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IMPROVING ENERGY EFFICIENCY THROUGH
CFD(COMPUTATIONAL FLUID DYNAMICS)
PRESENTED BY:
DEEP DAVE
(SR. ENGG . MARKETING)
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INTRODUCTION
ESTABLISHED IN 1983, MECHWELL IS A MULTI-DISCIPLINE APPLIED R&D ORIENTED ENGINEERING FIRM.
MECHWELL WAS ESTABLISHED TO PROVIDE SOLUTIONS FOR CEMENT, POWER & ALLIED INDUSTRIES FOR
FLOW, EMISSIONS & ENERGY CONSUMPTION PROBLEMS.
BUSINESS:
• TURNKEY SOLUTION TO CEMENT, POWER & ALLIED INDUSTRIES INCLUDING CUSTOM
ENGINEERING, SPECIALTY SYSTEMS DESIGN (EFIP), MANUFACTURING AND IMPLEMENTATION, AND
SUPPORT TO INDUSTRY IN EMISSIONS CONTROL.
• TO ACHIEVE SPM<30MG, HEAT AND MASS TRANSFER, AND APPLIED ENERGY SYSTEMS.
• DESIGN, MANUFACTURE & SUPPLY OF EXPANSION JOINTS, DAMPERS & GATES AND EFIP’S
CFD & FEA CONSULTANCY SERVICES
MECHWELL IS WORKING IN COLLABORATION WITH “CASTLE”.
MECHWELL’S TEAM CONSISTS OF THE ENGINEERING EXPERTS FROM IIT, & OTHER REPUTED ENGINEERING
INSTITUTES HAVING VAST EXPERIENCE.
INTRODUCING : MECHWELL INDUSTRIES LTD.
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R&D – CENTER FOR INNOVATION
Manufacturing Air pollution control
Testing & commissioning
PRODUCT OFFERING:
EXPANSION JOINT (METALLIC & NON – METALLIC) - DESIGN AND MANUFACTURE
SERVES TO : THERMAL POWER PLANTS, GAS TURBINE POWER PLANTS, CEMENT PLANTS ETC.
Manufacturing
DAMPERS & GATES - DESIGN AND MANUFACTURE.
SERVES TO : THERMAL POWER PLANTS, GAS TURBINE POWER STATIONS, CEMENT PLANTS ETC.
Manufacturing
AIR HEATER BASKETS & SEALS DESIGN AND MANUFACTURE.
SERVES TO : THERMAL POWER PLANTS
Manufacturing
Bag Filter AFGC ESP’s
Air pollution control
Testing Services Provided
• REMAINING LIFE ASSESSMENTS OF BOILERS AS PER IBR 391A
• CLEAN AIR DIRTY AIR TEST
• GD TEST
• APH PERFORMANCE TEST
• ADVANCED NDT SERVICES FOR BOILER & TURBINE DURING AOH
• VISUAL INSPECTION
• ULTRASONIC FLAW DETECTION.
• ULTRASONIC THICKNESS GAUGING.
• MAGNETIC PARTICLE TESTING
• LIQUID / DYE PENETRANT TESTING.
• RADIOGRAPHIC TESTING
• IN SITU FIBEROSCOPY / VIDEOSCOPY INSPECTION
• IN-SITU METALLOGRAPHY & PLASTIC REPLICATION.
• IN-SITU HARDNESS TESTING
• OXIDE SCALE THICKNESS MEASUREMENT
• SAMPLING INSPECTION - THESE TESTS WILL BE CONDUCTED AT IBR /
NABL APPROVED LABORATORIES.
• .
THE USE OF A RANGE OF ADVANCED TOOLS INCLUDING COMPUTATIONAL
FLUID DYNAMICS (CFD), FINITE ELEMENT ANALYSIS (FEA) COMPUTER AIDED
DESIGN (CAD) AND OTHER SIMULATION TECHNOLOGIES.
MECHWELL PROVIDES COMPUTER AIDED ENGINEERING SERVICES TO A HOST
OF INDUSTRIES, MOST NOTABLY THE POWER, CEMENT, AVIATION, OIL AND
GAS, RENEWABLE ENERGIES AND AUTOMOTIVE SECTORS.
