved in .igs file and before solving, for mesh optimization it is forwarded
to ANSYS ICEM-CFD

5.1.1 ANSYS ICEM Steps:

1. The Geometry Creation

Controls display of points, curves, surfaces and bodies (material volumes). Subsets
can also be created, displayed and modified. A given subset can contain any number of
different geometry types. A given entity can belong to more than one subset.

2. Creating Parts

All entities, geometry or mesh, are associated to a given part. An entity cannot belong
to more than one part. With this association, groups of entities, regardless of type can be
toggled on and off. Parts have a specific colour to discern them from other parts. Parts can
be made sub-categories of assemblies, created by right mouse selecting on “Parts.”
Individual parts can then be dragged and dropped into the assembly. Toggling the
assembly on/off will turn on/off all the parts within the assembly as for any category/sub-
category.

3. Starting the Project

From a UNIX or DOS window, start ANSYS ICEMCFD. Select File > Geometry >
Open and select the geometry.tin file.

4. The Blocking Strategy

The first step in generating a Mesh with Blocking is to decide on a blocking strategy.
The following steps are usually taken when blocking the model to obtain the desired
results. Fitting the Blocking Material to the geometry is accomplished by creating
Associations between the Edges of the Blocks and the curves in the geometry, and then

30 | P a g e
 moving the Vertices of the Blocks onto the corners of the geometry. The Split function is a
common technique when beginning blocking by carving a Cartesian set of blocks around
the object. An O-grid block is created around the model to give an orthogonal grid. Once
this is done, mesh sizes are set and the mesh is computed. The program will automatically
project the edge nodes onto the curves of the geometry and the Tetrahedral mesh will be
interpolated. The following Parts that have been defined in the geometry:
Fluid: Entire Fluid domain
Solid: Entire Solid domain
INLET: Inlet face of the fluid domain
OULET: Outlet face of the domain
Top Wall: Top face of the Solid domain
Bottom Wall: Bottom face of the solid domain
Side Wall: Side faces of the solid domain
Tube wall: Inner tube wall

5. Initializing the Blocking

Initialize the blocking: Select Blocking > Create Block > Initialize Blocks

as shown in Fig 5.1.0. First, a block is defined that encompasses the entire or selected
portions of the geometry. This block is associated to a part (SOLID is the default part
name) and Apply. This volume part should be different than any part containing geometry.
This initial block is then modified by splitting, discarding unused blocks, and creating O-
grids.

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 Fig. 5.1.0:Create Block Menu Fig. 5.1.1:Split Block Window

Fig. 5.1.2: Index Control settings

6. Splitting the Blocking Material with Prescribed Points

This option is under Blocking > Split Block > Split Block . The most
common way of “creating” blocks is to split existing blocks. The Split function, which
divides the selected block interactively, may propagate across all visible blocks, selected
blocks or selected faces. An edge is selected and the split (new) edges will propagate
perpendicular to the selected edge. In the Split Block panel, change Split Method to
Prescribed Point as shown in Fig 5.1.1.

7. Associating to Geometry (Projecting the Edges to the Curves)

The next step is to associate block entities to geometric entities. Most of the time,
this means associate edges to curves. This will make sure hard features are captured. Other
options are to associate vertices to points to capture sharp corners and faces to surfaces if
the default face projection, where node are projected to the nearest point in the normal
direction to the nearest surface, fails to give proper results.

8. Aligning the Vertices

Vertices are typically moved on to the geometry. Computation will automatically
move vertex nodes to the nearest point in the normal direction on the geometry. It’s always
best to manually position the node on to the geometry rather than leave it up to the default
projection.

9. Overview of the Index Control

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 By selecting Blocking (in the Display tree) > Index control, Blocks may be
visually blanked/ un blanked by using the Index control which toggles the blocks in I, J, K
or radial (if o-grids exist) directions. All block edges and vertices are assigned I, J, K
value. The index control menu will appear in the lower right hand corner of the screen as
shown in Fig 5.1.2 in the same area where the quality histogram is displayed. If the
histogram is turned on, it will take precedence and the index control will be displayed as a
pop-up menu.

