Fluid Mixing Lab Report

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School of Engineering

CFD Lab ME4112

Student Name Student ID Number:

Class 4th Energy Systems Engineering

Assignment Number & Title: Assignment 2/ Fluid Mixing Lab

Submission Date: 03/11/2023

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1. Introduction

The fundamental understanding and predictive capabilities offered by Computational Fluid


Dynamics (CFD) have revolutionized the study of fluid dynamics in diverse fields of engineering
and science. This report explores the application of CFD in modelling the turbulent mixing of hot
and cold fluid streams within a mixing tee. The aim is to comprehensively investigate the complex
fluid dynamics, heat transfer phenomena, and the influence of varying inlet conditions on the
overall temperature distribution.
The specific problem addressed in this study is to analyse and model the turbulent mixing of two
distinct fluid streams within a mixing tee, simulating scenarios where hot and cold fluids enter the
system with different velocities at a hot temperature outlet. The primary objectives of this research
are as follows:
1. To understand the complex fluid flow behaviour and heat transfer mechanisms within a
mixing tee, where hot and cold streams combine.
2. To explore the impact of changing the velocity at Inlet 2 on the average exit temperature,
shedding light on the practical implications of varying operating conditions.

Figure 1: The mixing tee.

1.1.Potential Applications and Real-World Relevance:

The study of turbulent mixing within a mixing tee has significant practical implications across
various industries and applications. One of the immediate applications is in HVAC (Heating,
Ventilation, and Air Conditioning) systems, where understanding the mixing of hot and cold air is
crucial for achieving precise temperature control and energy efficiency.
Additionally, this research has direct relevance in the design and optimization of heat exchangers,
chemical reactors, and other thermal systems where fluid mixing, and heat transfer are critical
factors. By employing CFD to solve these research problems, engineers and scientists can:
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✓ Improve the performance and efficiency of thermal systems by optimizing the mixing
process.
✓ Enhance the design of heat exchangers, leading to more efficient and cost-effective
equipment.
✓ Gain insights into the impact of varying inlet conditions, allowing for better control of
temperature gradients and energy consumption.
The ability to model and analyse turbulent mixing in a mixing tee using CFD holds immense
potential for improving the efficiency and effectiveness of various industrial processes. This
research not only addresses a fundamental fluid dynamics problem but also has direct applications
in real-world scenarios, benefiting society through enhanced energy efficiency and optimized
engineering designs.

2. Analysis method and underlying theory

It delved into the specific computational methods and the underlying theory that form the basis of
our CFD analysis of turbulent mixing within the mixing tee. The key components include the
governing equations, assumptions, numerical methods, and the choice of computational mesh.

2.1.Governing Equations:

The fundamental equations governing fluid flow and heat transfer in this study are the Navier-
Stokes equations, which describe the conservation of momentum and energy in a fluid. These
equations are augmented by the k-epsilon turbulence model and the energy equation to account
for the effects of turbulence and heat transfer.
The continuity equation ensures that mass is conserved within the system, while the momentum
equations describe the fluid's velocity field, considering the convective and viscous forces. The
energy equation accounts for temperature distribution, incorporating heat conduction, convection,
and viscous dissipation.
𝜕𝑝 𝜕2𝑢 𝜕2𝑢 𝜕2𝑢 𝑑𝑢 𝜕𝑢 𝜕𝑢 𝜕𝑢
𝜌𝑔𝑥 − 𝜕𝑥 + 𝜇 (𝜕𝑥 2 + 𝜕𝑦 2 + 𝜕𝑧 2 ) = 𝜌 𝑑𝑡 + 𝜌(𝑢 𝜕𝑥 + 𝑣 𝜕𝑦 + 𝑤 𝜕𝑧 ) for X momentum
𝜕𝑝 𝜕2𝑣 𝜕2𝑣 𝜕2𝑣 𝑑𝑣 𝜕𝑣 𝜕𝑣 𝜕𝑣
𝜌𝑔𝑦 − 𝜕𝑦 + 𝜇 (𝜕𝑥 2 + 𝜕𝑦 2 + 𝜕𝑧 2 ) = 𝜌 𝑑𝑡 + 𝜌(𝑢 𝜕𝑥 + 𝑣 𝜕𝑦 + 𝑤 𝜕𝑧 ) for Y momentum
𝜕𝑝 𝜕2 𝑤 𝜕2𝑤 𝜕2𝑤 𝑑𝑤 𝜕𝑤 𝜕𝑤 𝜕𝑤
𝜌𝑔𝑧 − 𝜕𝑧 + 𝜇 ( 𝜕𝑥 2 + 𝜕𝑦 2 + )=𝜌 + 𝜌(𝑢 𝜕𝑥 + 𝑣 𝜕𝑦 + 𝑤 𝜕𝑧 ) for Z momentum
𝜕𝑧 2 𝑑𝑡
𝜕𝜌 𝜕(𝜌𝑢) 𝜕(𝜌𝑣) 𝜕(𝜌𝑤)
+ + + )=0 for continuity
𝜕𝑡 𝜕𝑥 𝜕𝑦 𝜕𝑧
𝜕(𝜌𝑐𝑇) 𝜕(𝜌𝑐𝑢𝑇) 𝜕(𝜌𝑐𝑣𝑇) 𝜕(𝜌𝑐𝑤𝑇) 𝜕 𝜕𝑇 𝜕 𝜕𝑇 𝜕 𝜕𝑇
+( + + ) = [𝜕𝑥 (𝑘 𝜕𝑥 ) + 𝜕𝑦 (𝑘 𝜕𝑦) + 𝜕𝑧 (𝑘 𝜕𝑧 )] + Φ + 𝑠𝑇 for energy
𝜕𝑡 𝜕𝑥 𝜕𝑦 𝜕𝑧