R&D – CENTER FOR INNOVATION
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CAE - APPLICATION DOMAINS & FOCUS AREAS
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CAE- R&D CENTER FOR INNOVATION
Mechwell Industries Ltd. 12
Why CFD – Computational Fluid Dynamics ?
• It’s the numerical analysis method involving large computerized iterations for predicting fluid flow patterns .
• Time efficient & Optimized Solutions Process for Design Optimization
• Computerized 3D CAD model is developed – with Actual Site Drawings • High Quality Mesh is prepared for the model • After confirmation from client fluid flow simulation is proceeded to Analyze flow
patterns • Optimum of design Changes for Ideal fluid flow across the system
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COMPUTATIONAL FLUID DYNAMICS : STEPS
• IDENTIFICATION OF PROBLEM
• DATA COLLECTION
• MODELING
• MESH GENERATION
• BOUNDARY CONDITION
• EVALUATION
• MODIFICATION/ ANALYSIS
• SIMULATION
• Verification
We use CFD analysis to carry out studies pertaining to
Single Phase/Multi Phase Flow Analysis
Heat transfer
Combustion Analysis
Material/Particle behavior
As part of our FEA service, we carry out studies pertaining to
Thermal studies
Vibration Analysis
Stress Analysis (static, dynamic, non-linear, impact)
Fatigue Analysis
Pre Heater System
(Cement Industry)
Boiler
(Power Plant Industry)
3D MODELING SERVICES
3D MODELING SERVICES
McDonnell Douglas F-15 Eagl (Aerospace Industry)
3D MODELING SERVICES
Chevrolet Camaro (Automotive Industry)
Mesh Generation – ICEMCFD
MESH GENERATION
Mesh Generation – ICEMCFD
MESH GENERATION
Mesh Generation - Hypermesh
MESH GENERATION
Multi Phase Flow Combustion Analysis FEA Analysis
CFD & FEA ANALYSIS
POWER SECTOR PROJECTS:
CFD ANALYSIS OF BOILER
CFD ANALYSIS OF FLUE GAS DUCTS
CFD ANALYSIS OF ELECTRO STATIC PRECIPITATOR
ACOUSTICS
FINITE ELEMENT ANALYSIS OF COAL BUNKER
PERFORMANCE IMPROVEMENT IN COAL MILL
PERFORMANCE IMPROVEMENT IN WIND BOX
PARTICLE TRACKING IN COAL MILL
Particle size -200 mesh:
% of Particle leaving – 98.35 %
CFD ANALYSIS FOR -LANCO POWER ANPARA-660MW
Existing CFD Results
Figure illustrates the gas velocity streamlines at LTSH/LTRH
LTRH CFD RESULTS - STREAM LINE
Figure illustrates the gas velocity streamlines at LTSH/LTRH
Modified CFD Results
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Pre Modified arrangement Modified arrangement
3D Model Confirmation
Erosion Control Devices (ECD)
ECD’s are designed to protect the boiler tube from erosion due to impingement of high velocity ash particles. The C.A.V.T. data
and CFD analysis results are used to optimize the design of ECDs to get the best results
Existing Results Modified Results
Comparison of Pre & Post installation velocities
Erosion Control Scheme For Boilers
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0.00
0.50
1.00
1.50
2.00
1.00 2.00 3.00 4.00 5.00 6.00 7.00 8.00 9.00 10.00
No
rma
lis
ed
ave
. ve
l. -
m/s
Pre
Post
Bottom of LTSH Lower Bank from FRONT Wall
0.00
0.50
1.00
1.50
2.00
1.73 3.46 5.18 6.91 8.63 10.36 12.08 13.81 15.53 17.26 18.98 20.71
Pre
Post
Bottom of LTSH Lower Bank – From Left Wall
No
rma
lis
ed
ave
. ve
l. -
m/s
AS-IS Analysis
AS-IS Analysis
Modified CFD Results
Comparison Between Pre and Post CFD
Sr.No Modification Benefits in Power Saving
