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A special issue of Sustainability (ISSN 2071-1050). This special issue belongs to the section "Energy Sustainability".

Deadline for manuscript submissions: 31 July 2025 | Viewed by 17125

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Dr. Mohammad Reza Pendar

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Guest Editor

Department of Electromechanical Engineering, University of Beira Interior, 6200386 Covilhã, Portugal
Interests: high-performance computing CFD (computational fluid dynamics); multi-phase flows (cavitating flows); spray flows (electrostatic spraying); unsteady flows and turbulence models; renewable energies (WEC—wave energy convertors); plasma actuators; conjugate heat transfer (FSI—fluid–solid interactions)
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Dr. Frederico Miguel Freire Rodrigues

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Guest Editor

Department of Electromechanical Engineering, University of Beira Interior, 6200386 Covilhã, Portugal
Interests: renewable energies; plasma actuators; aerodynamics; fluid mechanics; heat transfer
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Special Issue Information

Dear Colleagues,

The Special Issue "Computational Fluid Dynamics Simulation: Application in Industries" provides a medium for the publication of original research and development work relating to problems in manufacturing and industrial systems that are experienced in the real world, whether through innovative mathematical modelling, innovative applications, or a combination of these. Papers employing existing numerical techniques and models must demonstrate sufficient novelty and efficiency in solving practical industrial problems.

The term "fluid" is interpreted in the broadest sense: hydrodynamics and aerodynamics, high-speed and physical gas dynamics, turbulence and flow stability, multiphase flow, rheology, tribology, and fluid–structure interaction. The scope of this Special Issue focuses on fluid flow applications in industries modelled by computers for industrial modification purposes.

This influential publication covers a wide spectrum of subjects, including modelling of industrial, inventory, manufacturing, and logistics systems for viable decision making; mechanical engineering systems and structures; CFD, fluid mechanics, heat transfer, turbulence, boundary layers, and transport phenomena; free shear layers, fluid transients, and wave motion; jets, pumps, and turbines; multiphase flows, bubbly flows, spray flow, and cavitating flow; relevant software engineering issues associated with OpenFOAM, ANSYS, CAD, and CAE; noise and acoustics; electromagnets, electrostatic, plasma flow, and MHD; reliability modelling and industrial system optimization; finite element, and boundary element procedures; fractional differential equations, bifurcation, and numerical methods; development of numerical methods relevant to fluid flow computations, computational analysis of flow physics and fluid interactions and novel applications to flow systems; other fundamental/applied fluid mechanical phenomena and processes.

Applications can be found in most branches of engineering and science: mechanical, chemical, civil, and aeronautical.

Dr. Mohammad Reza Pendar
Dr. Frederico Miguel Freire Rodrigues
Guest Editors

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Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Sustainability is an international peer-reviewed open access semimonthly journal published by MDPI.

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Keywords

industrial, manufacturing, and logistics systems
mechanical engineering structures
CFD, fluid mechanics, heat transfer, turbulence, boundary layers, and transport phenomena
free shear layers, fluid transients, and wave motion
jets, pumps, and turbines
multiphase flows, bubbly flows, spray flow, and cavitating flow
noise and acoustics
electromagnets, electrostatic, plasma flow, and MHD
industrial system optimization
finite element, and boundary element procedures
computational analysis of flow physics and fluid interactions, and novel applications to flow systems
other fundamental/applied fluid mechanical phenomena and processes

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Published Papers (9 papers)

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Research

35 pages, 24673 KiB

Open AccessArticle

Enhancing Automotive Paint Curing Process Efficiency: Integration of Computational Fluid Dynamics and Variational Auto-Encoder Techniques

by Mohammad-Reza Pendar, Silvio Cândido, José Carlos Páscoa and Rui Lima

Sustainability 2025, 17(7), 3091; https://doi.org/10.3390/su17073091 - 31 Mar 2025

