Finite Element-Based Transient Stress and Vibration Analysis of Mixing Chambers

Abstract

Pressure vessels, integral components in industries such as oil, gas, chemical processing, and power generation, are designed to handle highly toxic and compressible fluids under extreme pressure. With the increasing demand for alternative fuels, the need for high-pressure and high-temperature vessels has escalated, particularly in petroleum refineries and chemical plants. Recent advancements in pressure vessel technology have focused on new-grade materials, composite materials, and welding techniques, with finite element analysis (FEA) playing a pivotal role in understanding fatigue and creep behaviour. Mixing chambers, a type of pressure vessel used in chemical industries, experience significant deformation and distortion due to varying pressure and temperature conditions. For instance, additives are introduced at different time intervals, with pressures cycling from 0 to 0.16 MPa and fluid temperatures ranging from 0 to 200°C. This fluctuating environment generates high local stresses that reduce the fatigue life of the mixing chamber, often leading to premature failure. The present study aims to perform transient dynamic stress analysis to identify stresses within the mixing chamber under general time-dependent loads. Additionally, finite element analysis is employed to predict and enhance fatigue life by determining time-varying displacements, strains, and forces acting on the pressure vessel. The study also seeks to modify the existing design provided by the manufacturer, optimize the nozzle angle for improved mixing, and validate the findings through simulation using ANSYS. By addressing these objectives, the research contributes to the development of more resilient mixing chambers, enhancing their longevity and performance under variable operational conditions. These insights are crucial for industries reliant on high-performance pressure vessels, ensuring safety, efficiency, and reliability in their processes.