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http://www.hitechcae.com/case-studies/cfd/optimization-of-fluid-flow-inside-ducts.php

Optimization of Fluid Flow Inside Ducts

Case Study Highlights
Client Profile:
Cement Manufacturer, India
Objective:
Visualization of flow pattern inside the duct bend and
optimizing the design to reduce the pressure drop
Challenges:
=
Re-create CAD model of the duct to perform
pressure drop analysis
=
Utilize applicable governing equations
=
Identify accurate turbulence model to simulate

the air flow

=
Develop design alternatives to reduce the

Cement industries are prominent in consuming energy

and its efficient utilization has always been a matter of
priority. The total energy costs averages from 30 to 40
percent of the total cement production costs, urging
manufacturers to adopt innovative solutions to
minimize energy consumption.
Utilization of suitable duct design is one of the factors
that influence the overall plant efficiency and lower the
consumption of energy. Primarily, ducts carry high
pressurized air to transport raw materials, needed to
manufacture cement. As such, air supply through the
ducts with suitable pressure is crucial, pointing to the
requirement of effective duct logic.

pressure drop
Solution:
The duct utilized to carry air in the cement industry
was successfully analyzed for pressure drop. It was
found that the bend geometry was responsible for
pressure drop in the flow due to recirculation zones.
Two design modifications were suggested to reduce
the pressure drop significantly.
Software Used : ANSYS Fluent 14.5

One of the leading cement manufacturers from India

approached Hi-tech with a similar engineering problem
associated with the duct design. Their primary concern
was to devise an effective duct design that does not
promote excessive pressure drop, especially across
the bends.

The Solution
The duct design was first modeled using CAD tools,
and was analyzed for pressure drop through the
application of suitable boundary conditions and
turbulence model. The results showed the
development of recirculation zones near the bend
region, promoting pressure drop significantly.
Based on the results, two design alternatives were
suggested, which were aimed to reduce the pressure
drop considering the geometrical feasibility.
The comparative results obtained were beneficial in
terms of reducing the pressure drop. Both the designs
showed significant reduction in pressure drop, making
them a viable choice for an overall improvement in
plant efficiency.This solution can also be provided
using OpenFOAM, STAR CCM+, Abaqus CFD,
COMSOL Multiphysics.

Benefits
=
30% reduction in energy consumption from

compressors and blowers to maintain the mass flow

rate
=
Overall improvement in plant efficiency by applying

similar solutions for ducts at different locations

=
Reduced the time required to execute prototyping tests

About Hi-Tech

Author: Mehul Patel

CFD Consultant

Hi-Tech CAE is a division of Hi-Tech Outsourcing Services, a pioneer engineering outsourcing company since 1992
based in India & USA. It provides expert Computer Aided Engineering - CAE consulting services for engineering /
product design analysis by modeling & simulation.
The primary services extended include Computational Fluid Dynamics (CFD), Finite Element Analysis (FEA), product
design optimization and value engineering services to Automotive, Building / Construction, Process industry, Power
Generation, Manufacturing & Heavy Engineering industries.

Phone: +1-408-338-8047
Email: info@hitechcae.com

Outsourcing
Services
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Hi-Tech Outsourcing Services

547 Moreland Way
Santa Clara, CA 95054

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