Viewed by 424

Abstract

The impetus of the present work is to propose a comprehensive methodology for the numerical evaluation of drying/curing, as one of the most complex and energy-consuming stages in the paint shop plant, to guarantee a decrease in energy costs without sacrificing the final paint film quality and manufacturability. Addressing the complexities of vehicle assembly, such as intricate geometry and multi-zoned ovens, our approach employs a sophisticated conjugate heat transfer (CHT) algorithm, developed under the OpenFOAM framework, providing efficient heat transfer with the accompaniment of the Large Eddy Simulation (LES) turbulence model, thereby delivering high-fidelity data. This algorithm accurately simulates turbulence and stress in the oven, validated through heat sink cases and closely aligning with experimental data. Applying modifications for the intake supply heated airflow rate and direction leads to optimal recirculation growth in the measured mean temperature within with the curing oven and along the car body surface, saving a significant amount of energy. Key adjustments in airflow direction improved temperature regulation and energy efficiency while enhancing fluid dynamics, such as velocity and temperature distribution. Furthermore, the study integrates machine learning to refine the oven’s heat-up region, which is crucial for preventing paint burnout. A data-based model using a variational auto-encoder (VAE) and an artificial neural network (ANN) effectively encodes temperature and velocity fields. This model achieves an impressive 98% accuracy within a 90% confidence interval, providing a reliable tool for predicting various operational conditions and ensuring optimal oven performance. Full article

(This article belongs to the Special Issue Computational Fluid Dynamics Simulation: Application in Industries)

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32 pages, 11083 KiB

Open AccessArticle

Enhancing Heat Transfer Efficiency Through Controlled Magnetic Flux in a Partially Heated Circular Cavity Using Multi-Walled Carbon Nanotube Nanofluid and an Internal Square Body

by Eid S. Alatawi

Sustainability 2024, 16(23), 10632; https://doi.org/10.3390/su162310632 - 4 Dec 2024

Cited by 2 | Viewed by 895

Abstract

Applications including aircraft systems and electronics cooling depend on effective heat transfer. This study investigates magnetohydrodynamic (MHD) free convection and thermal radiation for heat transfer in a circular cavity filled with multi-walled carbon nanotube (MWCNT) nanofluid and containing a square obstruction. This study examines the impact of the internal geometry on heat transfer and fluid flow dynamics under three distinct boundary conditions, and it presents a comprehensive analysis based on a wide range of Hartmann (Ha) and Rayleigh (Ra) numbers. MWCNT nanofluid with high thermal conductivity was employed to enhance heat transfer efficiency, using a solid volume fraction (SVF) of 4% for MWCNTs and assuming Newtonian behavior for computational simplification. Magnetic properties were imparted to the nanofluid by assuming the dispersion of carbon nanotubes in a base fluid containing magnetic nanoparticles. Other walls were insulated, the bottom wall was heated, and a magnetic field (MF) with Ha ranging from 0 to 100 was applied. It was observed that raising Ra from 103 to 106 improved the Nusselt number (Nu) from 0.08 to 7.1 using the Galerkin finite element method. Ha increased from 0 to 100 and reduced Nu by 35%. Three boundary conditions for the square body showed that the heated conditions provided the largest Nu. By means of an increase in SVF from 0 to 0.04, the MWCNT nanofluid improved heat conductivity by 18%. Radiation effects with the radiation parameter Rd = 0.5 increased heat transmission by 22%. These results underline the importance of considering MHD and nanofluid characteristics in maximizing heat transfer for commercial purposes, and the approaches employed in this study contribute to a deeper understanding of the behavior of thermal systems under the influence of MHD and internal geometry. Full article

(This article belongs to the Special Issue Computational Fluid Dynamics Simulation: Application in Industries)

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26 pages, 23878 KiB

Open AccessArticle

Numerical Simulation of the Density Effect on the Macroscopic Transport Process of Tracer in the Ruhrstahl–Heraeus (RH) Vacuum Degasser

by Zhibo Xu, Xin Ouyang, Chao Chen, Yihong Li, Tianyang Wang, Ruijie Ren, Mingming Yang, Yansong Zhao, Liqiang Xue and Jia Wang

Sustainability 2024, 16(10), 3923; https://doi.org/10.3390/su16103923 - 8 May 2024

