Industrial CFD and Fluid Modelling in Engineering

Fluids is proud to present the Special Issue “Industrial CFD and Fluid Modelling in Engineering”, a carefully curated collection of pioneering research that underscores the transformative role of Computational Fluid Dynamics (CFD) in addressing the challenges of industrial fluid mechanics. This Special Issue bridges the gap between advanced CFD methodologies and their practical applications, showcasing innovative strategies that tackle the complexities of real-world engineering systems. Industrial systems are often characterized by complex geometries, multifaceted flow dynamics, and demanding computational requirements, and this collection highlights how modern modelling paradigms and simulation techniques are extending the capabilities of applied CFD to meet these challenges. The aim of this editorial is to provide a concise overview of the papers included in this Special Issue, along with relevant references to contextualize their contributions.

It is worth noting that, given the widespread nature of the topic, the articles featured in this Special Issue underscore the diverse applications of CFD, demonstrating its remarkable versatility in tackling a broad range of engineering challenges, starting with ref. [1], which offers a comprehensive review of CFD modelling for Darrieus turbines, comparing 2D, 2.5D, and 3D approaches. The study synthesizes insights from over 250 articles, providing detailed guidance on turbulence models and meshing techniques. Particular emphasis is placed on understanding wake vortex structures and power coefficient predictions, which are critical for accurately simulating turbine performance. Several investigations have, in fact, addressed this topic in the last decade, further advancing CFD modelling approaches for Darrieus Vertical Axis Wind Turbines (VAWTs). For instance, Alaimo et al. [2] employed QBlade, a specialized simulation tool for wind turbine blade design and aerodynamic analysis, to perform 3D CFD simulations of VAWTs, while Lanzafame et al. [3] focused on 2D CFD modelling for micro H-Darrieus wind turbines, leveraging an unsteady Delayed Detached Eddy Simulation (DDES) approach for turbulence modelling.

Environmental control applications represent another critical area of focus in this Special Issue, as demonstrated in ref. [4], where a 3D thermofluidic CFD model for a climatic chamber is developed and validated. This study explores strategies to optimize chamber efficiency through targeted design improvements, such as adjusting fan rotation and incorporating deflectors, ensuring precise control of airflow, temperature, and humidity distributions. Similarly, ref. [5] addresses the modelling of gas dispersion during liquefied natural gas leaks in bunkering operations, comparing the Flame Acceleration Simulator (FLACS) and BASiL models. The research highlights the importance of high-resolution simulations to refine safety zone assessments and mitigate gas dispersion risks, particularly under variable wind conditions. The challenges of enhancing environmental control applications and advancing gas dispersion modelling are pivotal topics within the realm of industrial CFD.

In addition to these topics, aerodynamic performance and structural integrity are explored in ref. [6], which investigates the effects of leading-edge erosion on wind turbine blades. By comparing 2D and 3D models, the study highlights how computationally efficient 2D approaches can effectively capture key aerodynamic features while identifying their limitations, particularly in predicting drag forces. This balance between computational efficiency and accuracy is crucial for predictive maintenance and digital twin development. Fluid–structure interaction problems are further examined in the Special Issue in ref. [7], where coupled simulations investigate the interplay between fluid flow and vibro-acoustic interactions. The study provides valuable insights into how flow-induced vibrations affect acoustic wave propagation and structural behaviour, offering design strategies for systems subjected to such forces. The broader topic of fluid–structure interaction is widely addressed in the recent literature. For instance, Ehsan Khalili et al. [8] developed a coupled CFD–FEA approach to study sound generation in a stenosed artery, elucidating how flow-induced vibrations propagate through surrounding tissues. Similarly, De Vanna et al. [9] introduced a robust numerical approach for simulating compressible flows around moving objects using the Ghost-Point-Forcing Method (GPFM). This methodology, as further detailed in ref. [10], is particularly effective in resolving challenges related to moving boundaries in compressible environments, including turbulent flows. Together, all of these contributions underscore the potential of advanced numerical methods to enhance the design and analysis of aerospace, energy, and mechanical systems’ aerodynamic performance.

Innovative surrogate modelling techniques are also collected in the present Special Issue, as reported in ref. [11], where heat transfer in oscillating flows is analysed using an efficient method that treats the fluid as a stationary solid with orthotropic thermal conductivity. This approach significantly reduces computational costs while maintaining accuracy, making it highly relevant for thermal design optimization. Similarly, ref. [12] focuses on supersonic flows, investigating the performance of binary fluid ejectors through computational and experimental methods. Their work provides critical insights into flow dynamics, entrainment ratios, and design optimization for applications in refrigeration and gas mixing.

In the context of multiphase flows, this Special Issue collects ref. [13], which explores the dynamic rearrangement of particulate matter in wall-flow filters during regeneration processes. By modelling particle detachment, transport, and deposition patterns, this study offers predictive insights that are instrumental in enhancing engine performance and extending the service life of filtration systems. Similarly, ref. [14] investigates droplet–wall interactions in Selective Catalytic Reduction (SCR) systems, introducing a new impingement model that effectively captures critical phenomena such as film formation, droplet breakup, and heat transfer. This research underscores the pivotal role of impingement behaviour in improving ammonia distribution and optimizing thermal performance. Further advancements in these areas have been achieved through recent studies. For example, Hafen et al. [15] employed lattice Boltzmann methods to analyse particulate detachment and transport within wall-flow filters during regeneration while, in the context of SCR systems, Bai et al. [16] developed a numerical model to examine the heat transfer characteristics and wall film formation caused by spray impingement, highlighting critical factors that influence ammonia distribution and system performance.

Finally, mixing efficiency in industrial systems is a critical area of investigation, as demonstrated in ref. [17], which evaluates the hydrodynamics of stirred reactors for lead recycling. This study identifies optimal tracer injection points, and highlights the significant influence of tank geometry and impeller design on operational performance. The model’s accuracy is validated through physical experiments, offering practical recommendations for improving industrial processes. In a related domain, innovative approaches to cryogenic applications are explored in ref. [18], which introduces a cryogenic duplex pressure-swirl atomizer for seafood preservation. This system combines liquid nitrogen and water sprays to achieve rapid cooling and efficient cold preservation, with its performance validated using a robust CFD framework.

To conclude, this Special Issue exemplifies the diverse and impactful applications of CFD in industrial contexts. By advancing the accuracy, efficiency, and applicability of simulation techniques, the collected studies not only push the boundaries of what CFD can achieve, but also pave the way for future developments in industrial fluid mechanics. We hope this collection inspires further research and innovation in this dynamic and essential field.