10. Generating the Mesh with edge parameters

The edge meshing parameter task has been greatly automated by providing the
user with unlimited flexibility in specifying bunching requirements. Assigning the edge
meshing parameters occurs after the development of the block topology model. This
option is accessible by selecting Meshing > Edge params. Controls display of all mesh
types: points (node elements), lines (bars), shells (tris or quads) and volumes (tetras,
pyramids, prisms, Tetras). The following pre-defined bunching laws or meshing laws:
Default (Bi-Geometric Law) Uniform Hyperbolic Poisson
Curvature Geometric 1 Geometric 2 Exponential 1
Exponential 2 Bi-Exponential Linear Spline

11. Set Pre-Mesh Parameters

Mesh sizes (parameters) can be set globally, or on the surfaces, curves or parts.
These sizes then have to be applied to the blocking: Pre-Mesh Params > Update Sizes.
Selecting Pre-Mesh in the Display Tree will then prompt the user to (re)compute the pre-
mesh. The Number of nodes, initial and final node spacing, expansion ratios and
mathematical meshing laws can be prescribed on individual edges. These distributions can
be copied to opposing parallel edges down and upstream of the selected edge.

12. Checking the Mesh Quality for determinants and angle

Before converting the pre-mesh to unstructured or multi-block, the quality should

be checked. To check the mesh quality, select Blocking >Pre-mesh Quality Histogram
Different criteria such as determinant, angle and warpage can be checked and displayed.
Select anyone of the criterion as Determinant (2x2x2)/Min Angle/Min Volume/Warpage
and press Apply. The histogram will display at the lower right. The Histogram window
shows a bar graph representing the mesh quality, where 0 represents the worst aspect ratio
and 1 represents the best aspect ratio. The X axis represents element quality (usually

33 | P a g e
 normalized to between 0 and 1) and the Y axis represents the number of elements. The
user may modify the display of the histogram by adjusting the values of Min X value, Max
X Value, Max Y Height and Num Bars by pressing the replot. A value of determinant
greater than 0.7 is acceptable for most commercial solvers.

13. Determining the Location of Elements

By clicking on any of the histogram bars with the left button, the user may
determine where in the model these elements are located. The selected histogram bars will
change in colour to pink. After selecting the bar(s), the Show button is pressed to highlight
the elements in this range. If the Solid button is turned on, the elements marked in the
histogram bars will be displayed with solid shading.

14. Further refinement with Edge Parameters to adjust the mesh

Again, turn off Pre-Mesh. Select Pre-Mesh Params > Edge Params >
Select edge(s) and again select one of the radial edges. Increase the number of Nodes and
Change Spacing. Turn on Copy Parameters and select Copy > Method > To All Parallel
Edges (default) and Apply. Turn on Pre-Mesh and recompute. Turn off Curves, Surfaces,
and Edges and view the final mesh

15. Verifying and Viewing with Scan Planes

Another display option within Pre-Mesh. With this function, the user can
visualize the interior volume mesh by “scanning” or scrolling a logical (I, J, K) index
plane through the model.

16. Saving the Mesh and Load from Blocking

Select File > Blocking > Save blocking As and enter a name, such as profile1.blk.
Saving the blocking will allow the user to change any meshing parameters in the future by
reloading the blocking onto the geometry. To write the mesh in an unstructured format,
right mouse click in the Display Tree on Blocking>Pre-mesh>Convert to Unstructured
Mesh. This will write the default name “hex.uns” to the working directory, and
immediately load the mesh. To save the mesh to a different name, the user can then select
File>Mesh>Save Mesh As. To write the mesh in a structured format, right mouse click in
the Display Tree on Blocking>Pre-mesh>Convert to Multi Block Mesh. Finally, save the
project.

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17. Writing Output to a desired Solver

Select Output > Select solver to open the Selection window. Choose the
appropriate Solver with Select Settings > Common structural Solver

18. Writing the Solver Input File to the selected solver

Next, choose Output > Ansys Fluent input to write Ansys Fluent input files, and
choose the Tetra unstructured domain to write to Ansys Fluent format.
Assign the parameters for the Ansys Fluent input file set. Select Done to close the
Ansys Fluent window, and the ICEM CFD messages window will indicate when the
translation process is complete. When the translation process is complete, the Ansys Fluent
files will have been written to the model directory. The Ansys Fluent solver is now
prepared to run with that file set. Select File > Quit to close the ANSYS ICEMCFD
window. The remainder of this section deals with ANSYS FLUENT.
5.1.2 Summary of ANSYS ICEM Steps:
1. The Geometry Creation
2. Creating Parts
3. Starting the Project
4. The Blocking Strategy
5. Initializing the Blocking
6. Splitting the Blocking Material with Prescribed Points
7. Associating to Geometry (Projecting the Edges to the Curves)
8. Aligning the Vertices
9. Overview of the Index Control
10. Generating the Mesh with edge parameters
11. Set Pre-Mesh Parameters
12. Checking the Mesh Quality for determinants and angle
13. Determining the Location of Elements
14. Further refinement with Edge Parameters to adjust the mesh
15. Verifying and Viewing with Scan Planes
16. Saving the Mesh and Load from Blocking
17. Writing Output to a desired Solver
18. Writing the Solver Input File to the selected solver