Cited by 5 | Viewed by 1428

Abstract

Silicon steel (electrical steel) has been used in electric motors that are important components in sustainable new energy Electrical Vehicles (EVs). The Ruhrstahl–Heraeus process is commonly used in the refining process of silicon steel. The refining effect inside the RH degasser is closely related to the flow and mixing of molten steel. In this study, a 260 t RH was used as the prototype, and the transport process of the passive scalar tracer (virtual tracer) and salt tracer (considering density effect) was studied using numerical simulation and water model research methods. The results indicate that the tracer transports from the up snorkel of the down snorkel to the bottom of the ladle, and then upwards from the bottom of the ladle to the top of the ladle. Density and gravity, respectively, play a promoting and hindering role in these two stages. In different areas of the ladle, density and gravity play a different degree of promotion and obstruction. Moreover, in different regions of the ladle, the different circulation strength leads to the different promotion degrees and obstruction degrees of the density. This results in the difference between the concentration growth rate of the salt tracer and the passive scalar in different regions of the ladle top. From the perspective of mixing time, density and gravity have no effect on the mixing time at the bottom of the ladle, and the difference between the passive scalar and NaCl solution tracer is within the range of 1–5%. For a larger dosage of tracer case, the difference range is reduced. However, at the top of the ladle, the average mixing time for the NaCl solution case is significantly longer than that of the passive scalar case, within the range of 3–14.7%. For a larger dosage of tracer case, the difference range is increased to 17.4–41.1%. It indicates that density and gravity delay the mixing of substances at the top area of the ladle, and this should be paid more attention when adding denser alloys in RH degasser. Full article

(This article belongs to the Special Issue Computational Fluid Dynamics Simulation: Application in Industries)

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23 pages, 7764 KiB

Open AccessArticle

Numerical Analysis of Air Supply Alternatives for Forced-Air Precooling of Agricultural Produce

by Long Chen, Wenzhi Wang, Jiazheng Li and Zhijun Zhang

Sustainability 2024, 16(8), 3119; https://doi.org/10.3390/su16083119 - 9 Apr 2024

Cited by 2 | Viewed by 1252

Abstract

Precooling agricultural produce is an intensive, energy-consuming process. To improve the efficiency of forced-air precooling and ultimately contribute to energy sustainability for postharvest storage of fresh produce, we designed three alternative air supply systems, simulated their cooling performances over a 96 h precooling process in a cold storage facility storing Chinese cabbages, and then compared their performances with a conventional design. All models were developed on a large scale on the basis of validated computational fluid dynamics models. The horizontal air supply scheme shortened the seven-eighths cooling time by 18.8%, and its maximum cooling rate increased by 19.7% compared to the conventional air supply scheme. The seven-eighths cooling time under another alternative design, the vertical air supply scheme, was 9.4% lower than the conventional, with the maximum cooling rate increasing by 10.5%. However, the maximum cooling rate of the last alternative design, the perforated ceiling air supply system, was 6.6% less than the conventional scheme, resulting in a 6.3% longer seven-eighths cooling time. The heterogeneity index of temperature implied that the horizontal air supply offered better overall cooling uniformity than the other designs, which can be attributed to its evenly distributed airflows and well-organized air movement paths, based on the combined analysis of temperature contours and air velocity contours at selected planes. Our findings are expected to provide practical guidelines for the refinement of the air supply system to improve its energy sustainability in forced-air precooling. Full article

(This article belongs to the Special Issue Computational Fluid Dynamics Simulation: Application in Industries)

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17 pages, 4507 KiB

Open AccessArticle

Investigation of Hydrokinetic Tidal Energy Harvesting Using a Mangrove-Inspired Device

by Jafar Zanganeh, Kiva Gwynne, Zhengbiao Peng and Behdad Moghtaderi

Sustainability 2023, 15(22), 15886; https://doi.org/10.3390/su152215886 - 13 Nov 2023

Cited by 1 | Viewed by 2006

Abstract

There is a trend towards harvesting tidal energy in shallow water. This study examined how tidal energy can be harvested using a device of oscillating cylinders inspired by the roots of mangroves. A specific focus was placed on optimising the configuration of these devices, informed by the computational fluid dynamics (CFD) analysis of wake interference in the von Kármán vortex street of the cylinders. A maximum efficiency of 13.54% was achieved at a peak voltage of 16 mV, corresponding to an electrical power output of 0.0199 mW (13.5% of the hydrokinetic energy of the water) and a power density of 7.2 mW/m² for a flow velocity of 0.04 m/s (

