CFD simulation with artificial intelligence: the key to optimizing energy, time and costs

In an industrial environment where every second and every resource counts, reducing the margin of uncertainty in process design and operation is a competitive advantage. This is where CFD simulation comes into play, a tool capable of anticipating complex physical behavior without the need for costly physical testing.

What is CFD simulation and how does it transform industry?

CFD makes it possible to model and analyze how fluids (liquids and gases) behave within a given environment. This includes everything from the flow of air inside an industrial furnace to the thermal distribution in an electrical cabinet or the behavior of smoke in a ventilation system.

By using advanced software and numerical models, it is possible to anticipate with high accuracy how air, water, gases or specific chemicals will behave in different scenarios and map key parameters such as velocity distribution, temperature, concentration, among others. This tool is fundamental for the virtualization and optimization of processes, enabling the diagnosis and prevention of failures, as well as improving energy efficiency and the competitiveness of companies.

Beyond simulation: AI for prediction and continuous improvement

At CIRCE we have evolved the CFD simulation service by integrating artificial intelligence algorithms that allow us to enrich the physical models with real operational data. Thanks to this combination, we can incorporate information from thermal sensors, historical records under different load conditions, air flows measured in the field or thermal maps captured by infrared cameras in hybrid models. This integration enhances predictive and optimization capabilities by combining detailed fluid analysis with machine learning algorithms, enabling continuous improvement in complex processes and reduction of operational uncertainties.

For example, if a heat exchanger exhibits thermal instabilities under certain environmental conditions, the model can anticipate those critical points and propose redesign scenarios before problems arise.

Artificial intelligence also helps to improve model calibration by automatically optimizing parameters such as surface roughness, fluid viscosity or friction losses from observed data. This increases the reliability of the results without the need to extend the number of physical tests.

Real applications: how different industries optimize with CFD + AI

1.Steel industry: thermal efficiency and energy savings
In thermally demanding industrial environments, such as the steel industry, we have applied these tools to analyze and optimize ventilation and combustion systems in smelting areas. Using parameterized simulations that replicate real furnace operation, we identified areas of thermal imbalance and studied alternatives for gas recirculation and insulation.
The redesign of the air flow and the application of new thermal linings improved the temperature distribution inside the furnace. As a result, greater operational stability was achieved and the system's thermal losses were reduced by 59%, resulting in energy savings and improved product efficiency. Read more about this success story

2. Energy: Thermal management of second-life batteries
In the energy sector, we are working on the virtualization of storage systems based on reused batteries. The challenge here is not only managing temperature, but also understanding how second-life cells behave under different load and environmental conditions.
Thanks to the combination of CFD simulation and artificial intelligence, we can predict critical points of thermal concentration, anticipate potential degradation, and design configurations that extend the systems’ lifespan. This predictive capability also helps minimize safety risks and accelerate the development of more reliable and sustainable energy storage solutions.

3. Building and air conditioning: Comfort and sustainability without overconsumption
In sectors far removed from heavy industry, such as building construction or air conditioning in public spaces, we have applied this technology to redefine natural ventilation strategies, leveraging existing airflows without increasing energy demand. Simulations also make it possible to optimize air conditioning and ventilation in critical spaces, such as industrial facilities, laboratories, and operating rooms, ensuring safe and efficient environmental conditions.
The result: more comfortable environments for people and aligned with sustainability goals, especially in buildings with environmental certifications or in urban areas where energy consumption must be kept under control.

Do you want to know how to apply CFD simulation and artificial intelligence to your specific case?

Contact our team and discover how we can help you save costs, improve performance, and reduce risks without affecting your production.

Article of interest: From data to decision: How AI and digitization are driving industrial competitiveness