Advanced CFD Solutions
At Kapwell Ltd, we harness the power of advanced Computational Fluid Dynamics (CFD) to drive innovation and optimize performance in critical process equipment. Our CFD studies focus on a range of applications—from evaluating and enhancing the design. By applying our expertise, we help clients reduce costs, prevent downtime, and improve the performance of their critical equipment in demanding environments.
Optimizing Performance Through Fluid Flow Simulation
By simulating fluid dynamics within these systems, our expert team identifies potential issues, such as flow irregularities, pressure drops, and inefficient separation processes, allowing us to fine-tune designs for maximum performance. The following case studies demonstrate how our CFD approach has delivered tangible benefits, from enhancing operational efficiency to extending equipment lifespan while maintaining rigorous standards for safety and environmental compliance.
CFD Modelling Capability
- Solver Expertise – Ansys Fluent and CFX for separation and process equipment applications.
- Advanced Meshing – High-quality hybrid, poly-hexcore and prism-layer meshes for accurate results.
- Multiphase Flow – VOF, Eulerian and particle-tracking models for gas, liquid and solid interactions.
- Turbulence Modelling – SST, RSM and LES approaches selected to match flow complexity.
- Heat & Mass Transfer – Thermal, species and phase-change modelling where process performance depends on transfer phenomena.
- Particle & Droplet Analysis – Tracking, capture efficiency, re-entrainment and internals performance assessment.
- Erosion & Integrity – Erosion risk screening and equipment integrity assessment.
CFD Case Studies: Data-Driven Engineering in Action
These case studies showcase how our expertise has been applied across a range of challenges—improving flow dynamics, reducing erosion, optimizing heat transfer, and ensuring compliance with environmental and safety standards. Each project reflects our commitment to delivering engineering solutions rooted in data, precision, and performance.
Case Study
Three-Phase Separator Flow Optimization Using CFD
This case study highlights Kapwell’s engineering and CFD expertise in optimizing separator performance. In the original deflector plate inlet design, the high-velocity inlet stream impinges directly onto the liquid surface at HHLL, resulting in droplet shatter, significant liquid re-entrainment, unstable operation, and poor downstream demisting efficiency. The modified design, incorporating a vane inlet device, redistributes the flow uniformly into the vessel core, eliminating direct impingement on the HHLL. This reduces gas velocities above the liquid level, minimizes re-entrainment, and delivers stable, highly efficient downstream separation performance.
Case Study
Enhanced Rotational Flow Performance via CFD Simulation
Case study demonstrating Kapwell’s engineering expertise: the modified design showcases enhanced rotational flow within the inlet cyclone, integrated with client-supplied upgraded internals. Substantial performance gains were achieved through the implementation of optimized baffles, replacement plate packs, and advanced de-foaming assemblies.
Case Study
Advanced Internal Flow Analysis for Separator Efficiency
This case study highlights Kapwell’s engineering and CFD expertise in optimizing separator performance through advanced flow analysis and targeted internal design improvements. The original design directs the inlet flow straight at the liquid level, resulting in poor internal flow distribution. CFD analysis reveals a large central recirculation zone between the plate pack and foam pack, with gas jetting along the sides toward the outlet. This non-uniform, highly disturbed flow deviates from the ideal plug flow regime, significantly reducing effective use of the vessel cross-section and compromising gravity-based droplet separation efficiency.
Case Study
Gravity Separation Improvement Through CFD Engineering
This case study highlights Kapwell Ltd’s engineering and CFD expertise in optimizing separator performance through advanced internal design and flow analysis. The vessel pathline analysis confirms that Kapwell Ltd’s revamped internals have effectively suppressed the central recirculation zone and enhanced flow uniformity within the gravity separation section, resulting in optimal utilization of the vessel cross-section by the gas phase. This case study further demonstrates Kapwell’s engineering excellence and proven capability in delivering high-performance separation solutions.
Case Study
H₂S Scrubber Performance Enhancement Using CFD
This case study highlights Kapwell’s engineering and CFD expertise in optimizing separator performance through advanced flow analysis, root-cause identification, and practical design enhancement solutions. The Liquid Knock-Out Drum revamp was undertaken to address increased throughput requirements and persistent liquid carry-over issues impacting operational efficiency. CFD analysis was employed to accurately diagnose the root cause of the carry-over, enabling the development of an effective design solution—demonstrating Kapwell’s project execution expertise and advanced CFD-driven engineering capability.
