Post on 09-Mar-2016
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CFD APPLICATIONS IN
CEMENT INDUSTRIES
CII Green Cementech 2009Hyderabad
About UsAbout Us..
Incorporated in 1983
Has grown progressively over last 25 years
Is an applied R&D oriented company
Works on providing solutions to various plant problems
and on improvement of Plant Load Factor.
Has offices and representatives throughout India.
Network in IndiaNetwork in India
H.O. & Marketing division Mumbai
R&DNasik
FactoryIgatpuri
Branch Office atChandrapurKorba Nagpur
Representatives at
U.P. M.P. Chattisgarh Tamil Nadu Orissa
West Bengal Gujarat Delhi Haryana
ResourcesResources
CAE and R&D division has a team of experienced IIT engineers, including the
Director.
Further we have privilege of having with us, senior retired executives from State
Electricity Board with vast experience in O&M of Thermal Power Stations.
Mech-Well is a well established company with AAA rating from bankers.
Mech-Well infrastructure:
9 Well established CAE division.
9 Advanced softwares to solve various CAE related problems.
9 Advanced manufacturing unit to make custom required components
CertificationsCertifications
9 S.S.I.
9 ISO 9001/2000
9 N.S.I.C
9 Indian Boiler Regulations (IBR).
Major Operational AreasMajor Operational Areas
We assist Power Industries in Performance Optimization & Availability Improvement
through
CFD solutions
CAVT & Erosion control devices for boiler
Boiler data management software
Erection, Testing & Commissioning
Ammonia flue gas conditioning
Manufacturing
MechMech--WellWells Manufacturings Manufacturing
Expansion Joints-metallic, non-metallic (Fabric)
Radial, Axial, Modified seals, Basket elements for air heaters
IBR approved tube bends & coils
Fabrication / machining of power plant spares
We also provide turnkey solutions for improving flow profile in duct & ESP
efficiency improvement.
CFD SolutionsCFD Solutions
Computational Fluid Dynamics (CFD) is the science of predicting the fluid flow
related problem by solving mathematical equations which govern the process
Application of CFD :
Flow analysis of Boilers, Ducts, ESP, Bag-house etc.
Discrete phase and Multiphase Flow modeling.
Turbo machinery Analysis.
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CFD Solutions for Cement IndustriesCFD Solutions for Cement Industries
Flow analysis of Duct, ESP, Bag-house etc.
Raw Mill and Coal Mill Analysis
Combustion analysis in Kiln
Cyclone Performance Analysis
Noise reduction in Fan using Aero-Acoustic Principle
The sequence of operations required to carry out the projects are as follows:
Collection of Drawings and Data from client.
3-D Modeling of System in ANSYS Workbench.
Grid generation in ICEM CFD and Gambit.
Performing the simulation using CFX and Fluent
Analyzing the results and locating the problematic areas in the existing design.
Iteratively modify the design so as to remove the problematic areas.
CFD MethodologyCFD Methodology
Computational Model
Pre-modified model Modified model
Raw Mill ESP AnalysisRaw Mill ESP Analysis
Streamlines illustrate fluid flow pattern in Duct and ESP & after
Modification Flow through ESP has been improved
CFD ResultsCFD Results
Streamline Plot forPre-modified model
Streamline Plot forModified model
Raw Mill ESP AnalysisRaw Mill ESP Analysis
Velocity pattern illustrate the flow distribution at ESP Fan inlet
Velocity Plot for Existing model at ESP Fan Inlet
CFD ResultsCFD Results
Velocity Plot for Modified model at ESP Fan Inlet
Raw Mill ESP AnalysisRaw Mill ESP Analysis
Equal distribution of flow Efficient.
High velocities at the bottom of the bags which explains excessive erosion.
Cost-effective solution in the shortest time.
(Premodified Baghouse) (Modified Baghouse)
Bag House AnalysisBag House Analysis
Coal Mill AnalysisCoal Mill Analysis
Reduced localized erosion
Reduced band width of coal particles
Reduced power consumption
Coal Mill AnalysisCoal Mill Analysis
Combustion AnalysisCombustion Analysis
Improved burner design.