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5.1.3 Domain for Contact Pad

The flow domain is required to be discretised to convert the partial differential

equations into series of algebraic equations. This process is called grid generation. First,
the surface model of the contact pad will be modelled and then generate the structural grid
with Tetrahedral cells commercially available grid generation code, ICEM Software was
used. Here Domain is prepared for solid and fluid units, the contact pad with domain is
shown in the Fig 5.15. The mesh is generated in such a way that cell sizes for solid is
coarse and fluid is small and increase towards centre of tube. A multi-block structured grid
of 0.5millions was created. Then after the mesh will be imported for flow analysis into a
suitable commercial CFD package like ANSYS FLUENT.

5.2 Analysis

5.2.1 Governing equation

The conservation equations in differential form for the three dimensional unsteady,
compressible flow, Navier Stokes equations are written as

∂Q ∂ Ei ∂ Fi ∂Gi ∂ E v ∂ F v ∂ G w
+ + + = + + + S(5.4)
∂t ∂x ∂ y ∂ z ∂x ∂ y ∂ z

Where Q is the state variable to be solved, E i and Fi are the in viscid fluxes in two
coordinate directions, Ev and Fv are the viscid fluxes in two coordinate directions, and S is
the source term. All the variables are defined as follows

[ ][ ]
ρu τ yz
2
τ xz
Ei= ρu + P Ev =
ρuv τ xy
( e+ P ) u u τ xx + v τ xy + w τ yz−q x

[ ][ ]
ρv τ yz
F i= ρuv τ yx
2
F v=
ρ v +P τ yy
( e+ P ) v u τ yx + v τ yy +w τ yz−q y

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 [ ][ ]
ρv τ zz
Gi= ρuv τ zx
2
Gv =
ρ v +P τ zy
( e +P) v u τ zx + v τ zy + w τ zz −q y

[ ][]
ρv
ρuv−τ yx ρ
S= v ∂v Q= ρu
(
ρ v 2+ 2 μ −
y ∂y ) ρv
e
( e+ P ) v−( u τ yx+ v τ yy ) + q y

Where prime variables in the unknown Q are density, velocity components u, v and w, and
total energy per unit volume E. Fluid pressure is denoted with p, which is related with the
equation of state for the perfect gas is given by (5.5)

p ρ 2 2 2
E= + ( u +v + w ) (5.5)
γ−1 2

For in viscid flows, the governing equations are obtained from the Navier strokes equation
by dropping all second-order viscous diffusion terms Eq (5.5) becomes

∂Q ∂ Ei ∂ Fi ∂Gi
+ + + =S (5.6)
∂t ∂x ∂ y ∂ z

5.2.2 Overview of flow solvers

The two types of solvers available in Fluent are

Pressure-based solver:

This approach was developed for low speed incompressible flows. The velocity field is
obtained from the momentum equations while the pressure field is extracted by solving a
pressure or pressure correction equation which is obtained by manipulating continuity and
momentum equations in pressure-based solver.

Density-based solver:

The density-based approach was mainly used for high speed compressible flows. The
velocity field is obtained from the momentum equations. In this approach, the continuity

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 equation is used to obtain the density field while the pressure field is determined from the
equation of state.

For the present CFD simulation, pressure -based solver was selected.

5.2.5. Initial and boundary conditions

Outlet

Inlet

Fig. 5.2: Initial & boundary conditions

The fluid domain is placed where the initial conditions behind the contact pad are pressure
P, temperature T and velocity V. The height of the contact pad is 0.8m and its width is
0.444m and 0.555m for inner and outer walls respectively and thickness is 80 mm. The
still air which is outside the tube is at atmospheric conditions. The contact pad material is
assumed to be copper and fluid to be water or TiO2.