Case Study
CFD-Based Inlet Configuration Improvement
This case study highlights Kapwell’s engineering and CFD expertise in optimizing separator performance and delivering enhanced separation efficiency through advanced flow analysis and inlet device design. The original gas box configuration resulted in droplet re-entrainment from the liquid interface directly beneath the inlet; this was mitigated through a redesigned inlet device and a re-engineered gas box incorporating side-mounted demisting cyclones. The inlet device distributes gas into the inlet head, generating a complex three-dimensional swirling flow that increases gas residence time and enhances oil droplet separation by gravity. Furthermore, the demisting cyclones are strategically oriented away from the liquid surface, eliminating droplet pick-up and significantly improving separation efficiency. This case study highlights Kapwell’s project execution and CFD expertise in delivering optimized, high-performance separation solutions.
Case Study
Gas Hold-Up Reduction & Separation Efficiency Analysis
This case study highlights Kapwell’s engineering and CFD expertise in optimizing separator performance through robust process analysis and advanced CFD-driven validation techniques. Gas hold-up, defined as the volumetric fraction of gas retained within the vessel, was evaluated through a detailed inlet–outlet flow balance. The analysis indicates that at a residence time of 2.25 seconds, the system achieves near-complete gas disengagement, with negligible gas retention within the vessel. This demonstrates Kapwell’s capability to deliver high-performance separator solutions through accurate engineering assessment, CFD-based optimization, and effective project execution.
Case Study
Advanced Droplet Separation & Demisting Optimization
Kapwell’s expertise in CFD for droplet separation focuses on selecting the optimal mist elimination technology, understanding re-entrainment risks, and balancing droplet removal efficiency with pressure drop. Their capabilities cover mesh pads, vane packs, swirl or cyclone mist extractors, coalescing internals, and demister retrofits within vessels and scrubbers, serving primarily the oil and gas sector while also supporting desalination, power, and broader process industries. Kapwell addresses critical operational challenges such as fine mist carry-over, re-entrainment, drainage failure, excessive pressure drop, underperforming chevrons, secondary droplet formation after impact, and constrained retrofit space. Their solutions are grounded in both industry data and in-house product expertise, where mesh eliminators typically target droplets in the 3–5 micron range, vane separators handle droplets above 8 microns, and cyclone mist extractors are suited for high-pressure, high-capacity applications, particularly in retrofit scenarios where performance is often limited by splash effects, droplet recombination, and re-entrainment dynamics.
Case Study
Dual Desander Package Performance Validation Using CFD
This case study highlights Kapwell’s engineering and CFD expertise in optimizing separator performance and validating high-efficiency inline separation designs under realistic operating conditions. A key performance requirement of the inline separator is the effective removal of entrained oil droplets to prevent downstream slugging and protect subsequent equipment. For this assessment, oil droplets in the size range of 80 µm to 120 µm were injected at the inlet, with the initial droplet velocity matched to the inlet mixture velocity to ensure realistic momentum interaction with the continuous flow field. The results indicate a clear separation threshold at 100 µm, with all droplets ≥ 100 µm successfully driven toward the separator wall by centrifugal action and recovered through the liquid outlet. Monitoring at the gas outlet confirmed that no oil droplets larger than 100 µm were present in the gas discharge stream, demonstrating effective droplet capture and overall separator efficiency under the evaluated operating conditions.
Case Study
Cyclone Flow Behaviour & Separation Efficiency Assessment
This case study highlights Kapwell’s engineering and CFD expertise in optimizing separator performance through detailed numerical analysis and advanced flow characterization techniques. The internal flow behaviour of the representative cyclone element was assessed through velocity streamlines, pressure distribution, and discrete phase tracking in order to verify the secondary separation performance. The numerical analysis confirmed stable vortex formation and effective radial migration of the liquid phase toward the cyclone wall, demonstrating that the cyclone geometry is capable of supporting the required secondary oil removal performance. By combining the primary inline separator with the secondary cyclone vessel, the overall system provides staged separation, improving liquid removal efficiency and reducing the risk of residual oil carryover to downstream equipment.
Case Study
Dual Vane-Type Inlet Device CFD Evaluation
This case study highlights Kapwell’s engineering and CFD expertise in optimizing separator performance through the implementation of advanced flow management solutions and proprietary inlet device technology. The study demonstrates Kapwell’s project engineering expertise through the implementation of proprietary dual vane-type inlet devices, designed to ensure controlled flow redirection, reduced droplet shatter, and uniform fluid distribution. The optimized design minimizes maldistribution, reduces liquid carryover and re-entrainment, and significantly enhances overall separation performance and operational stability.