R e = 239

). The configuration of upstream cylinders proved to have a significant impact on the power generation capacity, corroborated further in CFD simulations. The effect of wake interference was non-trivial on the magnitude and quality of power, with tandem arrangements showing the largest impact followed by staggered arrangements. Though with comparatively low energy densities, the device’s efficiencies found in this study indicate a great potential to harvest tidal energy in shallow water, which provides a consistent baseload power to supplement intermittent renewables (e.g., solar and wind). Full article

(This article belongs to the Special Issue Computational Fluid Dynamics Simulation: Application in Industries)

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31 pages, 6312 KiB

Open AccessEditor’s ChoiceArticle

Modified Accuracy of RANS Modeling of Urban Pollutant Flow within Generic Building Clusters Using a High-Quality Full-Scale Dispersion Dataset

by Mohammad Reza Kavian Nezhad, Khashayar RahnamayBahambary, Carlos F. Lange and Brian A. Fleck

Sustainability 2023, 15(19), 14317; https://doi.org/10.3390/su151914317 - 28 Sep 2023

Cited by 1 | Viewed by 2168

Abstract

To improve the reliability of the computational fluid dynamics (CFD) models of wind-driven pollutant dispersion within urban settings, a re-calibration study is conducted to optimize the standard

k - ε

model. A modified optimization framework based on the genetic algorithm is adapted to [...] Read more.

To improve the reliability of the computational fluid dynamics (CFD) models of wind-driven pollutant dispersion within urban settings, a re-calibration study is conducted to optimize the standard

k - ε

model. A modified optimization framework based on the genetic algorithm is adapted to alleviate the computational expenses and to further identify ranges for each empirical coefficient to achieve the most reliable and accurate predictions. A robust objective function is defined, incorporating both the flow parameters and pollutant concentration through several linear and logarithmic measures. The coefficients are trained using high-quality and full-scale tracer experiments in a mock urban arrangement simulating a building array. The proposed ranges are

0.14 \leq C_{μ} \leq 0.15

1.30 \leq C_{ε 1} \leq 1.46

1.68 \leq C_{ε 2} \leq 1.80

1.12 \leq σ_{ε} \leq 1.20

, and

0.87 \leq σ_{k} \leq 1.00

. A thorough evaluation of the predicted flow and concentration fields indicates the modified closure is effective. The fraction of predictions within the acceptable ranges from measurements has increased by 8% for pollutant concentration and 27% for turbulence kinetic energy. The generality of the calibrated model is further tested by modeling additional cases with different meteorological conditions, in which the calculated validation metrics attest to the noteworthy improvements in predictions. Full article

(This article belongs to the Special Issue Computational Fluid Dynamics Simulation: Application in Industries)

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24 pages, 8447 KiB

Open AccessArticle

The Biffis Canal Hydrodynamic System Performance Study of Drag-Dominant Tidal Turbine Using Moment Balancing Method

by Yixiao Zhang, Eddie Yin Kwee Ng and Shivansh Mittal

Sustainability 2023, 15(19), 14187; https://doi.org/10.3390/su151914187 - 25 Sep 2023

Viewed by 1450

Abstract

Drag-dominant tidal turbine energy holds tremendous clean energy potential but faces significant hurdles as unsuitability of the actuator disc model due to the varying swept blockage area, unaccounted bypass flow downstream interaction, and rotor parasitic drag, whereas blade element momentum theory is computably effective for majorly 3-blade lift-dominated aerofoil. This study validates a novel method to find the optimal TSR of any turbine with a cost-effective and user-friendly moment balancing algorithm to support robust tidal energy development. Performance analysis CFD study of Pinwheel and Savonius tidal turbines in a Biffis canal hydrodynamic system was carried out. Thrust and idle moment are analyzed as functions of only inlet fluid velocity and rotational speed, respectively. These relationships were verified through regression analysis, and the turbines’ net moment equations were established based on these parameters. In both simulation models, rotational speed and inlet velocity were proved excellent predictor variables (R² value ≈ 1) for idle and thrust moments, respectively. The optimal TSR values for Pinwheel and Savonius turbines were 2.537 and 0.671, respectively, within an acceptable error range for experimental validation. The optimal basin efficiency (η_opt, TSR) values for Pinwheel and Savonius in the 12% blockage channel were (29.09%, 4.0) and (25.67%, 2.87), respectively. The trade-off between TSR_opt and η_opt is the key instruction concerning electricity generation and environmental impact. Full article

