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Volume 104
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Mitterlindner, M., Niemann, M., Louw, D., Kieckhefen, P., Goniva, C., Salehi, M., & Radl, S. (2025). Advanced heat flux modeling in coarse-grained CFD-DEM simulations. Particuology, 104, 245-260. https://doi.org/10.1016/j.partic.2025.07.003
Advanced heat flux modeling in coarse-grained CFD-DEM simulations
Michael Mitterlindner a, Martin Niemann b, Daniel Louw b, Paul Kieckhefen c, Christoph Goniva b, Mohammadsadegh Salehi a, Stefan Radl a *
a Institute of Process and Particle Engineering, Graz University of Technology, Inffeldgasse 13/III, 8010, Graz, Austria
b DCS Computing GmbH, Industriezeile 35, 4020, Linz, Austria
c BASF SE, Carl-Bosch-Str. 38, 67063, Ludwigshafen am Rhein, Germany
10.1016/j.partic.2025.07.003
Volume 104, September 2025, Pages 245-260
Received 31 March 2025, Revised 18 June 2025, Accepted 7 July 2025, Available online 16 July 2025, Version of Record 28 July 2025.
E-mail: radl@tugraz.at
Highlights

• Novel heat exchange limiter to stabilize fluid-particle heat transfer calculations.

• View-factor corrections for coarse-grained radiative heat transfer simulations.

• Grid resolution guidelines ensure reliable P1 radiation predictions in CFD-DEM.


Abstract

Accurately predicting heat flux in coarse-grained CFD-DEM simulations is a significant challenge. Specifically, the rates of fluid-particle heat exchange, the effective thermal conductivity of a bed of particles, as well as radiative heat transfer rates are difficult to predict. By using a novel algorithm, we significantly improve the accuracy and stability of such simulations by using a heat exchange limiter. This limiter enables realistic predictions even at time steps that are three orders of magnitude larger than a typical fluid heat relaxation time. Additionally, view-factor-based corrections for radiative heat exchange computations are developed. These corrections ensure an effective thermal bed conductivity with less than 3 % error for a coarse-graining ratio of 10. The applicability of the P1 radiation model in coarse-grained settings is also examined, leading to recommendations for the CFD grid resolution to ensure accurate predictions. Our methods significantly enhance stability, accuracy, and computational efficiency, making coarse-grained CFD-DEM simulations more viable for industrial applications. These advancements enable more reliable modeling of high-temperature processes, accelerate optimization studies, and enable virtual equipment design of such processes.

Graphical abstract
Keywords
CFD-DEM simulation; Coarse-graining; Heat exchange; Heat conduction; Radiation
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