Numerically efficient two-step CFD simulation model of flow regime and heat transfer for hot water shower sterilizers

This work was carried out to create a numerically efficient validated simulation model for Hot Water Shower (SWS) sterilizers. The goal of the work was to achieve a more homogeneous temperature and water distribution inside the sterilizers developed in the future. A lab-scale test bench of an SWS sterilizer with a configurable water volume flow rate and temperature was designed to validate the Computational Fluid Dynamics (CFD) model that was created. The heating and cooling phases at water volume flow rates of 20 and 40 m3/h per m2 spraying surface were analyzed. Additionally, the flow and film regime were studied. The CFD model was split into two simulation steps to significantly improve the numerical efficiency. The novel two-step approach developed is computationally 1800 times faster as compared with a complete sterilization cycle than a state-of-the-art approach. The simulated temperature of the test load was in good accordance with the experimental measurements. The flow regime was largely accurately replicated. Overall, the created validated CFD model is suitable for upscaling to an industry-sized SWS sterilizer due to its numerical efficiency.