Flow distribution in an industrial application for diverse fluid types

Abstract (Swedish)

Helios Innovations har idag problem med spridarna i sin indunstningsteknik, där flytande farligt avfall fördelas över evaporativa block. De industriella duschmunstycken som används tenderar att sätta igen och orsaka ojämn spridning av vätskan. Målet med detta examensarbete har varit att utveckla en förbättrad design av spridaren.

En förbättrad spridardesign kan bidra till minskade underhållskostnader och en lägre miljöpåverkan, både för servicetekniker och den omgivande miljön. En jämnare spridning minskar risken för igensättningar och torra, ineffektiva ytor.

Flera designförslag har tagits fram och utvärderats med hjälp av flödesberäkningar (CFD). I rapporten jämförs olika alternativ och deras respektive för- och nackdelar. En slutlig design valdes ut, tillverkades och testades i en förenklad testmiljö. Resultaten visar att det är möjligt att förbättra Helios Innovations nuvarande spridare.

Abstract

Helios Innovations is currently facing issues with its distributors, which spread liquid hazardous waste over evaporative blocks in its evaporation technology. The industrial spray distributor tends to clog and distribute the liquid unevenly. This thesis project has aimed to develop an improved distributor design.

An improved design could reduce maintenance costs and minimise environmental impact, benefiting both service personnel and the surrounding environment. More even fluid distribution helps prevent clogging and reduces the risk of dry or inefficient surfaces.

Several design concepts were developed and evaluated using computational fluid dynamics (CFD) simulations. The report compares the different alternatives and assesses their respective advantages and disadvantages. A final design was selected, manufactured, and tested in a simplified test environment. The results demonstrate that it is possible to improve the current spray distributor used by Helios Innovations.

Popular Abstract

Improved liquid distribution in industrial evaporation systems

Clogged holes, dry surfaces, and uneven flows reduce the efficiency of industrial wastewater treatment. A new distributor design developed for Helios Innovations offers a more reliable method for spreading liquid waste, saving both money and the environment.

Helios Innovations is a growing Swedish company with a bold mission: to reduce hazardous industrial liquid waste using evaporation technology at atmospheric pressure. Instead of shipping away oily water, firefighting foam or degreasing fluids are often made up of over 97% water. Helios helps customers evaporate the water on-site and drastically reduce waste volume.

Their technology had a hidden weakness (in some of their machines). Inside the evaporation system, a spray distributor spreads the liquid across special blocks where evaporation occurs. When the spray is not even, it leaves dry areas, which lowers efficiency and increases maintenance. The existing distributor also tends to clog, especially with liquids that contain particles or change viscosity during evaporation.

This thesis project aims to address that. The goal is to design a better liquid distributor that works across a wide range of industrial fluids. To achieve this, 13 different design concepts were developed and tested using advanced computer simulations, known as computational fluid dynamics (CFD). One design showed clearly better performance and was selected for physical testing.

The results of the new design improved the evenness of flow dramatically, reducing variation by over 85%, and seem to work well with different fluid types. Although small vortex zones in the flow could not be eliminated entirely, they were made smaller and less disruptive.

A more even flow leads to better evaporation, less clogging, and fewer maintenance stops. This means lower costs for customers and a smaller environmental footprint. The improved distributor design also requires no big changes to Helios’ existing systems, making it easy to implement as the company prepares to scale up internationally.

This project shows how smart engineering, supported by simulations and real-world testing, can solve tricky design problems and help green technologies grow stronger.

• author: Berndtsson, Elvin
• supervisor: Lei Wang
• organization: Department of Energy Sciences
• course: MVKM01 20251
• year: 2025
• type: H2 - Master's Degree (Two Years)
• subject: Technology and Engineering
• keywords: Flow maldistribution, hazardous liquid waste, evaporation, product development
• report number: ISRN LUTMDN/TMHP-25/5623-SE
• ISSN: 0282-1990
• language: English
• id: 9204093
• date added to LUP: 2025-06-23 09:49:44
• date last changed: 2025-06-23 09:49:44