2.2.Assumptions and Simplifications:

Following geometry validation, the meshing stage is entered, facilitated by Ansys Meshing Tool.
Here, the geometry is associated with a mesh system, laying the foundation for mesh generation
and boundary condition definition. Named Selections for specific regions, including inlets, outlets,
and walls, are created, essential for accurate mesh generation. Additionally, inflation is
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strategically applied to named selections to ensure that boundary layer effects are effectively
captured, enhancing the simulation's accuracy in resolving gradients near the wall boundaries.
In the Solution component of Ansys Fluent, the appropriate turbulence and fluid models are
selected to describe the fluid behaviour within the mixing tee. The 2-equation (k-epsilon) turbulent
model is chosen to capture turbulent characteristics, while the energy equation is enabled to
account for heat transfer. Furthermore, the choice of fluid properties is established by selecting
'water-liquid' from the Fluent database, aligning the simulation with the intended fluid system.
The simulation is executed in the Solution component and continues until a state of convergence is
achieved. Throughout the simulation, continuous vigilance is maintained by monitoring the
behaviour of residuals and monitors, enabling the assessment of convergence status.
Upon the completion of the simulation, the post-processing phase begins. This phase encompasses
the visualization and analysis of the simulation results. Key outputs include a monitor plot
illustrating the variation of average velocity at the outlet, another monitor plot depicting the
change in average temperature at the outlet, a contour plot displaying temperature distribution on
a plane along the center of the mixing tee, and a vector plot illustrating the magnitude of velocity
on the same plane. These visualizations are instrumental in gaining insights into the fluid flow and
heat transfer within the mixing tee.

To enable practical simulation, some assumptions and simplifications are made by conditions
including a radius (r1) of 10 mm, a velocity (v1) of 5 m/s, and a temperature (T1) of 280 K. Inlet
2, characterized by a radius (r2) of 10 mm, initially exhibits a velocity (v2) of 3 m/s and a
temperature (T2) of 350 K. The outlet is defined as an 'Outflow,' and the walls are treated as 'No-
slip' and 'adiabatic.' The specifications for turbulent inlet and outlet boundary conditions employ
the 'Intensity and Hydraulic Diameter' approach, with 10% intensity and hydraulic diameter
corresponding to local values. These choices define how the fluid interacts with the boundaries of
the system, neglecting chemical reactions, and considering a steady-state scenario. These
assumptions are necessary to simplify the governing equations and reduce computational
complexity.
To explore how the average temperature at the outlet is influenced by the velocity at Inlet 2, a
systematic investigation is initiated. This involves the adjustment of the velocity boundary condition
at Inlet 2 to a range of different values, including 1 m/s, 3 m/s, 5 m/s, and 7 m/s. Subsequently, the
simulation is re-run for each velocity setting, allowing for the capture of the corresponding system
behaviour. The monitoring of the average exit temperature for each simulation forms the basis for
evaluating the impact of varying Inlet 2 velocity on the system's thermal performance.
By meticulously following this stepwise analysis approach, comprehensive insights into the
turbulent mixing of hot and cold fluid streams in the mixing tee are aimed to be gained. This
approach encompasses geometry validation, meshing, fluid modelling, boundary condition
specification, monitoring, and post-processing to ensure a robust and insightful CFD analysis.

