Fillers Simulation

Method Development for the numerical Optimization of Fillers for the Chemical Industry

The production of new filler geometries is currently being carried out by means of complex tests, which cause considerable costs. In addition, these manual tests lead to a high level of time spent on development. An expensive and lengthy production process is therefore the result.

Merkle & Partner is planning to develop a simulation model that will make it possible to examine and optimize various types of fill material. This should save costly test procedures for different chemical substances and geometry variants.

In the process, different demands are placed on the fillers, which can be represented and taken into account by the developed method:

  • high load capacity with gas and liquid
  •  large, volume-related phase interfaces with simultaneously low pressure loss
  •  optimal material transport conditions
  •  good wettability for the liquid
  •  low tendency to stream formation and marginal movement
  •  sufficient mechanical strength
  •  Production from a wide variety of materials
  •  low manufacturing costs

Practical Example

Multi-body Simulation

The design of a new filler is created three-dimensionally using CAD. A multi-body simulation is used to numerically fill a container with fillers. Contact is described between all the fillers. Due to friction, the individual bodies finally come to rest.

3D Geometry

The data is extracted as a 3D model and merged into a volume.


Boolean operations are used to create the flow volume and mesh it with mesh generators.

Fluid Mechanics

A 3D flow simulation is then created, which can be used to determine the required characteristics of the fillers in terms of pressure loss, flow, etc.

Project Results

The various visualisation options allow conclusions to be drawn about the geometry of the fillers and, if necessary, a new calculation run with a modified and optimised geometry can be carried out.

As this process is purely virtual, it can be carried out until the fill has the required properties.

Fillers can now be designed faster and more efficiently for the chemical industry. Existing fillers can be analyzed and optimized. Due to the improved efficiency of the fillers, plants can be built more compactly or designed for higher flow rates in the future, resulting in lower energy consumption and faster production times.


Fillers Simulation I

Fillers Simulation II

Fillers Simulation III

Contact our engineering office:

Stefan Merkle

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