Today, industries such as manufacturing, defense, automotive, mining, cement, and pharmaceuticals increasingly require advanced engineering simulations to understand the behavior of granular materials, powders, sand, gravel, liquid droplets, and all types of particle-based structures. The flow, collision, rebound, deposition, and surface interaction of particles directly influence product performance, equipment lifetime, and overall process efficiency.
At this point, ANSYS Particle Simulation provides highly reliable and realistic insights, enabling engineers to make more accurate and confident design decisions. As Fetech Advanced Engineering, we deliver advanced simulation capabilities through ANSYS Fluent, ANSYS Rocky DEM, and comprehensive granular modeling solutions.
Particle simulation is a numerical analysis method used to calculate the physical behavior of a large number of particles or droplets moving within a medium. These particles may include:
Dust and sand particles
Granular chemicals
Fuel droplets
Mineral ores
Gravel, coal, aggregates
Tablets and capsules
Aerosol particles
Accurately modeling how these particles interact with fluids and surfaces is essential for process optimization, design validation, and extending equipment lifespan.
The ANSYS ecosystem offers three primary modeling approaches for particle simulation. Each method is optimized for different process conditions and physical interactions.
In this approach:
The fluid phase (air/water) is solved using the Eulerian method.
The particle phase is tracked individually using the Lagrangian method.
The DPM model is ideal for low-concentration particle flows.
Fuel spray and atomization
Cyclone separators
HVAC particle transport
Filter efficiency analysis
Smoke and aerosol dispersion
Erosion and wear prediction
Evaporation of hygroscopic droplets
Fully integrated with CFD
Supports two-way coupling (particles influence the flow field)
Thermal and chemical reactions can be modeled
This method is used for dense particle flows with high solid volume fractions.
Silo and bunker discharge
Fluidized beds
Granular mixing processes
Catalytic reactors
Dense powder transportation
The model accounts for inter-particle collisions, granular pressure, and shear stresses, enabling more realistic predictions of complex particle behavior.
Rocky is a highly advanced DEM tool developed for realistic particle simulation. Each particle is treated as an individual solid body with its own:
Mass
Shape
Rotation
Collision behavior
Breakage and fragmentation characteristics
Particle breakage and fragmentation modeling
Non-spherical particle shapes (angular, polyhedral, elongated)
Precision in conveyor belt simulations
GPU-accelerated high-volume particle calculations
Two-way co-simulation with Fluent (CFD + DEM)
Crusher and mill design
Conveyor belt load analysis
Mining and cement plant processes
Screening, chute, and hopper optimization
Agricultural and food processing lines
Particle-induced wear prediction
The most accurate method for modeling real-world industrial processes is:
ANSYS Fluent (CFD) + ANSYS Rocky DEM (granular flow)
working simultaneously to model fluid–particle interactions.
This enables highly realistic predictions of phenomena such as:
Dust lifting and dispersion
Load distribution on conveyor belts
Conveyor and chute design optimization
Erosion hotspots
Particle bouncing, accumulation, and spillage
Issues such as material loss, improper flow routing, and clogging can be detected early.
Simulation-based improvements for chutes, hoppers, conveyors, cyclones, and filtration systems.
Identification of critical wear zones that reduce equipment lifetime.
Fewer physical prototypes and reduced design revision costs.
Risks associated with particle dispersion, dusting, and unstable flow patterns are mitigated.
By combining advanced CFD + DEM simulation tools with our engineering know-how, Fetech offers industries:
Accurate physical modeling
Reliable and validated simulation results
Optimized design recommendations
Industry-focused engineering reports
Simulation-driven product development
We provide particle simulation solutions across defense, automotive, mining, chemistry, energy, and numerous other sectors.
Particle simulation plays a critical role in verifying designs, optimizing processes, and improving safety in fluid–solid and granular material systems. By integrating ANSYS Fluent and Rocky DEM, engineers gain access to one of the most powerful modeling platforms in modern engineering.
As Fetech Advanced Engineering, we support your industrial processes with high-accuracy simulation solutions, helping you achieve greater efficiency, safety, and operational reliability.