Due to the symmetric nature of the model, only the single contact pad figure is
modelled for the simulation so that the computing effort of the full domain can be reduced.
The boundary conditions applied on the present model can be seen from the above
Fig. 5.2

Velocity boundary condition is applied to the inlet of the present computational

domain and the wall boundary conditions are applied to the walls of the contact pad
surfaces of the present computational domain.

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5.3 Computational setup in fluent

Fig. 5.3: Fluent setup

Step 1: Setting Up the CFD Simulation in ANSYS FLUENT

After creating a computational mesh for the launcher geometry in ICEM, a CFD analysis
can setup using ANSYS FLUENT. Start > ANSYS FLUENT.

When ANSYS FLUENT is started, FLUENT Launcher is displayed as shown in Fig 5.3,
allowing viewing and/or setting certain ANSYS FLUENT start-up options. ANSYS
FLUENT Launcher allows to decide which version of ANSYS FLUENT will use based on
the geometry and on the processing capabilities. Ensure that the proper options are
enabled. Click OK to launch ANSYS FLUENT.

Step 2: Read case and data

File Read CASE & DATA

Read the CASE & DATA file (.cas)

As ANSYS FLUENT reads the case & data file, it will report the progress in the console.
the warnings about the use of axis boundary conditions can disregard, as it will make the
appropriate change to the solver settings in the next step.

Step 3:Pre-processor

Step 3.1: Set some general settings for the CFD analysis.
Select General in the navigation pane to perform the mesh-related activities and to choose
a solver
Define General

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 a. Retain the default selection of Pressure-Based in the Type list. The pressure-based solver must be
used for current simulation.
b. A transient state is opted to simulate the flow inside the launcher

Step 3.2: Check the mesh scale.

Mesh Scale

(a) Retain the default settings in ‘mm’.

(b) Close the Scale Mesh dialog box.

Step 3.3: Check the grid.

Mesh Check

FLUENT will perform various checks on the mesh and will report the progress in the console
window. Any errors in the mesh will be reported at this time. Pay particular attention to the
reported minimum volume. Ensure that the minimum volume is not negative, since ANSYS
FLUENT cannot begin a calculation when this is the case. This mesh is quadrilateral. The
gradients normal to the launcher wall are much greater than that tangent to the launcher;
consequently, the cells nearest the surface have very high aspect ratios.

Fig. 5.4: Entire Domain mesh

Step 3.4: Set up the models for the CFD simulation.

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Enable the Energy equation on

Define Models Energy On

Step 3.5: Set up the materials for the CFD simulation.

Click the FLUENT Database button in the Materials panel. The Database Materials dialog box will
open.

Define Materials Fluid Water

Define Materials Solid Copper

Step 3.6: Set up the cell zone conditions for the CFD simulation.

Define Cell Zone Conditions

a. Select fluid in the Zones list and water in the Cell Zone Conditions task page, then click the Edit
button to open the Fluid dialog box.
b. In the Fluid dialog box, select stationary from the motion type drop-down list.
c. Click OK to close the Fluid dialog box.

Step 3.7: Set up the Boundary Conditions for the CFD analysis.

Inlet:
Set the boundary condition for domain/velocity inlet : 2.28m/sec /Temperature : 26.80C
/Pressure: 215746 Pa

Fig. 5.5: Setting of Boundary conditions

Outlet:
Set the boundary condition for domain/Outflow: 1

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Internal :
Set the boundary conditions for :
Top Wall : Electric potential- i=64522Amps/m2, R = 0.0001
Fluid Domain/interior
Solid Domain/interior
Bottom Wall : Heat Flux = 776080W/m2K
Side Wall : Stationary wall, Via System coupling
Tube Wall : Stationary wall, coupled
Outer Wall : Stationary wall, Via System coupling
Inner Wall : Stationary wall, Via System coupling
Step 4: Solver
Step 4.1: Set up Solution parameters for the CFD simulation

Solve Solution Methods

Fig. 5.6: Solution methods

a. Select Coupled from the Scheme drop-down list in the Pressure-Velocity Coupling group
box.
b. Select Least Square Cell Based from the Gradient drop-down list in the Spatial
Discretization group box.
c. Select Standard from the Pressure drop-down list in the Spatial Discretization group box.
d. Select QUICK for Momentum

Step 4.2: Set up Solution Controls for the CFD simulation.

