cooling experiments, simulations and more
Because cooling conditions vary greatly in terms of target cooling objects/substances, worksite conditions and other factors, applying an approach that was successful with one customer may not be effective at another customer's location. It is vital to optimize each cooling system for each facility's setup and conditions.
Consulting services, which serve as the core of the Cooling Division's operations, involve meetings between highly experienced IKEUCHI specialists and the customer in order to carefully discern customer requirements, facility conditions and other relevant information. Our staff engage in discussions with the customer as we pursue an ideal solution.
When making proposals, we place particularly strong emphasis on cooling experiments and simulations, and by presenting these and their results in visual form we are able to convey to the customer precisely what it is we are trying to do before installing any product in their facilities.
Most of our experimental cooling equipment falls into two general categories: solid-matter cooling test equipment and gas cooling test equipment.
Because no two cooling operations share the same conditions, we prepare testing equipment with consideration of various conditions in order to simulate actual usage conditions.
Pictured here is test equipment used for gas cooling experiments. Ducts of various diameters are available, and factors such as duct-entry flow speed, temperature and humidity can be controlled. Specific conditions matching actual usage conditions can be set for the intake points to be used in testing before carrying out spraying tests. During tests, optimization for equipment as well as control methods can be taken under consideration by the customer.
We create 3D images/models of customer worksites using computational fluid dynamics (CFD) technology and use them to carry out monitoring of cooling conditions and various other factors.
We start with nozzle atomization mechanism modeling, which involves simulation of spray-droplet sizes , spray patterns and so forth to be used in cooling sprays, after which we move on, depending on the objects/substances to be cooled, to either gas cooling optimization or solid-matter cooling optimization simulations.
1. Nozzle Atomization Mechanism Modeling
Nozzle mechanism modeling is a very challenging task since it entails consideration of spray droplet sizes, spray droplet distribution, droplet/particle densities, initial speeds, spray patterns and a diverse array of other particle-related conditions and factors. The use of high-precision simulations for such modeling operations lays the foundations for success in building high-efficiency cooling systems.
We employ specialized measuring equipment, incorporate data on factors such as airflow and temperature distribution, and otherwise pursue simulations with the greatest precision possible.
2. Gas cooling optimization
A wide range of conditions must be considered when it comes to gas cooling. Temperature conditions, for example, range from gases at ordinary-temperature to high-temperature gases around 1500°C . Various types of gases are targeted for cooling: those in a steady state are characterized by calm, gradual volumetric and temperature changes, whereas unsteady-state gases may exhibit rapid shifts from zero to maximum gas volume levels in mere seconds.
If one hopes to properly model cooling mechanisms in all of these cases, high-precision nozzle mechanism modeling alone is not enough. In addition to accurate reproduction of factors such as form and gas conditions, engineers with real-life experience and keen sensibilities developed along the way are needed to run these simulations.
Example results from an flue gas cooling tower simulation
3. Solid-matter cooling optimization
When it comes to solid-matter cooling operations, various types of objects and substances are targeted, and in almost all cases unsteady-state modeling is required. Microscopic-level examination is needed to analyze surface-level phenomena such as surface-adhering vaporization, rebound, redispersion, liquid film formation and so forth.
And because many of the items targeted for cooling are large in size, macroscopic-level considerations are also necessary.
IKEUCHI was one of the first to focus on these areas and start pursuing relevant research, giving our engineers a rich array of experience that now enables them to offer optimal customer solutions.