Simulation Electrically Heated Nozzle

If you want to perform a simulation of an electrically heated nozzle, the CFD software NOGRID points offers the ideal solution. It delivers detailed insights into both the thermal behavior and fluid dynamics of electrically heated nozzles. By simulating the electrical heating process, engineers can optimize temperature distribution and improve product quality.

There are numerous industrial applications involving electrically heated nozzles, feeders or channels. In this case study, a metal-shelled nozzle is simulated. The metal shell is electrically heated, which in turn heats the liquid flowing through the nozzle. Due to the electrical resistance of the metal - and its dependence on the thickness distribution - the metal is heated to different degrees. The temperature distribution can thus be manipulated in a well defined manner by the thickness distribution of the casing.

Because multiple materials are simulated simultaneously and interact at their interfaces, this setup qualifies as a multiphase simulation.

CAD model electrical heating nozzle created in NOGRID's COMPASS

Figure 1: CAD created in NOGRID's COMPASS

Electrical potential heater, displayed in NOGRID points CFD software

Figure 2: Electrical potential for the heater

Electrical Power Density, displayed in NOGRID points CFD software

Figure 3: Electrical power density for the heater

Simulation results in NOGRID's points CFD software's GUI: Temperature in the heater after 100 seconds

Figure 4: Temperature in the heater and fluid after 100 seconds

Simulation results electrically heated nozzle: Velocity distribution, displayed in NOGRID points CFD software

Figure 5: Velocity distribution

Based on a geometric model - either imported from your CAD system or created using our CAD preprocessor COMPASS - you can quickly generate a computer model of a specific geometry. Compared to traditional mesh-based methods, the setup time is significantly shorter, allowing you to analyze the thermal characteristics in advance.

To solve the electrical potential u in liquids and solids, NOGRID points uses the following equation:

u electrical potential u = u (x, y, z)
σ electrical heat conductivity
q source term

In the field of electrostatics, the electrical potential does not change with time and the valid differential equation for the electric potential u is the Poisson equation

Conduction in solids and liquids is described by Ohm's law, which states that current is proportional to the applied electric field. The current density (current per unit area) j in an area is directly proportional to the electric field E and the proportionality factor is the electric conductivity σ:

The electric field E can be calculated directly from the electric potential u by

In this study, the metal is treated as a solid, meaning only the temperature equation and the Poisson equation for the electrical potential are computed. The fluid flowing through the nozzle is in direct contact with the solid, allowing heat exchange between the two. As a result, the temperature in the fluid is influenced by the temperature of the solid - and vice versa.

For example, if the fluid's viscosity is temperature-dependent, the thermal state of the solid directly affects the flow behavior inside the nozzle.

Heat transfer can occur via conduction, radiation, or convection through fluid movement - and all these mechanisms can be coupled within the simulation. In this particular example, ideal thermal contact between the nozzle and the fluid is assumed.

Benefits of simulation with NOGRID points CFD software

NOGRID points provides in-depth insight into flow behavior by visualizing mass, momentum, and heat transfer in both single-phase and multiphase systems. You receive integral quantities that can be used to analyze the heat exchange efficiency.

Additionally, NOGRID combines advanced capabilities to handle free-surface flows and moving parts within the domain. It supports the simulation of any conceivable geometry and operating mode, including:

fully 3D computation solving the complete Navier-Stokes equations
easy and intuitive setup, including for FSI (Fluid-Structure-Interaction) cases
freely definable material properties by equations or curves
coupled solutions for electrical heating and fluid mechanic cases
open or closed domains including inflow and outflow areas (non-batch mode)
moving of parts and flexible thermal contact behaviour

Whitepaper Nogrid points Technology

Why choose Nogrid?

NOGRID provides professional CFD software for the simulation of fluid flow, heat and mass transfer, and chemical reactions. Its efficient modelling workflow helps engineers analyse flow behaviour, evaluate designs and make informed decisions without creating a conventional volume mesh.

Faster model preparation

With NOGRID, only the geometry boundary needs to be meshed. The finite points inside the fluid domain are generated automatically according to user-defined settings, both at the start of the simulation and during the calculation.

This approach reduces preprocessing effort and makes it easier to prepare complex geometries and cavities for simulation.

Efficient CFD workflow

The modelling process follows four straightforward steps:

Build the geometry. Mesh the boundary. Define the simulation. Start the calculation.

NOGRID is designed to provide short computation times, including for applications involving complex cavities. Engineers can use the resulting data to examine flow distribution and other relevant flow characteristics.

Better insight into fluid-flow processes

CFD solves the fundamental equations governing fluid flow. NOGRID software enables engineers to predict and analyse the behaviour of fluids and related physical processes before or alongside physical testing.

The simulation results can support:

evaluation and comparison of design alternatives
optimisation of construction and operating parameters
improved planning reliability
reduction of development time and testing effort
faster progression from design to market or operation

Steps from geometry generation to simulation results

TRAINING

Our two-day training courses teach participants how to set up, run and evaluate simulations efficiently with NOGRID CFD software. The courses include practical guidance for handling different types of simulation cases.

For more details please refer to Training Courses →

Technical Support

Professional support is available from the beginning of your work with NOGRID. Our technical team assists users by telephone and email with software operation, case setup and simulation-related questions.

For more details please refer to Software Support →

Simulation Service

When internal time, expertise or resources are limited, NOGRID can support your project with individual numerical simulation services. Our engineers develop and evaluate CFD models based on the specific requirements of your application.