Solve Solution Controls

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 Fig. 5.7: Solution controls
Click on equations and add flow and energy equations- ON

Step 4.3: Solution initialization

Solution Inlet Initialize

Fig. 5.8: Solution Initialization

Click on initialize the solution

Step 4.4: Run calculation (RC)

RC TIME STEP No.of time steps

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 Fig. 5.26: Run calculation

Solve Run Calculation Calculate

a. Enter Number of Iterations.

b. Click Calculate. As the calculation progresses, the residuals will be plotted in the graphics
window.
Step 4.5: Save the case & data file (cav.dat).

File Write Case & Data

Step 4.6: Close the ANSYS FLUENT application.

File Exit

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 Chapter 6

RESULTS AND DISCUSSION

This chapter presents a vivid description of the simulation results that are obtained by running
tests on the virtual model created using CATIA V5 by using ANSYS ICEM CFD, ANSYS
Fluent. The test results were first presented and then these results were analysed and
comparisons were drawn between the conventional coolant and the suggestive nano fluid.
These comparisons were about various behavioural characteristics between the coolants
under same operational parameters.

6.1 ANSYS Fluent simulation results:

The generated virtual model specified in chapter 4 following the simulation test procedure
mentioned in chapter 5 different test results regarding behavioural and working
characteristics of the two fluids were obtained, major concern in the study is about the heat
transmissibility of the two fluids, which has an effect on the temperature of the copper
clamp, whose temperature is to be reduced. This is indirectly known from the thermal
gradient of the coolant and the copper clamp surface. The tests were run for three velocity
(m/s)s 1.5m/s, 2.28 m/s (working velocity) and 3 m/s. the temperatures of coolant,
temperature of copper clamp surface, velocity , current were determined from the simulation
results the obtained. Contours, Graphs of corresponding obtained results were presented.

6.1.1 CFD RESULTS:

6.1.1.1 Simulation 1:

Simulation 1
Velocity 1.5 m/s
Pressure 2.2 kg/cm2
Fluid Water

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6.1.1.1.1 Contours:

Fig 6.1: Contour of Coolant Temperature Fig 6.2: Contour of Copper Clamp Temperature

Fig 6.3: Contour of Velocity (Coolant)

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6.1.1.1.2 Simulation plots:

Fig 6.4: plot of Temperature of coolant vs time

Fig 6.5:plot of Velocity vs flow time

6.1.2 Simulation 2:
Simulation 2
Velocity 2.28 m/s
Pressure 2.2 kg/cm2
Fluid Water

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6.1.2.1 contours:

Fig 6.6:contour of Temperature of Coolant Fig 6.7:contour of temperature of copper clamp

Fig 6.8:contour of Velocity Magnitude (coolant)

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6.1.2.2 Simulation Plots:

Fig 6.9: plot of Temperature vs time

Fig 6.10: plot of velocity vs flow time

6.1.3 Simulation 3:
Simulation 3
Velocity 3 m/s
Pressure 3 kg/cm2
Fluid Water

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6.1.3.1 Contours

Fig 6.11:contour of temperature(coolant)

Fig 6.12: contour of Temperature (cooper clamp) Fig 6.13:contour of velocity (coolant)

6.1.3.2 Simulation plots:

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 Fig 6.14: plot of Temperature vs time

Fig 6.15: plot of Velocity vs flow time

6.1.4 Simulation 4:
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 Simulation 4
Velocity 1.5 M/S
Pressure 2.2 Kg/Cm2
Fluid TiO2

6.1.4.1 Contours:

Fig 6.16: Contour Of Temperature (Coolant) Fig 6.17:Contour Of Temperature (Copper Clamp)

Fig 6.18: Contour Of Velocity Magnitude (Coolant)

6.1.4.2 Simulation Plots:

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 Fig 6.19: Plot Of Temperature Vs Time Fig 6.20: Plot Of Velocity Vs Time

6.1.5 Simulation 5:
Simulation 5
Velocity 2.28 M/S
Pressure 2.2 Kg/Cm2
Fluid TiO2

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6.1.5.1 Contours:

Fig 6.21: Contour Of Temperature (Coolant)

Fig 6.22: Contour Of Temperature (Copper Clamp) Fig 6.23: Contour Of Velocity (Coolant)

6.1.5.2 Simulation Plots:

Fig 6.24: Plot Of Temperature Vs Time Fig 6.25: Plot Of Velocity Vs Time

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6.1.6 Simulation 6:
Simulation 5
Velocity 3 M/S
Pressure 2.2 Kg/Cm2
Fluid TiO2

