Application note

CFD simulation of water ow in sandstone using micro-CT

Materialises engineering network facilitates top-level research
For years, researchers around the globe have had a hard time examining objects at a very small scale, say micrometer level. Such research requires the use of very accurate tools: micro-CT scanners that can retrieve structural information down to the micrometer level and state-of-the-art software that has the ability to process and analyze small scale images without any compromise. In the following case study researchers were looking for a way to understand water ow through Belgian sandstone. The obtained insights will be used for the study of extraction of fossil fuels from porous rock formations. Thanks to the joint expertise of inCT, Materialise and TotalSim, this analysis was made effortlessly.

Synergy leads to the greatest results

Over the years, Materialise has acquired extensive knowledge and expertise in the eld of micro-CT data handling. In order to be able to provide its customers with the very best solution to their problem, Materialise has built up a vast network of reliable partners, which all rise to the same high standards Materialise itself is known for. Recently, one such successful collaboration led to a CFD simulation of micro-CT sandstone data.
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The researchers in this case turned to Materialise to help them with their project. Materialises Engineering Services department specializes in solving a wide variety of engineering problems, from start to nish. In order to provide an accurate ow analysis of the sandstone data, three areas of expertise were combined. First of all, high quality non-destructively obtained slice images of the specimen were captured. InCT (Ghent, Belgium) provided Materialise with exactly this type of data using their broad micro-CT hard expertise. Next, accurate 3D model generation and surface mesh optimization were performed by the Materialise Engineering Services Team using the Mimics Innovation Suite. Finally, this model was used as input of the volume meshing and solving process performed by the CFD consultancy experts of TotalSim (Brackley, UK).

Capturing micro-CT image of sandstone sample

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Close-up image of the sandstone sample 2D micro-CT slice, courtesy of inCT

In order to create the most accurate 3D reconstruction of the sandstone data, Materialise turned to inCT, known for its state-of the-art image capturing techniques. Their customized X-ray CT scanners are congured to produce an optimal result for the high-resolution imaging of geological samples. They use a transmission-type X-ray tube, which was congured to produce an X-ray beam with a spot size of only a few micrometers. During the CT scan, more than 1000 projection images were recorded, while the sample, a 7 mm core drilled from Belgian sandstone (Bray), was rotated accurately over 360. This resulted in a complete 3D volume of over 1500 voxels, with an isotropic voxel size of 6 m, ensuring the images accuracy.

Generating 3D model and surface mesh

Next, a team of Materialises Engineering Services experts got to work. The 2D scanned slices were imported into Materialises scanner image processing software Mimics, which allowed them to make a separate segmentation of rock material and air. Based on this, they constructed a 3D STL model of a portion of the rock effortlessly. The softwares built-in mesh optimization algorithms yielded a high quality, extremely accurate mesh, ready for export to any major FEA or CFD package.
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Generating volume mesh and solving

The volume mesh and CFD simulations were performed by the consultants of TotalSim, combining STL based meshing and solving procedures in OpenFOAM with Materialises design, mesh and geometry optimization software 3-matic. The water ow was simulated using an incompressible uid denition, with an inlet speed of 0.05mm/s at the top and left face, and free outlets on the opposing faces. The other faces of the block were dened as impassable symmetry planes. The experts at TotalSim were able to visualize the water ow easily. After studying the ow results, they noticed little non-laminar behavior because of the very low speed of the water. The simulation also showed a drastic pressure change in tight constrictions. The pressure gradient dominates the ow, driving the water through the block as directly as possible.
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Optimized surface mesh in Mimics CFD simulation shows total pressure loss in tight constrictions, courtesy of TotalSim

Materialise started as a specialist in rapid prototyping and manufacturing in 1990 and has almost 20 years of core competence in le repair, surface mesh (STL) manipulation and image processing. Based on this knowledge, and its acquired expertise in CAE software solutions, Materialise is the perfect partner for those who are involved in simulations on complex geometry. inCT is a spin-off of the Ghent University and originates from the Centre for X-ray Tomography (UGCT). inCT provides services in non-destructive inspection and material characterization by means of X-ray radiography and microtomography. Using state-of-the-art 2D and 3D imaging techniques, inCT offers a solution to a variety of problems in material research, with a focus on retrieving three-dimensional structural information down to the micrometer level. www.inct.be TotalSim is an independent limited company established in 2007. The company was started as a natural replacement for the successful Advantage CFD consultancy that operated as part of the Honda Formula 1 team until 2006. They combine open source, commercial and in-house codes to provide a competitive and exible approach to analyses of all sizes. www.totalsim.com
3-matic, Mimics, Materialise, and other names mentioned in this yer are registered trademarks and/or trade names either owned by or licensed to Materialise. No user has any right, title, or interest in those marks or names not previously expressly granted in writing to such user by Materialise. OpenFOAM is a trademark of OpenCFD ltd.

For more information: cae@materialise.com or www.materialise.com/cae

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