Performance engineering
For equipment operating below requirements: energy consumption above design, skewed flow distribution, emissions over the limit, or output stuck at a ceiling. It starts from measurements on the real system.
Equipment performance assessment
Before simulation, the actual operating point of the equipment must be established against design. This is the lowest-cost step and the basis for deciding whether to proceed.
Collecting operating data
Operating logs, on-site readings, design parameters, equipment drawings and piping ISOs. CFDWAYS specifies the minimum list if the data is incomplete.
Heat & mass balance
A balance of the whole system to locate the losses; in many cases the bottleneck lies outside the equipment originally suspected.
The performance gap
The result is quantified: the gap to design, the share recoverable through operation, and the share that requires hardware intervention.
Energy & process optimization
Most of the wasted energy in a plant lies in how the machines work together under real operating conditions.
- Operating window: the range of temperature, flow rate and feed ratio that gives the highest efficiency while keeping the equipment safe and staying under the emission limit.
- Waste-heat recovery: which heat sources are still usable, and which recovery schemes are feasible in terms of both layout and economics.
- Lower fan and pump consumption: duct pressure losses, flow-guiding devices, the fan operating point — usually the fastest improvement available.
- KPIs tracked continuously: after the improvement, the indicators go onto a monitoring platform to track whether the gain is sustained over time.
Diagnosis & root-cause tracing
Sensors show the outcome, not the cause. Simulation acts as a microscope, revealing zones that no instrument can reach.
Common symptoms
- Temperature differences between zones inside the same equipment
- Corrosion or fouling concentrated on one side
- Pressure loss higher than the design calculation
- Flue gas treatment underperforming despite sufficient reagent
- Vibration, localized wear, unusually short material life
How CFDWAYS works
- Building the model on the real geometry and operating conditions
- Calibrating against design data or measurements before concluding anything
- Locating the cause by quantitative criteria, not by impression
- Separating causes in design, in operation, and in the fuel or feedstock
Equipment & system retrofit
This step turns the diagnosis into a concrete hardware change that can be ordered and installed.
Propose the options
A few feasible retrofit options, each stating the scope of intervention and a relative cost estimate.
Verify on the model
Every option is re-run on the same validated model and KPIs compared before/after — the decision rests on data.
Detailed design
Fabrication drawings for the chosen option; manufacturing and supply are carried out with partners.
Post-installation tracking
Measurements after the retrofit are compared with the model prediction, closing the loop and calibrating for later projects.
Talk to us about your equipmentSee capabilities by equipment
Start from the performance gap
Send your current operating parameters and the design parameters. CFDWAYS replies within 24 working hours on the most significant gap and how to verify it.