Case Study
Separator Interface Stability & Liquid-Liquid Separation Analysis
Kapwell offers advanced CFD expertise in liquid separation, helping improve interface stability, residence-time utilisation, and liquid-liquid or three-phase disengagement across separators, settlers, and coalescing systems. Their capabilities cover oil-water separation, three-phase separators, gravity settlers, coalescing plate packs, deoiling hydrocyclones, and detailed liquid-liquid disengagement studies. While strongly rooted in oil and gas applications, Kapwell also supports chemical processing, wastewater treatment, and broader process industries, leveraging proven CFD and CFD-PBM approaches in settler and mixer-settler design. Their simulations address key operational challenges such as unstable interfaces, short-circuiting, inefficient retention-time usage, oil carry-under, gas entrainment in liquid outlets, emulsion and dispersion control, weir sensitivity, and uncertainties in outlet conditions and internal configurations, recognising that separation performance is heavily influenced by outlet design, agitation, droplet dynamics, and overall flow-field behaviour.
Case Study
CFD Evaluation of Gas Separation & Scrubber Performance
Kapwell’s expertise in CFD for gas separation services enables operators to reduce liquid carry-over, improve gas dryness, and validate separator internals performance before fabrication, retrofit, or shutdown work begins. Their capabilities cover a wide range of equipment, including two-phase separators, suction scrubbers, gas scrubbers, inline de-liquidisers, fuel-gas conditioning systems, and compact gas–liquid separation skids, serving primarily the oil and gas sector while also supporting chemical manufacturing, power generation, and pharmaceutical industries. Using advanced CFD analysis, Kapwell addresses critical operational challenges such as liquid carry-over, inlet momentum effects, slug sensitivity, compact footprint constraints, inadequate flow calming after inlet devices, excessive pressure loss, underperforming demisting stages, and uncertainty in selecting horizontal versus vertical configurations, ensuring optimized hydrodynamics and reliable separation performance aligned with their proven two-phase, three-phase, and scrubber design expertise.
Case Study
Hydrocyclone and Sand Management Performance Analysis
Kapwell’s CFD expertise in sand separation focuses on optimizing desanders, hydrocyclones, and sand-management systems to improve solids removal, reduce erosion risk, and protect downstream equipment. Using advanced multiphase CFD analysis, Kapwell refines cyclone geometry and vessel internals to address challenges such as solids carry-over, pressure drop, ineffective sand withdrawal, wear hotspots, and retrofit optimisation, with applications across oil and gas, water treatment, mining, and industrial processing. Through CFD-led design optimisation and robust engineering integration, including solutions for harsh and sub-zero environments, Kapwell has achieved up to 99% solids removal efficiency, significantly enhancing equipment reliability and operational performance.
Case Study
Sand-Jetting & Vessel Flow Distribution Analysis
Kapwell demonstrates strong expertise in CFD through its sand-jetting and vessel sand-management retrofit solutions, aimed at reliably removing settled sand from separator vessels, including difficult dead zones often missed by conventional systems. Using CFD modelling, Kapwell analyses water-jet coverage and sand suspension behaviour to optimise nozzle placement and develop abrasion-resistant slurry routing strategies. This approach ensures comprehensive sand-bed coverage in both horizontal and vertical vessels, while incorporating durability-focused features such as wear pads and specialised nozzle materials. The overall impact is improved whole-bed sand removal with retrofit feasibility within existing access constraints, significantly reducing manual clean-out requirements and enhancing long-term vessel integrity.
Case Study
Compact High-Pressure Separator CFD Optimization
Kapwell demonstrates strong expertise in CFD through the design and optimisation of compact two-phase separators, with the objective of delivering high-purity gas–liquid separation within strict space and performance constraints. Their approach, as publicly described, integrates an inlet diverter, gravity settling, and high-efficiency internals such as vane packs or demisting cyclones, aligning with established research that emphasises the critical role of inlet configuration, internal flow distribution, and droplet removal mechanisms in achieving high separation efficiency. The resulting performance shows very dry gas output, minimal gas entrainment in the liquid phase, and up to 99% removal of entrained solids and liquid droplets from the gas stream, all while complying with relevant pressure-vessel and hazardous-area codes. This translates into clear business value: a compact footprint, clean gas export, and reduced downstream fouling risk without wasting vessel volume.
Case Study
Separator Internal Flow & Droplet Distribution Analysis
This case study highlights Kapwell’s engineering and CFD expertise in optimizing separator performance through detailed flow analysis and validation of droplet behaviour under challenging operating conditions. The CFD yielded the expected droplet size range at the vessel inlet and the fraction of liquid carried as droplets. These results fed directly into the scrubber model and confirmed that, even with the short run, the droplet sizes were within typical scrubber design targets (e.g. scrubber designs target droplets smaller than 500 µm).