6.1.6.1 Contours:

Fig 6.26: Contour Of Temperature (Coolant)

Fig 6.27: Contour Of Temperature (Copper Clamp) Fig 6.28: Contour Of Velocity (Coolant)

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6.1.6.2 Simulation Plots:

Fig 6.29: Plot Of Temperature Vs Time Fig 6.30: Plot Of Velocity Vs Flow Time

6.2 INFERENSES OF SIMULATION RESULTS:

Total six simulations were run considering three velocity (m/s)s and two coolants, water and
TiO2 and results were successfully generated and well presented above, from these simulation
results various inferences were made and tabulated. Most of these inferences were direct
values from the simulation while some were calculated.
6.2.1 Results table:

Mass Temperature
Type Velocity(m/s) Velocity Copper Coefficient of Resistance
coolant R(20) ∆T
(m/s) (Kg/s) clamp temperature(α)
1.5 1.64 34.32 112.89 0.004041 92.89 4.04E-07
H2O 2.28 2.49 31.89 97.332 0.004041 77.332 3.86E-07
3 3.28 30.52 89.33 2.94E 0.004041 69.33 3.76E-07
1.5 1.88 34.46 104.84 -07 0.004041 84.84 3.95E-07
TiO2 2.28 2.86 31.92 91.68 0.004041 71.68 3.79E-07
3 3.77 30.6 82.07 0.004041 62.07 3.68E-07

From the above table it’s clearly evident that there is a noticeable change in the value of
temperature of the copper clamp at the working velocity (m/s) and also at other velocity (m/s)
between the two coolants Viz. Water and TiO 2. The temperature values of both fluids were
not of large variation; this clearly indicates that there won’t be any overheating of the nano

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fluid it would behave as same as the conventional coolant with greater efficiency than water
with same rise in temperature

6.3 Comparison between water and TiO2:

Based upon the results that are tabulated above, comparisons can be drawn between the two
coolants. The effect of using two coolants are compared by using plots that are generated by
using the values inferred from the simulations that are run, by virtually creating the real life
conditions which is vividly presented in chapter 5. These values were after all considered for
single copper clamp and mathematically applied for the entire plant, the value compared
below were very close but when applied to the whole plant overall difference would be
substantial enough.

6.3.1 Temperature of Coolant:

∂Q ∂Ei ∂Fi ∂Gi ∂Ev ∂Fv ∂Gw

+ + + = + + +S
∂t ∂x ∂y ∂z ∂x ∂y ∂z
Fig 6.31: comparison between water and TiO2 based on coolant temperature

The graph is plotted between temperature of coolant and velocity (m/s), for three velocity
both curves were almost overlapping, clearly indicating the temperature rise of the coolant is
not much varied. There by it indicates that there is no requirement for additional secondary
coolant required when TiO2 is applied for cooling process, also suggests that there is no
additional components to be installed for its pliability

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6.3.2 Temperature of Copper Clamp:

[ ][ ]
ρu τ yz
2
ρu +P τ xz
Ei= Ev =
ρuv τ xy
( e+P ) u uτ xx+v τ xy+w τ yz−q x
Fig 6.32: comparison between water and TiO2 based on clamp temperature
The graph is plotted between temperature of Copper clamp and velocity (m/s), for three
velocity (m/s)s. It’s clearly evident that there is a notable difference between the two curves,
implying that with the application of TiO 2 there is a reduction of temperature of the copper
clamp. This clearly suggests that TiO2 is more efficient with the same rise in coolant
temperature as water

6.3.3 Resistance of Copper Clamp:

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 [ ][ ]
ρv τ yz
ρuv τ yx
F i= 2 F v =
ρv +P τ yy
( e+P ) v uτ yx +vτ yy +wτ yz−q y
Fig 6.33: comparison between water and TiO2 based on clamp resistance

The graph is plotted between resistance of Copper clamp and flow velocity, for three velocity
(m/s), using two coolants. It is clearly evident that there is a steep decrease in both the curves
between 1.5 m/s and 2.28 m/s velocities this is due to the fact that there is a variation in
RESISTANCE of copper with the temperature, between those velocities, the heat dissipation
is more when compared to the other range. The two curves were notably separated these due
to the fact that clamp temperature is more efficiently reduced using TiO 2. As the temperature
decreases the RESISTANCE also decreases, reducing the resistance and thereby reducing the
resistance loses