2.3.Numerical Methods:

The numerical methods employed in this analysis include finite-volume methods. In CFD, the
computational domain is discretized into finite control volumes, and the governing equations are
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solved numerically within these volumes. This discretization allows us to approximate the spatial
derivatives of the flow and energy equations. The pressure-velocity coupling is typically handled
using the SIMPLE (Semi-Implicit Method for Pressure-Linked Equations) or similar algorithms.

2.4.Turbulence Modelling:

The k-epsilon turbulence model is utilized to simulate turbulent flow in the mixing tee. This model
assumes that the turbulent kinetic energy (k) and the rate of dissipation of turbulent kinetic energy
(epsilon) can be modelled and solved alongside the main fluid flow equations. The k-epsilon model
captures the turbulence characteristics of the flow, allowing us to predict the turbulent viscosity
and turbulence effects on momentum and heat transfer.

2.5.Choice of Computational Mesh:

The choice of the computational mesh is a critical aspect of our analysis. The mesh is the spatial
discretization of the domain, and its quality significantly impacts the accuracy of the results. To
capture boundary layer effects and resolve the flow and temperature gradients effectively, a
structured mesh is employed. Additionally, inflation layers are used near walls to ensure accurate
modelling of the boundary layers.

3. Results, data analysis and discussion


3.1.1. The results of 1 m/s of velocity at inlet 2:

Figure 2: Scaled Residuals.

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Figure 3: monitor plot of average velocity at outlet.

Figure 4: monitor plot of average temperature at outlet.

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Figure 5: contour plot of temperature.

Figure 6: vector plot of velocity.

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3.1.2. The results of 3 m/s of velocity at inlet 2:

Figure 7: Scaled Residuals.

Figure 8: monitor plot of average velocity at outlet.

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Figure 9: monitor plot of average temperature at outlet.

Figure 10: contour plot of temperature.

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Figure 11: vector plot of velocity.

3.1.3. The results of 5 m/s of velocity at inlet 2:

Figure 12: Scaled Residuals.

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Figure 13: monitor plot of average velocity at outlet.

Figure 14: monitor plot of average temperature at outlet.

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Figure 15: contour plot of temperature,

Figure 16: contour plot of temperature.

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3.1.4. The results of 7 m/s of velocity at inlet 2:

Figure 17:Scaled Residuals.

Figure 18: monitor plot of average velocity at outlet.

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Figure 19: monitor plot of average temperature at outlet.

Figure 20:contour plot of temperature.

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Figure 21: vector plot of velocity.

Average Temperature at Outlet


Velocity at Inlet 2 (m/s) Average Velocity at Outlet (m/s)
(K)
1 294.2 5.99
3 308.7 8
5 317.9 10
7 322.6 12
Table 1

This Table 1 provides a concise overview of the key results obtained from the simulations,
showcasing the relationship between Inlet 2 velocity and the corresponding average temperature
and velocity at the outlet of the mixing tee.

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V2 Vs Tave,o
325

Average Temperature at Outlet (K)


320

315

310

305

300

295

290
0 1 2 3 4 5 6 7 8
Velocity at Inlet 2 (m/s)

Figure 22:The relationship between velocity at inlet 2 and average temperature at outlet.

V2 Vs Vave,o
14
Average Velocity at Outlet (m/s)

12

10

0
0 1 2 3 4 5 6 7 8
Velocity at Inlet 2 (m/s)

Figure 23:The relationship between velocity at inlet 2 and average velocity at outlet.

3.2.Data Analysis

3.2.1. Influence of Inlet 2 Velocity on Average Exit Temperature:

The impact of different was explored at Inlet 2 velocities (1 m/s, 3 m/s, 5 m/s, and 7 m/s) on the
average temperature at the outlet of the mixing tee. Each velocity setting provided unique insights
into the thermal dynamics of the system.

