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Bronswerk Heat Transfer BV

Bronswerk Heat Transfer BV design engineers used FloEFD 3D CFD software to develop an oil and gas industrial-plant cooling fan that is more energy efficient, quieter, and lighter weight than predecessors.

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FloEFD was crucial because I couldn’t have proven it to myself or others that this design could possibly work so that we could start manufacturing prototypes; and, much more important, it gave us the opportunity to really understand the aerodynamics of air-cooled coolers for the first time in the world, because the flow, the aerodynamics, is more than just a flow through the intake and the fan itself.”

Guus Bertels, Associate Director of Advanced Design and Analysis, Bronswerk Heat Transfer BV

Problem

Need to Increase Efficiency and Decrease Noise of Cooling Fans in Large Industrial Plants Fans as large as 33 ft. move air across bundles of coils inside a gas- or oil-field cooling system. Dozens, even hundreds, of fan systems may be needed to cool the gas or oil, along with megawatts of electrical power to run these fans. Fan noise is as important as cost issues--large industrial plants are subject to stringent noise regulations. The fans used traditionally deliver a maximum efficiency of about 50%. What would happen if that efficiency could be increased to 80% or more? Fewer fans could do the same work with less energy, less noise, and lower operational costs. The design engineering team at Bronswerk Heat Transfer BV set out to create a new generation of air-cooled cooling systems that would solve age-old problems.

Solution

FloEFD Enables Analysis and Validation that are Impossible Solely with Physical Measurements They chose FloEFD, a proven concurrent 3D computational fluid dynamics (CFD) toolset, for analysis and validation of their design updates. They have used both CFD tools and physical measurements to characterize the behavior-particularly the aerodynamics-of large air-cooled cooling systems. They found that concurrent CFD often can produce data that would be impossible to acquire with measurements because of physical constraints, the Heisenberg principle, and other factors.

Results

Whizz-Wheel-based Cooling Systems Breaking Industry Records The new Bronswerk cooling solution they developed includes fans and housings that take their technology cues from gas turbines, aircraft wings, and a generous helping of homegrown creativity. The practicality of these creative touches was validated quickly and accurately with FloEFD. In addition to their purely quantitative output, the CFD simulations helped them to explore bold ideas--without risking project budgets and schedules. Physical measurements were essential to the project’s success, but couldn’t produce the needed data in every case. With simulation, they were able to look at static pressure distributions through a flow field and obtain information on the total pressure, which is a direct measure of the entropy in the system. A loss in total pressure is energy loss, and FloEFD delivered a color picture of where the losses were. Whizz-Wheel-based cooling systems are now breaking all industry records for energy efficiency, noise reduction, and weight savings.

Bronswerk Heat Transfer BV

Bronswerk Heat Transfer BV specializes in the design and production of heat exchangers and condensers, air‐cooled coolers, and comprehensive systems. Bronswerk Heat Transfer BV has offices and locations in the Netherlands (Nijkerk), the Czech Republic (Benešov nad Ploučnicí), and Russia (Moscow), employing a total of approximately 300 people. Established in 1940, Bronswerk designs, produces, and delivers industrial systems of (shell and tube) heat exchangers, cooling equipment, Aframe condensers, air‐cooled coolers (ACC), and fans. Bronswerk supplies and provides maintenance services for process cooling systems around the globe. Bronswerk focuses on high‐quality, innovative solutions to heat exchanger issues.

 
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