Consulting Projects

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 assessed the cooling and ventilation of two steam turbines at a power plant in Cyprus, focusing on the challenges posed by hot summers. Using Fluent's solar load model, the study simulated the worst-case thermal loads. The HVAC system's performance was evaluated, identifying temperature hot spots and areas of stagnant air. The results confirmed effective cooling without noise hazards, helping engineers avoid the need for additional fans, thus reducing costs.

Simtec simulated the ventilation and indoor air quality for a mall in Ioannina, Greece, focusing on its HVAC system's ability to maintain comfortable temperatures during harsh winters and hot summers. The detailed model accounted for solar heat load, building materials, and occupant heat. The study also calculated air renewal rates, identifying areas with stagnant air. The results ensured the mall's HVAC system could provide comfort and high air quality year-round.

Simtec simulated the flow of heavy fuel oil through a subsea pipe transferring fuel from tanker ships to a Greek island's power plant. The study aimed to determine if insulation was needed to prevent fuel solidification during winter. The CFD model, using multiphase modeling, confirmed that despite small pockets of solidified fuel, the pipe remained functional without insulation. This validation helped Public Power Corporation SA avoid unnecessary insulation costs.

Simtec collaborated with ELKEME, the research center of VIOHALCO Group, to simulate an industrial furnace used for annealing aluminum coils. The CFD model analyzed heat transfer between nitrogen and aluminum within the furnace, driven by radiation and forced convection from axial fans. This simulation helped create a predictive library for standard annealing cases, enabling ELKEME to optimize production by achieving uniform heating and reducing annealing times.

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.