Simcenter STAR-CCM+ Example: Static Mixer

Summary

We explore the workflow of creating the geometry of static mixer in 3D CAD and analyzing the flow and temperature variation. Static mixers are extensively used where a single-phase mixing is required without involving the complexity of moving parts. These have proven effective in investigating the flow behavior ranging from laminar to transitional to turbulent for miscible (and immiscible) fluids. Apart from studying the flow characteristics, the static mixers have given insights in understanding the heat transfer, mass transfer, pressure drop and more.

Details

1. Open a new Simulation and save as Mixer-Static
2. Expand Geometry, right click on 3D-CAD Models and select New
3. Select the XY Plane and create a New Sketch
4. Under display option click on Grid Spacing to fix the spacing between the lines for quickly creating the geometry. This is quick as the dimensions are already specified by means of grid spacing.

          
         
     

5. Activate the create line option to create the sketch as shown.

          

6. The solid lines at 0.1 m apart and the dotted lines divide the spacing of the solid lines by two.
7. Click OK and rename the sketch to Mixer
8. In the same plane create another sketch, rename the sketch to Tube1
9. Edit the sketch and create a circle as shown.

             
 

10. Similarly create another sketch and rename the sketch to Tube2
11. Edit the sketch and create a circle as shown.

12. Right click on the sketch Mixer and select Revolve
13. The following are the settings;

14. Click OK
15. Right click on the sketch Tube1 and select Extrude
16. The following the settings;

17. Right click on the sketch Tube2 and select Extrude . The direction type of this would be reversed. 
18. The following are the settings;

19. Click OK
20. Rename the Body as Mixer
21. Orient the geometry and select the right click on the Tube1 face to rename as Inlet1

22. Select the Tube2 face to rename to Inlet2
23. Right click on the lower face of the mixer to name it to Outlet.

24. Close the 3D-CAD
25. Right click on the 3D-CAD Models and select New Geometry Part

26. Right click on Scenes in the tree view and select new Create a new Geometry Scene to explore the part.

27. Right click on the part and select assign parts to regions;

28. Expand Regions>Mixer>Boundaries

Inlet1 & Inlet 2	Mass Flow Inlet
Outlet	Pressure Outlet

29. Right click on operation to create an Automated Mesh Operation.  
30. Select the part, Mixer and the following: Mesh models;

31. The following are the values set under default controls.

Base Size	10mm
Target Surface Size	50%
Prism Layer Thickness	5mm

 

32. The mesh is generated, and we create various scenes to visualize the mesh.
33. We create two plane sections under derived parts ( Plane Section X & Plane Section Y )

34. Cells Surface are created under derived parts;

 

35. Different mesh scenes are created to visualize the mesh;
36. Scalar scenes are created to assess the mesh quality.
37. The scenes related to mesh are grouped together.

38. The following models are selected for the Physics Continuum;

39. Under the Region>Mixer>Boundaries;

            Inlet 1 & Inlet 2: Mass Flow Rate : 0.9
           

40. Scalar scenes are created for Pressure, Temperature
41. A vector Scene is created for visualizing the velocity.
42. For ascertaining the temperature at the outlet, we create a Mass Flow Averaged Report and rename it to Outlet Temperature

 

43. Another report for temperature is created and the plane sections are created.

44. We create a mass flow report for determining the mass flow at the outlet;

45. A report for Pressure drop at the outlet is created;

46. We create another report for Mass imbalance selecting the two inlets and one outlet;

47. The reports are plotted for visualization.
48. The solver is with the default number of iterations.
49. Multiple scenes are linked and visualized.
50. The drag and drop option allows arrange the scenes as shown.

51. In the Temperature section scenes, the animation can be set to Continuous sweep under animation of scalar displayer. Here we display on the Plane Section Y

Note: The example was created for objective of learning the steps involved in creating the geometry using 3D CAD Modeler and simulating the flow. So this is for demonstration purpose only and does not endorse best practices.