6.4. Power Losses:

Based on the evidences collected and presented above some basic calculations were done to
find the total power wastage that is comprehensive of the usage of conventional coolant,
which can be overcome by the usage of subject coolant (TiO 2). The power wastage is due to
two major causes they were pump work required for pumping more amount of coolant for
satiating the need of heat dissipation of the cooper clamp, this could be unaltered due to the
fact mentioned in the chapter 3 that both pump works are nearly the same, as the excess pump
work required for nano fluid is compensated by reduced flow rate of the nano fluid due to its
effectiveness near to the water at reduced flow rate and the second part is due to the fact that
as the temperature increases the resistance, as resistance and temperature follow the
following relation:
R = Ro (1+α (∆T))
Where, α - thermal coefficient
∆T - thermal gradient

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 R - Total Resistance
Ro - Resistance at room temperature
Where R0 is given by,
R0 = ρ.L/A
ρ – resistivity
L – length of conductor
A – area of cross section

There will be increase in the resistance of copper clamp, which acts a power transmission
line between supply and carbon electrode. Thus if the clamp resistance increases due to
temperature raise due to insufficient heat dissipation, there is a minute power loss in the form
of resistance for every cycle, now each electrode has 8 such clamps and each furnace has 3
electrodes and plant has total of 3 furnaces operating for 8 hours per day, this itself is a large
amount of power of furnace operation has a electric power. The difference between the power
loss while using two coolants can be referred as the power wastage with the usage of
conventional coolant and all this power could be saved by using the subject coolant viz
(TiO2).

6.4.1 Model calculations:

At V=2.28m/s, obtained Tc = 97.3320C
R = Ro (1+α (∆T))
R0 = ρ.L/A
= 1.72 x 10-8 x 0.8
0.04971
= 2.94E-07 Ω/m

As we know R0 of copper = 2.94E-07

R = Ro (1+α (∆T))
= 2.94E-7(1+ 0.004041(97.332-20))
= 3.86E-07 Ω
Resistance Power loss E = I2R = 27002 x 3.86E-07 = 2.81394/cycle
As there are 24 copper clamps in each furnace = 24 x 2.81394
= 67.53456/cycle
As there are 8 Furnaces in the plant, total energy = 8 x 67.53456
= 540.27648/cycle
So, the total power loss per day = 540.27648 x 3600x20 = 38899907 W

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6.4.2 Power Consumption table:
Based on the calculations done using the pre achieved simulation results the power consumption
details for the two coolants at three different velocities were tabulated:

Velocity
1.5 m/s 2.28 m/s 3.0 m/s
H2O TiO2 H2O TiO2 H2O TiO2
Resistance(ohm) 4.04E-07 3.95E-07 3.86E-07 3.79E-07 3.76E-07 3.68E-07
Resistance
loss(W) 2.94516 2.88 2.81394 2.76291 2.74104 2.68272
Per furnace (W) 70.68384 69.1092 67.53456 66.30984 65.78496 64.38528
Per Plant (W) 565.47072 552.8736 540.27648 530.47872 526.27968 515.08224
Per Hour (W) 2035694.5 1990345 1944995.3 1909723.4 1894606.8 1854296.1
Per Day (W) 40713891 39806899 38899907 38194468 37892137 37085921
Resistance loss 906992.64 705438.72 806215.68
difference (W)

From the table it is evident that the resistance loss due to the temperature rise of copper
clamp while employing water as coolant can be minimized with the application TiO 2 nano
fluid as coolant. Resistance loss difference in the table gives us the value of the power that
could be saved by altering the coolant; this is of the range 0.9 - 1.0 MW per day for whole
plant. This value is nearly equal to 0.5% of the total power consumption of the plant per day.
Thus these values clearly indicate the achievement of the objective, to enhance the
functioning of the plant

6.4.3 Comparison between water and TiO2:

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 [ ][ ]
ρv τ zz
ρuv τ zx
G i= 2 G v =
ρv +P τ zy
( e+P ) v u τ zx +v τ zy +wτ zz−q y
Fig 6.34: comparison between water AND TiO2 based on resistance loss

From the figure 6.49 it is clear that the resistance loss linearly decreases for water due to
increased velocity and for TiO 2, it is not linear but the there is a sudden enhancement in the
slope of the curve implying the further enhancement in thermal conductivity thereby more
efficient cooling which in turn reduces the resistance there by reducing the resistance losses.
There is an observable difference between the two curves, and TiO 2 reduces the power loss
due to resistance. From the graph the resistance losses could be minimized to maximum
extent with TiO2 at a velocity of 3 m/s the velocity can be further increased to achieve even
better results but this would increase the pump work.

