Comparative Computational Fluid Dynamics Analysis of Pipe-Heating Methods: Jacketed Piping Versus Contro-Trace

Abstract

Abstract. This article presents a computational fluid dynamics (CFD) comparison between two heat transfer technologies for liquid sulfur piping systems: Contro-Trace and jacketed piping. These systems are designed to maintain liquid sulfur at a temperature of approximately 126 °C (259 °F). This study aims to model, simulate numerically, and compare the thermal efficiency of these two pipe-heating systems with ANSYS Fluent R19. The goal is to ensure stable-state liquid sulfur transport and improve the reliability of phosphate production units. For this purpose, three heating designs were modeled in SolidWorks to evaluate their thermal performance: a full-jacketed pipe for uniform heat distribution, and two Contro-Trace heating configurations, mounted in both top and bottom positions. The study is conducted in a 3D steady-state Cartesian framework, accounting for cross-sectional thermoconvection and assuming plug-flow conditions in the axial direction. These models were analyzed under different operating scenarios in terms of temperature and velocity distributions. The findings show that the steam Contro-Trace placed in the bottom performs better than the jacketed pipe and achieves better homogeneity. By inducing a continuous convective loop, this configuration maintains lower sulfur viscosity, effectively mitigating the risk of clogging and ensuring uninterrupted flow within the process pipe.