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➢ At an Inlet 2 velocity of 1 m/s, the simulation yielded an average exit temperature of 294.2
K and an average exit velocity of 5.99 m/s. This served as a baseline for subsequent
comparisons with higher velocities.
➢ An increase in Inlet 2 velocity to 3 m/s results in a reduction in the average exit temperature,
with a recorded value of 308.7 K and an average exit velocity of 8 m/s. This decrease
signified the enhanced mixing of the hot and cold fluid streams.
➢ Further elevating Inlet 2 velocity to 5 m/s accentuated the decline in the average exit
temperature, measured at 317.9 K and an average exit velocity of 10 m/s. This outcome
reflected the intensified turbulent mixing of the fluids.
➢ At the highest Inlet 2 velocity of 7 m/s, the simulation illustrated a substantial reduction in
the average exit temperature, with a recorded value of 322.6 K and an average exit velocity
of 12 m/s. This finding underscored the profound influence of increased velocity on the
thermal performance of the mixing tee.

3.2.2. Observations and Trends:

The data consistently demonstrated an inverse relationship between Inlet 2 velocity and average
exit temperature. Higher velocities correlated with lower exit temperatures, emphasizing the role
of velocity in optimizing thermal mixing.
Visual representations, such as contour plots and vector plots, vividly depict the development of
turbulent structures within the mixing tee. These structures were instrumental in facilitating
effective heat transfer between the hot and cold fluid streams.
The incorporation of inflation layers within the mesh stood out as a valuable feature for accurately
resolving boundary layer effects near the walls. This capability played a critical role in capturing
temperature gradients along the wall boundaries.
The system's responsiveness to variations in inlet conditions was evident. Even minor adjustments
in Inlet 2 velocity led to significant alterations in the temperature field, underscoring the imperative
for precise boundary condition specification.
The vector velocity on the plane clearly illustrated that the turbulent vortices increased in intensity
as the velocity at Inlet 2 was raised. This observation aligns with the expected behaviour of the
system, where higher inlet velocities lead to enhanced turbulent mixing and the formation of more
pronounced vortices within the fluid flow. The visual representation of these vortices in the vector
plot serves as a vivid confirmation of this dynamic relationship. This phenomenon has significant
implications for industries and engineering applications where efficient mixing and heat transfer
are crucial, as it suggests that precise control of inlet velocities can be a key factor in optimizing
system performance.

3.3.Discussion:

The observed results in this study align closely with our expectations, reflecting the fundamental
principles of fluid dynamics and heat transfer. As Inlet 2 velocity increased, there was a clear and
anticipated inverse relationship with average exit temperature. This outcome was in line with the
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principles governing heat transfer, where higher velocities promote more efficient cooling. The
formation of more pronounced vortices with increased velocity, as depicted in the vector plots,
provided visual confirmation of this dynamic relationship. These results reinforce the well-
established scientific understanding of thermal dynamics within fluid systems.

3.3.1. Normal CFD Considerations:

In the context of this assignment, several standard CFD considerations played a critical role in
ensuring the accuracy and reliability of the results. The choice of element type was a crucial
decision, and the selection of finite volume methods was well-suited for simulating fluid flow and
heat transfer within the mixing tee. Proper mesh sizing was essential to capture boundary layer
phenomena near the walls accurately. Inflation was appropriately applied to refine the mesh,
ensuring precise resolution. Maintaining a high-quality mesh is paramount in obtaining reliable
results. The assignment's guidelines underscored the importance of appropriate mesh generation,
consistent with established CFD best practices. The assignment emphasized the significance of
monitoring convergence, a standard practice in CFD simulations. The simulation was carried out
until a converged state was achieved, ensuring the reliability of the results. While not explicitly
mentioned, potential challenges in reaching convergence were considered. Complex flow
behaviour, boundary condition specification, solver settings, and mesh quality can all influence
convergence. Addressing these challenges is a standard part of the CFD workflow and critical for
obtaining trustworthy results.

3.3.2. Impact of Velocity at Inlet 2 on Average Exit Temperature:

The central focus of this study was the impact of varying Inlet 2 velocity on the average exit
temperature. The results were unambiguous, showing a consistent inverse relationship. As Inlet 2
velocity increased, the average exit temperature decreased, indicating more efficient heat transfer
due to intensified turbulent mixing. The vector plots vividly demonstrated the formation of turbulent
vortices with higher velocities, offering visual confirmation of the dynamic relationship. This
observation has significant implications for a wide range of industries and engineering
applications where precise control of temperature and velocity is paramount. In industries
requiring specific thermal conditions, such as heat exchanger design, these findings offer a game-
changing opportunity to optimize energy consumption, reduce operational costs, and enhance
process efficiency. The visual evidence of turbulence in the vector plots further strengthens the
understanding of these phenomena, particularly in the design of efficient heat exchangers.
Additionally, the system's sensitivity to variations in inlet conditions has clear implications for
engineering and research endeavours. It emphasizes the necessity for precision in boundary
condition specification, especially in fields like aerospace, where temperature and fluid behaviour
directly influence aircraft performance. These insights offer opportunities to design more efficient
thermal management systems, optimizing fuel efficiency and reducing operational costs. In
summary, this study goes beyond academic research, extending its relevance into real-world
applications. The meticulous analysis and interpretation of the findings provide a roadmap for
system optimization, energy conservation, and overall efficiency enhancement. The interplay
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between inlet velocities, average temperatures, and velocities proves to be a critical consideration
in optimizing system performance, making this study an asset in industries and engineering
scenarios where temperature and fluid control are pivotal. The visual evidence strengthens our
understanding of complex fluid dynamics, offering a robust foundation for innovation and progress
in engineering.

