Consulting Projects

The cleaning performance of a chemical dishwasher was analyzed using an SPH simulation to capture complex droplet dynamics and surface interactions. With GPU acceleration, high-resolution multiphase flow simulations were performed efficiently. By tracking liquid coverage time on contaminated surfaces, the study enabled accurate evaluation of dilution and cleaning effectiveness, supporting optimized operating parameters.

A custom 4D temporal and spatial cylindrical interpolation method was developed to map discrete measurement data onto a curved surface for simulation boundary conditions. The implemented UDF performed surface-based distance calculations and time-dependent interpolation directly on the cylindrical geometry, ensuring accurate data mapping. This approach provided a significantly more realistic and reusable boundary condition for multiple simulation cases.

The filter clogging behavior of a truck brake system was analyzed using a customized CFD approach. A porous zone model combined with DPM and User-Defined Functions enabled simulation of particle capture, clogging progression, and size-dependent filtration efficiency. The workflow improved prediction accuracy of pressure drop and filter performance, supporting more reliable design decisions.

The thermal performance of the bypass chimney and silencer was assessed to verify compliance with external temperature limits. A 3D CFD model using Conjugate Heat Transfer (CHT) and shell conduction was used to efficiently evaluate heat transfer through gas, walls, and insulation. The results confirmed that all temperature limits were met and no hot spots were identified.

A CFD-based methodology was developed to improve prediction of fluid-fluid mass transfer in chromatography applications with limited experimental data. Using a 2D VOF model, a single droplet in crossflow was simulated to resolve detailed concentration fields. From the concentration decay, an effective mass transfer coefficient was determined, providing more accurate input data than empirical correlations for column-scale simulations.

The RTM process for e-motor components was simulated to improve process understanding and defect prediction. A 3D CFD model captured resin flow, curing, and solidification, including temperature- and age-dependent material behavior. The simulation enabled identification of potential air entrapment and void formation, supporting process optimization and reducing manufacturing risks.

An electromagnetic-thermal co-simulation framework was developed for power cables, enabling accurate calculation of temperature-dependent electromagnetic losses with fully distributed heat sources at the mesh-cell level. Traditional IEC 60287 methods assume uniform conductor and sheath temperatures, which become inaccurate in the presence of strong thermal gradients, magnetic armor, proximity effects, and circulating currents. The framework couples an extended IEC 60287-based electromagnetic loss model directly to Ansys Fluent using PyFluent, retrieving local temperature values for every mesh cell to calculate temperature-dependent properties and corresponding volumetric heat sources. These spatially distributed heat sources are applied back to Fluent, where the thermal field is resolved with full geometric and material fidelity. This two-way, cell-resolved coupling ensures that electromagnetic losses and thermal fields are fully consistent, accurately representing cable behavior under real operating conditions.

A detailed CFD study was conducted to design and validate the ventilation system of an underground car park, ensuring effective pollutant control during normal operation and supporting smoke extraction strategies for emergency scenarios. In accordance with BS 7346-7, a comprehensive 3D model was developed including inlets, exhausts, and jet fans. Simulations evaluated airflow distribution and local mean age of air as key performance indicators, identifying low velocity and recirculation zones. Alternative jet fan layouts were tested to optimize air movement. The final design delivers a compliant, energy efficient ventilation concept that ensures safe air quality and improved smoke management.

A Python and SpaceClaim-driven workflow was developed to accelerate external condenser placement analysis for data centers, cutting setup time from one week to minutes. The system automates PyFluent script generation, including on-the-fly C++ UDF creation and compilation, allowing users to perform reliable simulations without deep CFD expertise. This framework streamlines repetitive tasks, reduces human error, and enables rapid evaluation of multiple design iterations.

A CFD and electro-thermal study was conducted to optimize battery pack thermal management. Using a detailed 3D model of modules and internal cells, coupled simulations under realistic drive cycles identified hotspots and ensured uniform temperature distribution. Python automation and Reduced Order Modeling accelerated the workflow, enabling rapid design optimization and support for Digital Twin applications. The framework improves thermal uniformity, extends battery life, and reduces computational time.

A detailed CFD study was performed to assess and optimize pulverized fuel (PF) duct distribution, ensuring uniform fuel delivery to all burner fingers and minimizing flow imbalances that could compromise combustion efficiency and component longevity. A full 3D model of the duct system and burner geometry captured gas-solid interactions using Euler-Lagrange simulations with realistic particle size distributions (PSD) and inhomogeneous coal inlet conditions. Baseline and modified duct designs were compared across different coal mass flow rates, revealing design changes that significantly improved fuel distribution uniformity. The optimized layout reduces deviations, enhances combustion efficiency, and minimizes hotspots, delivering a robust and reliable solution for PF distribution.

A conjugate heat-transfer CFD analysis was performed on an axial-flux motor using three stator-carrier solid materials with different thermal properties. The study assessed liquid coolant’s performance which flows inside specially designed channels, as well as the convective cooling to the surrounding air of the motor. Steady-state simulations, combined with material sensitivity studies, provided insight into temperature distribution, heat removal efficiency, and influence of thermal insulation.