Scope for analysis using alternative fuels
in Kiln.
Gas combustion
Coal combustion
Efficiency of fan increases with better inlet and outlet flow distribution
Designing flow grid for flow measurement
Without modifying fan, only just small modification in duct improves fan
performance
CFD Analysis For Turbo Machinery CFD Analysis For Turbo Machinery
Prediction & Testing of noise generated due to fan.
Recommend noise exposure for workers in industry
Study of existing problem
Suggestion for noise control
Design, Analysis & Manufacture of Silencer.
Aero Acoustic Solution Aero Acoustic Solution
Case study 1 Case study 1
Aim:- To analyze Cyclone connecting duct design to reduce pressure drop across it.
Maihar Cement Industries
Poor flow distribution to the cyclone inlet affects the performance of the cyclone.
CFD was used to design the connecting duct between cyclones.
Cyclone Connecting Duct AnalysisCyclone Connecting Duct Analysis
Maximum velocity near to wall and minimum
velocity at the center.
This flow pattern is useful for the designing
of duct connecting cyclones.
Cyclone Performance AnalysisCyclone Performance Analysis
The new duct design eliminates high velocity region.
Improved flow distribution at the cyclone inlet.
Cyclone Connecting Duct AnalysisCyclone Connecting Duct Analysis
Pre-modified duct
Cyclone Connecting Duct AnalysisCyclone Connecting Duct Analysis
Pre-modified Cyclone analysis with duct
Modified Cyclone analysis with duct
AchievementsAchievements-- Maihar Cement IndustriesMaihar Cement Industries
Reduced pressure drop by 60 mm WC.
Energy savings 50 KW/h.
Payback period less than 4 months.
The suggested modifications as per your drawings based on CFD
analysis were carried out recently in the connected duct from cyclone 4 to
cyclone 3 in kiln 1 of Unit 1. The benefit achieved after modification is in the
pressure drop across cyclone 4 which results in power saving. The approximate
values in the respect are pressure drop reduction of 60 mm WG across cyclone 4
and power saving of 50 KW- MAIHAR CEMENT
Aim:- 1. To reduce pressure drop across down comer duct.
2. Improve flow at the fan inlet.
DowncomerDowncomer Duct AnalysisDuct Analysis
Down Comer Duct AnalysisDown Comer Duct Analysis
Velocity profile on plane (Premodified Duct)
Velocity profile on plane (Modified Duct)
Case study 2Case study 2
Dalmia Cement Industries
Down Comer Duct AnalysisDown Comer Duct Analysis
Velocity profile on plane (Premodified Duct)
Velocity profile on plane (Modified Duct)
Reduced pressure drop by 37mm WC.
Energy savings 64 KW/h.
Payback period less than 4 months.
This is to certify that we have provided flow diverter plates ( 3 no.) in our
KHD kiln pre heater down comer duct as per the CFD analysis carried out by
M /s MECHWELL INDUSTRIES LTD MUMBAI to reduce the pressure drop
across the duct from top stage cyclone to pre heater fan inlet.
We are happy to share that the pressure drop across the duct has reduced
from 70mmwg to 33mmwg resulting in preheater fan power saving.
- DALMIA CEMENT
AchievementsAchievements-- DalmiaDalmia Cement IndustriesCement Industries
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Benefits to our ClientsBenefits to our Clients
Improved performance of ESP, Bag-House, Cyclone, Raw mills, Coal mills and
auxiliary.
Meet the emission legislation by increasing equipment collection efficiency.
Lower noise brings plants into statutory environmental compliance.
Drive down the operational cost with improved quality.
And the most important - cost effectiveness.
List of some of our valued clients List of some of our valued clients
Nasik, Bhusawal, Parli, Chandrapur, Khaperkheda, Koradi, Uran
Shaktinagar, Rihand, Vindhyachal, Korba, Unchahar, Ramagundam, Dadri, Auraiyya
Trombay
Thermal Power Stations
Other Thermal Power Stations
Cement Plants
Others
JAPAN TTK LIG Ltd.