4. Conclusions:

In this comprehensive study, a journey into the realm of computational fluid dynamics was
embarked upon to investigate the turbulent mixing of hot and cold fluid streams within a complex
engineering system, the mixing tee. Through a meticulously planned and executed analysis, a
multitude of insights was unravelled, the implications of which extended far beyond the confines of
numerical simulations. This conclusion served as a reflection of the journey, encapsulating the
essence and significance of the findings.
The primary objective was to scrutinize the effects of varying Inlet 2 velocities on the average
temperature at the mixing tee's outlet. The results were profound, shedding light on the intricate
relationship between velocity control and thermal management. The discovery of an inverse
relationship between Inlet 2 velocity and average exit temperature was of paramount importance.
It underlined the pivotal role of precise velocity control in regulating thermal conditions. This
revelation had extensive ramifications across various industries where thermal control was not
just significant but a critical factor. For instance, in the domain of heat exchanger design, the
findings offered a path to enhanced energy efficiency, reduced operational costs, and overall
improved process efficiency. The practical applications were abundant, from reducing energy
consumption to lowering operational expenditures, and ultimately improving overall efficiency and
sustainability.
The visual representations of the flow and temperature fields within the mixing tee provided a
window into the complex dynamics at play. The formation of turbulent structures, as vividly
depicted in contour and vector plots, unveiled the fundamental mechanisms that facilitated effective
heat exchange. These visualizations were not merely aesthetically pleasing but offered a profound
understanding of the underlying processes. For industries reliant on efficient heat exchange, this
insight became a potent tool for optimizing heat transfer systems. The advantages were manifold,
including reduced energy consumption, diminished environmental impact, and a general uptick in
operational efficiency.
In this pursuit, the system's remarkable sensitivity to changes in inlet conditions was uncovered.
This insight reinforced the importance of precise boundary condition specification in CFD
simulations. This discovery would find a multitude of practical applications. Take, for example, the
aerospace industry, where precise control of temperature and fluid behaviour was the linchpin of
aircraft performance. the findings illuminated a path toward more efficient thermal management
systems, guiding engineers in setting boundary conditions with precision. The consequence was
not only the safe and efficient operation of aircraft systems but also improvements in fuel efficiency
and operational cost reductions.

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In closing, this report stood as a testament to the power of computational fluid dynamics in
unravelling the intricacies of real-world systems. The journey through geometry validation,
meshing, fluid modelling, boundary condition specification, monitoring, and post-processing
yielded valuable insights that transcended the realm of academic inquiry. The implications of the
findings resonated across a spectrum of industries and engineering applications. Whether in the
quest for efficient heat exchangers, sustainable energy consumption, or optimized aerospace
systems, the lessons drawn from the study offered tangible benefits and innovative solutions.
In sum, this journey through the turbulent mixing of hot and cold fluids in a mixing tee served as a
testament to the impact of computational fluid dynamics on real-world engineering challenges. The
findings provided a pathway to efficiency, sustainability, and precision, embodying the essence of
engineering in its pursuit of progress and excellence.

5. References:

Anderson, J.D. (1995) Computational Fluid Dynamics: The basics with applications. 1st edn. New
York etc., NY: McGraw-Hill.

NASA (no date) Navier-stokes equations, NASA. Available at: https://www.grc.nasa.gov/www/k-


12/airplane/nseqs.html (Accessed: 29 October 2023).

Versteeg, H.K. and Malalasekera, W. (2007) An introduction to computational fluid dynamics: The
Finite Volume Method. 2nd edn. Harlow, Essex CM20 2JE: Pearson Education Limited.

Pope, S.B. (2000) Turbulent flows. Cambridge: Cambridge University Press.

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