ANSYS Case Studies Simulation-Driven Design for Commercial Buildings: A Case Study

	Simulation-Driven Design for Commercial Buildings: A Case Study ANSYS

Simulation-Driven Design for Commercial Buildings: A Case Study

ANSYS

Technology Category	Sensors - Air Pollution Sensors Sensors - Environmental Sensors
Applicable Industries	Buildings Construction & Infrastructure
Applicable Functions	Product Research & Development
Use Cases	Indoor Air Quality Monitoring Outdoor Environmental Monitoring
Challenge	Air Science & Engineering was approached by a client in the metalworking industry who was grappling with the issue of metal fumes from a large torch cutting operation. These fumes were escaping into adjacent work areas, bypassing an existing ineffective side-draft hood, and contaminating the work environment. The challenge was to develop a hood design that would effectively capture and contain the process fumes while minimizing the required exhaust flow rate. The new hood also needed to be designed in a way that it would allow parts to be loaded by an overhead crane and accommodate the existing high-velocity push jet necessary to prevent the buildup of flammable gases under the workpiece. Read More
About Customer	The customer in this case study is a company in the metalworking industry. They were dealing with a significant issue of metal fumes from a large torch cutting operation contaminating their work environment. The fumes were bypassing an existing ineffective side-draft hood and escaping into adjacent work areas. The company needed a solution that would not only capture and contain these fumes but also minimize the required exhaust flow rate. Additionally, the solution had to be designed in a way that it would allow parts to be loaded by an overhead crane and accommodate the existing high-velocity push jet necessary to prevent the buildup of flammable gases under the workpiece. Read More
Solution	Air Science & Engineering combined traditional industrial hygiene (IH) engineering with Computational Fluid Dynamics (CFD) analysis to address the challenge. Since the process was unique, field testing was necessary to characterize the fume source, the high-velocity push jet, and the cross drafts in the open-bay shop environment. A baseline CFD model of the existing condition was developed and validated using the field data. This model was then used to evaluate the likely effectiveness of possible new hood configurations and to optimize the design of the final selected configuration. Various combinations of exhaust rate, cutting position, and environmental conditions were modeled, leading to a final design exhaust rate of 11,500 cfm. The optimization process also indicated that a second push jet would likely be necessary for worst-case cutting conditions. Detailed designs for the exhaust hood and the secondary push jet were developed. Read More Log in to view content
Contents

Technology Category

Sensors - Air Pollution Sensors

Sensors - Environmental Sensors

Applicable Industries

Buildings

Construction & Infrastructure

Applicable Functions

Product Research & Development

Use Cases

Indoor Air Quality Monitoring

Outdoor Environmental Monitoring

Challenge

Air Science & Engineering was approached by a client in the metalworking industry who was grappling with the issue of metal fumes from a large torch cutting operation. These fumes were escaping into adjacent work areas, bypassing an existing ineffective side-draft hood, and contaminating the work environment. The challenge was to develop a hood design that would effectively capture and contain the process fumes while minimizing the required exhaust flow rate. The new hood also needed to be designed in a way that it would allow parts to be loaded by an overhead crane and accommodate the existing high-velocity push jet necessary to prevent the buildup of flammable gases under the workpiece.

About Customer

The customer in this case study is a company in the metalworking industry. They were dealing with a significant issue of metal fumes from a large torch cutting operation contaminating their work environment. The fumes were bypassing an existing ineffective side-draft hood and escaping into adjacent work areas. The company needed a solution that would not only capture and contain these fumes but also minimize the required exhaust flow rate. Additionally, the solution had to be designed in a way that it would allow parts to be loaded by an overhead crane and accommodate the existing high-velocity push jet necessary to prevent the buildup of flammable gases under the workpiece.

Solution

Air Science & Engineering combined traditional industrial hygiene (IH) engineering with Computational Fluid Dynamics (CFD) analysis to address the challenge. Since the process was unique, field testing was necessary to characterize the fume source, the high-velocity push jet, and the cross drafts in the open-bay shop environment. A baseline CFD model of the existing condition was developed and validated using the field data. This model was then used to evaluate the likely effectiveness of possible new hood configurations and to optimize the design of the final selected configuration. Various combinations of exhaust rate, cutting position, and environmental conditions were modeled, leading to a final design exhaust rate of 11,500 cfm. The optimization process also indicated that a second push jet would likely be necessary for worst-case cutting conditions. Detailed designs for the exhaust hood and the secondary push jet were developed.

Impact #1	The solution provided by Air Science & Engineering was successful in addressing the customer's challenge. By using ANSYS Airpak CFD modeling software along with traditional IH engineering, a new exhaust hood was designed and installed, effectively capturing the process fumes. The new hood performed as predicted from startup, which meant that field prototype development and associated rework costs and production delays were avoided. This not only led to significant cost savings but also ensured a safer and healthier work environment for the employees.

Impact #1

The solution provided by Air Science & Engineering was successful in addressing the customer's challenge. By using ANSYS Airpak CFD modeling software along with traditional IH engineering, a new exhaust hood was designed and installed, effectively capturing the process fumes. The new hood performed as predicted from startup, which meant that field prototype development and associated rework costs and production delays were avoided. This not only led to significant cost savings but also ensured a safer and healthier work environment for the employees.

Benefit #1	The new exhaust hood and exhaust rate were optimized before construction, leading to an estimated savings of $50,000 in capital costs.
Benefit #2	The optimized design also resulted in an estimated $5,000 savings in annual operating costs.
Benefit #3	The final design exhaust rate was optimized to 11,500 cfm.

Benefit #1

The new exhaust hood and exhaust rate were optimized before construction, leading to an estimated savings of $50,000 in capital costs.

Benefit #2

The optimized design also resulted in an estimated $5,000 savings in annual operating costs.

Benefit #3

The final design exhaust rate was optimized to 11,500 cfm.

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Overview

Simulation-Driven Design for Commercial Buildings: A Case Study

Operational Impact

Quantitative Benefit