Case story
CFD simulation of flow and temperature distribution in buffer tank
A Danish manufacturing company specializing in stainless steel components for the food industry was tasked with delivering a buffer tank for a heat pump project at a dairy plant. The buffer tank, a large vessel for hot water and a key component in the heating system, needed to ensure proper temperature control and stratification of hot water for both heat production and heat pumps. The client faced strict design requirements that were outside their usual scope. Therefore, Process Engineering was brought in to validate the design. Our role in the project was to perform calculations and conduct CFD (Computational Fluid Dynamics) simulations of the flow and temperature distribution inside the buffer tank.
The process
We worked closely with the client, receiving technical data and drawings as the basis for our calculations. The project was divided into sub-deliveries, and each simulation was carried out using approved input from the client. Based on PFDs (Process Flow Diagrams) and datasheets from the end customer, we built a 3D model of the buffer tank and ran CFD simulations for three scenarios:
- Flow simulation at the bottom of the tank to ensure stable return heat and full utilization of the heat pumps.
- Simulation of the stratification zone (hot water at the top and cooler water at the bottom) to verify that the layer was not too large.
- Simulation of stable temperature for central water production.
The project was executed by two of our engineers from our Danish office in Aalborg and our Dutch office in ‘s-Hertogenbosch. Reporting was delivered in a comprehensive technical report including results and recommendations.
Fact box
CFD stands for Computational Fluid Dynamics, and is a method that uses mathematical models and computer-based calculations to predict how liquids and gases behave. Instead of physical testing, CFD analyzes flow patterns, temperature, pressures, and other phenomena to optimize product design, improve processes, or diagnose issues in existing systems. In this project, CFD was used to refine the tank design and ensure compliance with strict requirements for flow and temperature distribution.
Service and scope of the project
- CFD calculations: Simulation of flow and temperature distribution in the tank under various operating scenarios
- Documentation of temperature variation during start-up (requirement: max ±1 °C – achieved)
- Documentation of return temperature to heat pumps (requirement: max 0.5 °C/min – achieved)
- Documentation of stratification zone (requirement: min. 2.5 m – achieved 7.5 m)
- Documentation of buffer tank design compliance with requirements for maximum temperature variation in return water to heat pumps, stability in central water temperature, and maximum stratification zone
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