The study predicted airflow and temperature distribution in the external mechanical rooms of the residential and office buildings of 17-storey and 16-storey, respectively, "Landmark Towers" in Nicosia under hot summer conditions. The goal was to ensure that air-conditioning units located in mechanical rooms of each floor operate under acceptable conditions and draw in fresh air that is not "contaminated" by the recirculation of hot air rejected from other units of the same or adjacent floors. In order to achieve this, the simulation of a large air volume around the buildings, in addition to mechanical rooms volume, was necessary. Simulations revealed the great effect of the perpendicular louvers and covers, which greatly determine the airflow pattern and temperature distribution.

A Computational Fluid Dynamics (CFD) study was performed on behalf of Novenco Marine & Offshore to assess the performance of the ventilation system within a multi-deck ship environment. The goal was to identify hot zones and modify airflow distribution so that more cooling air is delivered to these regions. Using Ansys Fluent, Simtec team modeled complex heat dissipation from engines and gensets and simulated airflow from supply ducts under realistic operating conditions.

This project applied advanced CFD simulations to assess and optimize climate control and solar load management in a luxury residential complex in Voula, Attica. The simulations, conducted using Ansys 2024R1 tools, evaluated airflow patterns and temperature distributions across multiple levels of residential spaces. Key areas of focus included optimizing HVAC system performance, especially in challenging spaces like double–height living rooms with large glass facades, which are highly susceptible to solar heat gains. The findings guided HVAC system modifications that improved energy efficiency and resident comfort, in alignment with Greek national standards (KENAK and TOTEE). The results of this study provide actionable insights for reducing energy consumption and enhancing the performance of HVAC systems in high–end residential developments.

Simtec conducted a comprehensive cooling study for two Data Centers located in the Attica region, utilizing Computational Fluid Dynamics (CFD) simulations. The study included both the analysis of external heat flow from the air conditioning units and the simulation of the internal spaces.

Simtec used Ansys Fluent to validate Lindbergh KFT's rain louvre through CFD analysis, bypassing time constraints of physical certification. The simulation replicated the CSN EN 13030 test, including turbulent airflow and droplet tracking. The CFD model was validated against a certified louvre (type 78Z) and applied to the louvre under assessment (type Z100). The results confirmed Z100's superior performance, allowing Lindbergh to save time and costs in certification.

Simtec used CFD to analyze the hydraulic oil flow in a control valve, focusing on cavitation phenomena caused by pressure drops. The study modeled phase changes using a multiphase approach, revealing that cavitation occurs in three stages, each with distinct frequencies. These frequencies are linked to noise and potential structural fatigue, offering insights into the valve's performance and durability.

Simtec assisted MELAMIN engineers in simulating the behavior of a batch reactor during a scale-up study. Three different impeller configurations were analyzed using CFD to evaluate mixing efficiency, required time, and rotation torque. The simulations revealed the best impeller design, identified potential mixing issues from local vortices, and helped the engineers make safer and more cost-effective decisions.

Simtec investigated severe vibrations in an installed heat exchanger, initially suspected to be caused by unsteady fluid flow. Using transient CFD modeling, the flow inside the heat exchanger's gas and liquid circuits was analyzed, focusing on high-frequency forces on the walls. The study found no significant frequency-induced forces, allowing engineers to explore other potential causes of the vibrations.

Simtec simulated ELPEN's double-blister Dry Powder Inhaler to verify its drug dispersion efficiency. Using CFD modeling, the airflow and particle dynamics within the inhaler were analyzed, ensuring effective drug delivery even under low suction pressure. The study confirmed that the design allows proper mixing and quick particle exit, providing ELPEN with valuable insights for optimizing the inhaler's aerodynamic performance.

Simtec evaluated the health and safety systems of the National Museum of Contemporary Art in Athens, focusing on its standard and emergency HVAC systems. Using CFD modeling, they simulated fire scenarios in the museum, which occupies a former industrial brewery with flammable art exhibits. The study assessed the effectiveness of the fire sprinklers, evacuation plans, and smoke extraction systems, determining the building's safety within the first 15 minutes of a fire outbreak.

SIMTEC utilized Computational Fluid Dynamics (CFD) simulations to evaluate the wind energy potential of a challenging site in Greece with steep slopes. Traditional methods were insufficient, so ANSYS FLUENT was used to analyze wind patterns and energy potential across various directions and speeds. The results supported TERNA engineers in assessing the economic viability of a potential wind farm.

SIMTEC used CFD modeling to verify the efficiency of KRONOSPAN's new batch reactor design. The model confirmed effective mixing and heat transfer, ensuring safe operation and preventing material solidification.

SIMTEC used CFD to study the air flow inside an Air-Curtain. Air–Curtains are usually placed over doors and openings in commercial stores, shops and other public spaces.

SimTec performed CFD simulations for “INSTA Consultants Engineers” to calculate the flow and temperature fields inside and around the “Piraeus Tower”.

Simtec simulated the ventilation and cooling of a power generation facility in the Libyan desert, addressing the challenges of excessive solar heat and diesel engine output. Using Fluent's solar load model, the study focused on the worst-case summer scenario. The simulation included realistic geometry and material properties, assessing the HVAC system's capacity to manage heat from three engines. The results showed the system's ability to handle the high heat load, ensuring effective cooling and ventilation.