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CFD APPLICATIONS
IN
CEMENT INDUSTRIES

CII Green Cementech 2009
Hyderabad

About Us….
¾ Incorporated in 1983
¾ Has grown progressively over last 25 years
¾ Is an applied R&D oriented company
¾ Works on providing solutions to various plant problems
and on improvement of Plant Load Factor.
¾ Has offices and representatives throughout India.

P.O. West Bengal Chattisgarh Tamil Nadu Gujarat Delhi Orissa Haryana .P.Network in India H. & Marketing division Mumbai R&D Nasik Factory Igatpuri Branch Office at Chandrapur Korba Nagpur Representatives at U. M.

Resources ¾ CAE and R&D division has a team of experienced IIT engineers. ¾ Mech-Well infrastructure: 9 Well established CAE division. 9 Advanced manufacturing unit to make custom required components . including the Director. ¾ Mech-Well is a well established company with AAA rating from bankers. 9 Advanced softwares to solve various CAE related problems. ¾ 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.

9 ISO 9001/2000 9 N.I.S.I. .C 9 Indian Boiler Regulations (IBR).S.Certifications 9 S.

Testing & Commissioning ¾ Ammonia flue gas conditioning ¾ Manufacturing .Major Operational Areas We assist Power Industries in Performance Optimization & Availability Improvement through ¾ CFD solutions ¾ CAVT & Erosion control devices for boiler ¾ Boiler data management software ¾ Erection.

. Axial. Modified seals. Basket elements for air heaters ¾ IBR approved tube bends & coils ¾ Fabrication / machining of power plant spares ¾ We also provide turnkey solutions for improving flow profile in duct & ESP efficiency improvement.Mech-Well’s Manufacturing ¾ Expansion Joints-metallic. non-metallic (Fabric) ¾ Radial.

Bag-house etc. ESP. ¾ Turbo machinery Analysis. . ¾ Discrete phase and Multiphase Flow modeling. Ducts.CFD 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 : ¾ Flow analysis of Boilers.

ESP. Bag-house etc. ¾ Raw Mill and Coal Mill Analysis ¾ Combustion analysis in Kiln ¾ Cyclone Performance Analysis ¾ Noise reduction in Fan using Aero-Acoustic Principle 10 .CFD Solutions for Cement Industries ¾ Flow analysis of Duct.

. ¾ Iteratively modify the design so as to remove the problematic areas. ¾ Performing the simulation using CFX and Fluent ¾ Analyzing the results and locating the problematic areas in the existing design. ¾ Grid generation in ICEM CFD and Gambit. ¾ 3-D Modeling of System in ANSYS Workbench.CFD Methodology The sequence of operations required to carry out the projects are as follows: ¾ Collection of Drawings and Data from client.

Raw Mill ESP Analysis Pre-modified model Computational Model Modified model .

Raw Mill ESP Analysis CFD Results Streamline Plot for Pre-modified model Streamline Plot for Modified model Streamlines illustrate fluid flow pattern in Duct and ESP & after Modification Flow through ESP has been improved .

Raw Mill ESP Analysis CFD Results Velocity Plot for Existing model at ESP Fan Inlet Velocity Plot for Modified model at ESP Fan Inlet Velocity pattern illustrate the flow distribution at ESP Fan inlet .

(Premodified Baghouse) (Modified Baghouse) . ¾ High velocities at the bottom of the bags which explains excessive erosion. ¾ Cost-effective solution in the shortest time.Bag House Analysis ¾ Equal distribution of flow Efficient.

Coal Mill Analysis ¾ Reduced localized erosion ¾ Reduced band width of coal particles ¾ Reduced power consumption .

Coal Mill Analysis .

Coal combustion Gas combustion . ¾ Scope for analysis using alternative fuels in Kiln.Combustion Analysis ¾ Improved burner design.

CFD Analysis For Turbo Machinery ¾ Efficiency of fan increases with better inlet and outlet flow distribution ¾ Designing flow grid for flow measurement ¾ Without modifying fan. only just small modification in duct improves fan performance .

¾ Recommend noise exposure for workers in industry ¾ Study of existing problem ¾ Suggestion for noise control ¾ Design.Aero Acoustic Solution ¾ Prediction & Testing of noise generated due to fan. Analysis & Manufacture of Silencer. .

To analyze Cyclone connecting duct design to reduce pressure drop across it.Case study 1 Maihar Cement Industries Aim:. .

Cyclone Connecting Duct Analysis Poor flow distribution to the cyclone inlet affects the performance of the cyclone. CFD was used to design the connecting duct between cyclones. .

¾ This flow pattern is useful for the designing of duct connecting cyclones.Cyclone Performance Analysis ¾ Maximum velocity near to wall and minimum velocity at the center. .

¾ Improved flow distribution at the cyclone inlet. Pre-modified duct .Cyclone Connecting Duct Analysis ¾ The new duct design eliminates high velocity region.

Cyclone Connecting Duct Analysis Pre-modified Cyclone analysis with duct Modified Cyclone analysis with duct .

¾ Payback period less than 4 months. ¾ Energy savings 50 KW/h. The benefit achieved after modification is in the pressure drop across cyclone 4 which results in power saving.Achievements.Maihar Cement Industries ¾ Reduced pressure drop by 60 mm WC. 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 . 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.

. 2.Downcomer Duct Analysis Aim:.1. Improve flow at the fan inlet. To reduce pressure drop across down comer duct.

Case study 2 Dalmia Cement Industries Down Comer Duct Analysis Velocity profile on plane (Premodified Duct) Velocity profile on plane (Modified Duct) .

Down Comer Duct Analysis Velocity profile on plane (Premodified Duct) Velocity profile on plane (Modified Duct) .

Dalmia Cement Industries ¾ Reduced pressure drop by 37mm WC.) 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.Achievements.DALMIA CEMENT . This is to certify that we have provided flow diverter plates ( 3 no. . We are happy to share that the pressure drop across the duct has reduced from 70mmwg to 33mmwg resulting in preheater fan power saving. ¾ Payback period less than 4 months. ¾ Energy savings 64 KW/h.

Benefits to our Clients ¾ Improved performance of ESP. Raw mills. ¾ Meet the emission legislation by increasing equipment collection efficiency. 31 .cost effectiveness. Bag-House. Cyclone. ¾ Lower noise brings plants into statutory environmental compliance. ¾ And the most important . Coal mills and auxiliary. ¾ Drive down the operational cost with improved quality.

Korba. Dadri. Rihand.List of some of our valued clients Thermal Power Stations Nasik. Auraiyya Trombay Other Thermal Power Stations Cement Plants Others JAPAN TTK – LIG Ltd. Bhusawal. Ramagundam. Unchahar. Uran Shaktinagar. Koradi. . Vindhyachal. Chandrapur. Parli. Khaperkheda.