1. Design of Duct for Nashik TPS 210 MW Mahajenco
200 KWh Saving
2. Design of Deflectors in DUCT for Rajghat TPS 62.5 MW BHEL
100 KWh Saving
3. Auxillary Power Saving- Gandinagar TPS, GEB
6.6 KV
4. Pressure Drop Reduction in flue gas Duct- TATA Power
53 mm WC
5. Auxillary Power Savings in Ducts- Jindal Power
6.6 KV
CEMENT SECTOR PROJECTS:
CFD ANALYSIS OF CYCLONES
CFD ANALYSIS OF RAW MILLS
THERMAL EFFICIENCY IMPROVEMENT IN PRE-HEATERS
CFD ANALYSIS OF KILN CASTABLES
CFD ANALYSIS OF SEPARATORS/ PARTICLE TRACKING
MATERIAL DEPOSITION STUDY IN PH SYSTEM
THERMAL EFFICIENCY IMPROVEMENT IN PH SYSTEM
Modification in Spreader box & Feed Pipe for Heat transfer Improvements
MODIFICATION TO PH SYSTEM TO AVOID MATERIAL ACCUMULATIONS
Expected Benefit : Reduction in Material
Deposition
BENEFITS BY CFD ANALYSIS IN THE KILN, Cold CFD Simulation: to predict the flow pattern & Improvement in flow for combustion CFD simulations in combustion: To predict the Flame length propagation Reduction in Kiln hood Erosion
Sr.No Project Benefits
1. Thermal Efficiency Improvement in PH system – JK Cement
5% Increase In Production
2. Thermal Efficiency Improvement in PH system – Sagar Cement
100 KWh Saving & Heat Rate Improvement by 5 deg celcius
3. Duct Design for Maihar Cement
50 KWh Saving
4. Deflector Design in Down comer For Dalmia Cement
Tamilnadu
30 KWh Saving
5. Duct Design in Raw Mill- Shree Cement
Pressure drop reduction by 18 mmWC
SUMMARY:
OIL & GAS PROJECTS
CFD ANALYSIS OF COMBUSTION AIR DUCTS
CFD ANALYSIS OF HRSG SYSTEM
CFD ANALYSIS OF OIL & GAS SEPARATION
CFD ANALYSIS OF FLARE GAS SYSTEM
HVAC PROJECTS
CFD ANALYSIS OF DATA CENTER
CFD ANALYSIS OF BASE MENT/ CAR PARKING
FIRE DYNAMIC SIMULATION OF BASEMENT
CFD ANALYSIS OF HVAC SYSTEM
Air flow & temperature distribution pattern over the server rack
AUTOMOTIVE SECTOR PROJECTS
EXPLICIT & IMPLICIT ANALYSIS
CAR CRASH ANALYSIS
CFD ANALYSIS OF CAR FOR COOLING
Interior Airflow Pattern
CASE STUDY FOR PROCESS INDUSTRIES
FAR FIELD SOUND NOISE PREDICTION
CFD ANALYSIS OF RUBBER LATEX MIXTURE
Less Velocity Zone
CFD results of NAS600 Fan
CFD ANALYSIS OF TURBO MACHINERY:
JAPAN
PERFORMANCE CERTIFICATES:
RECENT R&D PROJECT :
JINDAL STEEL AND POWER LTD.
DESCRIPTION :
1. DEVELOP 3D MODEL OF CFBC BOILER WITH TOTAL TUBES CONSIDERING MIX GAS FIRINGS STRUCTURES WITH THE HELP OF THE DETAIL
DRAWINGS PROVIDED BY JSPL
2. ASSESSING IMPACT OF GAS FIRING ON NOX AND SOX EMISSION.
3. EVALUATION OF GCV RANGE OF MIX GAS FIRING IN BOILER.
4. EVALUATION OF MAXIMUM AND MINIMUM FLOW OF MIX GAS (BF AND CO GAS) FIRING IN BOILER AND STUDY OF BOILER CRITICAL
PARAMETERS
5. THERMAL MODELING OF CFBC BOILER
6. EVALUATION OF REDUCTION OF COAL CONSUMPTION WITH UTILIZATION OF MIX GAS IN BOILER
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JSPL,ANGUL 135MW , U#3 - CFBC BOILER
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Cyclone Cad Model –
CFBC Boiler
Cold Flow
Simulation
CFBC BOILER- SIMULATION & COMBUSTION ANALYSIS
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THESE CUSTOMERS TRUST US
OEM’s
Thermal Power Stations
THANK-YOU !!
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Contact us At : Mr. Deep Dave
Sr. Engineer Marketing
Mech-Well R & D Division,
Mobile: +91 70280-44499
[email protected],[email protected]
R&D Center for Innovation