Case Study
Demisting Cyclone Flow Stability Optimization Using CFD
This case study highlights Kapwell’s engineering and CFD expertise in optimizing separator performance. The swirling flow regime observed within the demisting cyclone was successfully addressed through Kapwell’s redesigned swirl geometry and enhanced drainage configuration, effectively eliminating liquid accumulation and flow instability issues. CFD-validated geometry ensured the removal of stagnation zones while achieving homogeneous flow velocity profiles across the cyclone cross-section, resulting in improved separation efficiency, stable operational performance, and enhanced reliability of the demisting system.
Case Study
Advanced CFD Validation of Demisting Cyclone Design
This case study highlights Kapwell’s engineering and CFD expertise in optimizing separator performance through advanced demisting cyclone design and validation. Kapwell’s Demisting Cyclone features a CFD-validated geometry that ensures elimination of stagnation zones and delivers homogeneous flow velocity profiles across the cyclone cross-section, resulting in highly efficient droplet separation performance. The CFD analysis demonstrates that a significant fraction of droplets in the 1–2 micron range are successfully separated, while 100% separation efficiency is achieved for droplets sized 4–5 microns under atmospheric simulation conditions.
Case Study
Vane Type Inlet Device CFD Performance Evaluation
Kapwell’s engineering and CFD expertise in optimizing separator performance is highlighted in this case study through the detailed analysis and validation of the Vane Type Inlet Device. The inlet device in a separator vessel is the most critical component within the vessel, as it must effectively control and distribute the incoming flow without generating fine droplets that become difficult or impossible to separate downstream. The CFD analysis demonstrates that the oil droplets exiting the Vane Inlet Device are sufficiently large to be effectively separated by gravity within the vessel. The minimum predicted droplet size was 407 microns, confirming the device’s capability to achieve efficient phase separation while maintaining optimal flow distribution and separator performance.
Case Study
Advanced CFD Analysis for Gas-Liquid Separation Systems
Kapwell Ltd demonstrates strong expertise in Computational Fluid Dynamics (CFD) analysis using ANSYS Fluent DPM simulations to optimize separator and mist elimination systems in accordance with client requirements and industry standards. For the Swirl Tube Mist Eliminator study, CFD analysis confirmed an exceptionally low pressure drop of 0.00198 mbar, well below the client’s maximum allowable limit of 0.03 mbar, while achieving a high liquid separation efficiency of 95.42% for 8-micron droplets. The simulation results validated the system’s gas-liquid separation performance, confirming alignment with process design calculations and ensuring reliable, efficient operation for demanding industrial applications.
Case Study
Flare KO Drum Separator Performance Analysis Using CFD
Kapwell has extensive expertise in CFD analysis using ANSYS Fluent DPM simulations for process and separation equipment design validation. For the Flare KO Drum study, all simulations were conducted in accordance with client requirements and industry standards, confirming that the inlet device achieved a pressure drop of only 6.985 kPa, significantly below the client’s maximum allowable limit of 50 kPa. The CFD results also verified that the Flare KO Drum performance aligns with the process design calculations and meets the specified operational and performance criteria.
Case Study
Separator Carryover Prevention Through CFD Simulation
Kapwell’s CFD expertise was demonstrated through Fluent DPM simulations of the LP Separator (V-3103), conducted in line with client requirements and industry standards. The analysis confirmed an inlet device pressure drop of only 3.62 kPa, while also achieving 100% separation efficiency for 3-micron liquid particles with a density of 794.7 kg/m³. The results verified that no liquid carryover occurred through the gas outlet, confirming that the separator performance fully meets process design calculations and project performance criteria.
Case Study
HP Separator Flow Distribution & Separation Efficiency Study
Kapwell has extensive expertise in CFD Fluent DPM analysis for separator performance validation, ensuring compliance with client requirements and international standards. Our simulations accurately assess critical parameters such as pressure drop, flow distribution, and separation efficiency. In this HP Separator study, the inlet device achieved a low pressure drop of only 5.353 kPa, well below the client’s allowable limit of 50 kPa, while delivering 100% separation efficiency for 3-micron liquid particles with no liquid carryover through the gas outlet. The CFD results confirmed that the separator performance fully aligns with process design calculations and project performance criteria, demonstrating Kapwell’s capability in delivering optimized and reliable gas-liquid separation solutions.