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 Chapter 7
CONCLUSIONS AND RECOMMENDATIONS

7.1 General conclusions:

A detailed study has been done on the organisation working process and the submerged arc
furnace is studied and hindrance factor has been found as the coolant mediocre performance
and a way to overcome this was addition of nano particles to the existing coolant. After
studying a wide range of particles that could be viable for the addition and serve our purposes
a conclusion was drawn that most pliable nano particle additive to the water to enhance its
performance as a coolant was TiO2.
In the intention proving the bare hypothesis that is an outcome of only literature study on
different nano particles, from the studies it was evident that nano fluids are viable for wide
range of applications in real life. Preliminary studies on nano fluids do suggest that nano
fluids has enhanced thermal conductivity compared to the conventional coolant. As
mentioned before the clear outcome of literature review is selection of TiO 2 which has sheer
dominance over other nano fluids such as metallic oxides in terms of thermal conductivity
and the electrical conductivity of TiO 2 is minimum compared to the other fluids and its
value is very close to the thermal conductivity of water.
In order to prove the viability of nano fluid as a better alternative to conventional coolant, a
virtual system is developed with help of ANSYS ICEM CFD, ANSYS Fluent. Into which
the subjective components upon which the heat transfer process is carried or the component
to be cooled is replicated by using CATIA V5 and this was imported into the simulated space
to carry out tests and Out comes this study and simulation tests were quite promising and the
obtained results imply a clear edge of TiO 2 to be an enhancement alternative for the
conventional coolant which is water. There is no big observable difference in the temperature
of the nano fluid compared to water suggesting a similar behaviour of nano fluid like as water
indicating no additional secondary coolant setup required.
When the clamp temperature is considered the nano fluid used is more efficient than water
the difference is noticeable from the temperature of the copper clamp with the application of
both coolants. With the more efficient cooling or heat transfer from the copper clamp surface
the resistance of the copper clamp is reduced and there by our objective of optium usage of
electric power for enhanced functioning of the submerged arc furnace is achieved. From the
calculated results which is clearly mentioned in the previous section a total of 0.9 MW can be

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saved per day which makes total of 328.5 MW per year which is nearly 0.5% of the total
consumption of the plant per year.

7.2 Recommendations:
 In this study nano fluids which are prevalent and already in use for other practical
applications were considered and studied there is a scope for other nano fluids such as
carbon nano tube based and metallic Fe3O4 can be studied and tested
 Although the testing is done on virtual replica and simulated environment each
iteration consumes lot of time and very tardy process so multiple nano fluids were no
tested , confined to single fluid other fluids can be tested for
 Only the study component is modelled and studied due to the problems in meshing
and iteration in ICEM CFD, a total coolant can be modelled and tested for more
reliable results of the study.

Chapter 8

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 SUMMARY

A study is conducted on the functioning of a ferro alloy organization named Abhijeet Ferro
Alloys limited which employs submerged arc furnace for the smelting of metals and
production of alloys and hindrance factor is found in the form of coolant mediocre efficiency
in heat conductivity. Due to mediocre heat conductivity of the existing coolant which is water
there is power loss in the form of increased resistance of the copper clamp which is a support
and also electrical transmission component to the base carbon electrode. The increased
resistance is a outcome of mediocre cooling increasing its working temperature. This problem
has taken as the primary objective of the study and through literature study a conclusion was
found that, an alteration of the existing coolant with an aqueous nano fluid could enchance
the thermal dissipation from the copper clamp. After an intensive study on nano fluids, TiO 2 is
found to be most viable nano fluid for the present application. To prove its viability and
testing its behavioural characteristics as working fluid, a virtua; model of the subjective part
which is a copper clamp and coolant channel is modelled using CATIA V 5 and tested in
simulated conditions using ANSYS ICEM CFD , ANSYS fluent. The test results were
tabulated and also comparisons were vividly presented. The outcomes are quiet satisfying
with an enhanced heat dissipation from the copper clamp without noticeable change in
temperature of fluid. The calculated power savage due to the nano fluid application is
presented and a notable 0.5% of total consumed power can be saved by altering the working
fluid.

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