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Industry: Energy

  • Domin – Engineering Advanced Hydraulic Valves

    Challenges Previous CFD software produced variable accuracy, forcing physical test iterations to close the gap. Locally stored simulation files locked results away from the wider team. Static design review reports created high dependency on the designer’s own judgment of what mattered. Local compute meant simulations blocked designers from other work while running. A new analysis…

  • Allegro Energy – Flow Batteries for Grid Energy Storage

    Challenges Need for uniform mixing in large, bespoke electrolyte tanks to ensure battery performance. Microchannel flow architecture in battery cell/stack determines efficiency and pressure drop. Legacy simulation tools running on-premises could not provide simulation throughput needed to keep pace with design needs. Results Multiphase CFD visualized mixing across baffle designs, nozzle depths, and flow rates,…

  • Fourier – Designing a Next-Generation Electrolyzer Stack

    Challenges Standard handbook rules for elastomeric seal design do not apply to the shallow gland geometries required for thin PEM electrolyzer plates. With no previous in-house stack design to reference, the team had no established tolerance bands and no way to predict the effect of manufacturing variation without physical testing. Seal stability under pressurization —…

  • TEGnology – Building the Wireless Industrial Edge

    Challenges Accurate power prediction requires a validated approach to modeling contact resistance between component interfaces. Thermal design of the housing and clamping system need to evolve in line with mechanical design so that the two work in concert Limited ability to measure internal heat flows with lab testing to inform design direction As a lean…

  • Emrgy – Designing Hydro Turbines for Irrigation Canals

    Challenge Designing vertical-axis turbines for non-disruptive canal installation presents complex fluid dynamics challenges. Emrgy’s design goals extend beyond maximizing power output; they must also minimize hydraulic disruption, maintain acceptable upstream water levels, and preserve flow conditions vital to irrigation system operators. A key challenge in deploying these systems is understanding both localized and large-scale hydrodynamic…

  • Siemens Energy – Optimizing 3D-Printed Products

    Challenges Required optimization to push thermal performance to the limits Complex geometry and physics with multiple conflicting goals Long simulation pre-processing and turnaround times with incumbent 3D design software stack Results Fast design iterations and parallel validations using cloud-native simulation Parallel assessment of heat transfer efficiency and pressure drop using CHT analysis Pre-processing times reduced…

  • Versogen – Designing AEM Electrolyzer Stacks

    Challenge Design an innovative cell architecture for an anion exchange membrane (AEM) electrolyzer. Develop a cost-effective hydrogen electrolyzer stack optimized for high performance and scalability. Test high-pressure membrane seals to ensure durability and prevent hydrogen leakage under demanding operating conditions. Results Developed an industry-leading AEM electrolyzer cell that exceeds the U.S. Department of Energy’s 2026…

  • Hephae – Unlocking Geothermal Energy

    Challenge Unlock unconventional geothermal energy Develop high-temperature-resistant sensors and electronics for deep hot rock drilling Evaluate shock and vibrations on drilling tools Make local geothermal energy cost-effective Results Applied cloud-native simulation to analyze thermal, structural, and vibration effects of deep hot rock drilling Successfully developed heat-resistant circuit boards using novel heat dissipation technology Proved the…

  • Scanmudring – From Design to Depth in Subsea Drilling

    Challenge Improve traditional offshore cutting and dredging equipment for harder subsea clays. Rapidly design, test, and deploy a novel suction nozzle that attaches to a 40-ton offshore excavator. Improve overall drilling efficiency and productivity in a cost-sensitive industry. Results After simulating, optimizing, and fabricating the new suction nozzle, the team deployed the excavator offshore. The…

  • Methanex – Containing a Leak Without Plant Downtime

    Challenge Methanex Corporation is the world’s largest producer and supplier of methanol. A leak was detected in a methanol production plant. Traditional remediation would have involved a costly plant shutdown. Results Deployed SimScale to simulate allowable structural stresses on a new component The leak containment component was designed and optimized within 8 hours on the…

  • Energyminer – Optimizing a Micro-Hydropower Plant

    Challenge The Energyfish by Energyminer is a micro-hydropower plant that harnesses the power of water and produces electricity continuously in a river. Energyminer’s engineering team was looking to simulate and analyze the fluid-structure interaction, material selection, structural resilience, and turbine. Results Increase in hydrodynamic efficiency via fluid-structure interaction simulation and optimization. Turbine body refined for…

  • Cryo Pur – Liquefying Biogas for a Decarbonized Future

    Renewable Energy Alternatives to Diesel Oil Biomethane and bio-GNL are renewable energies derived from organic waste and reduce greenhouse gas emissions by over 80% compared to diesel. The production of fuel for trucks (bio-GNL), The production of biomethane from landfill gas, Production of liquid bio-CO2. It is considered a major solution to many problems for…