(This article belongs to the Special Issue Computational Fluid Dynamics Simulation: Application in Industries)

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20 pages, 2974 KiB

Open AccessArticle

Modelling Hydrate Deposition in Gas-Dominant Subsea Pipelines in Operating and Shutdown Scenarios

by Oghenethoja Monday Umuteme, Sheikh Zahidul Islam, Mamdud Hossain and Aditya Karnik

Sustainability 2023, 15(18), 13824; https://doi.org/10.3390/su151813824 - 16 Sep 2023

Cited by 2 | Viewed by 2068

Abstract

This study addresses a significant research gap related to hydrate formation in subsea gas pipelines, with a specific focus on deposition rates during shutdown scenarios, which has received limited attention in previous studies. Past research has employed various methodologies, including experimental, analytical, and computational fluid dynamics (CFD) approaches, to predict hydrate formation conditions, but none have tackled the prediction of hydrate deposition during shutdowns. In this study, we employ a multiple linear regression modeling approach using the MATLAB regression learner app. Four distinct regression models were developed using data generated from 81 CFD simulations, utilising a 10 m length by 0.0204 m diameter 3D horizontal pipe model in Ansys Fluent, as previously developed Through cross-validation against experimental data, the standard linear regression model emerged as the most reliable choice for predicting hydrate deposition rates, providing predictions within ±10% uncertainty bounds of experimental results up to pressures of 8.8 MPa at hydrate-forming temperatures. The uniqueness of this new model lies in its ability to estimate the risk of hydrate deposition in subsea gas pipelines, especially with low gas flow rates and during shutdown periods, which are critical for maintenance planning. Furthermore, by estimating depositional volumes, the model predicts hydrate slurry volumes at receiving facilities, contributing to energy sustainability and benefiting gas transport pipeline operators, particularly in aging gas fields with declining production. Full article

(This article belongs to the Special Issue Computational Fluid Dynamics Simulation: Application in Industries)

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18 pages, 4742 KiB

Open AccessArticle

Manifold Design in a PEM Fuel Cell Stack to Improve Flow Distribution Uniformity

by Mazaher Rahimi-Esbo, Ahmad Rezaei Sangtabi and Ebrahim Alizadeh

Sustainability 2022, 14(23), 15702; https://doi.org/10.3390/su142315702 - 25 Nov 2022

Cited by 5 | Viewed by 3790

Abstract

In this paper, a numerical study was performed to investigate the flow distribution in a 52-cell proton exchange membrane (PEM) fuel cell stack. The non-uniformity factor and standard deviation parameters were used to determine the flow distribution uniformity. Flow channels of each bipolar plate were replaced with straight parallel channels filled with porous media to reduce computational costs. The effect of external and integrated humidifiers on the gas distribution among the channels was investigated. Using integrated humidifiers improved the non-uniformity factor and standard deviation by 35% and 19%, respectively. Two methods were employed to improve the flow distribution: gradual reduction of the manifold height, and installing a bump at the bottom wall of the inlet manifold. Reducing the height of the inlet manifold in the stack with integrated and external humidifiers decreased the non-uniformity factor by 62% and 44%, respectively. The installation of the bump on the manifold wall enhanced flow distribution in the stack with the external humidifier. The results show that by using an integrated humidifier in this method, the flow distribution became more non-uniform. The best flow distribution in the stack was obtained with an integrated humidifier and a 90% reduction in manifold height. In this case, the flow rate passing through each channel was more than 99% of the average mass flow rate passing through the entire channel. Full article

(This article belongs to the Special Issue Computational Fluid Dynamics Simulation: Application in Industries)

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