CFD APPLICATIONS

IN
CEMENT INDUSTRIES

CFD S oluti ons CFD S oluti ons f or Cem ent I ndust ries

Computational Fluid Dynamics (CFD) is the science of predicting the fluid flow
r elated pr oblem by solving mathematical equations which g over n the pr ocess Ø Flow an alysis of Duct, ESP, Ba g-house etc.

Ø Raw Mill and Coal Mill Analysis

Application of CFD :

Ø Flow analysis of Boilers, Ducts, ESP , Bag-house etc. Ø Combustion analysis in Kiln

Ø Discr ete phase and Multiphase Flow mod eling.

Ø Cyclone Per for mance Analysis
Ø Turbo machiner y Analysis.
Ø Noise r eduction in F an using Aer o-Acoustic Pr inciple

CFD M eth od ology Cy clone P erf ormance Analysis

The sequence of op er ations r equir ed to car r y out the pr ojects are as follows:

Ø Collection of Dr awings and Data from client.

Ø Maximum velocity near to wall and minimum
Ø 3-D Modeling of System in ANSYS Workbench.
velocity at the center .

Ø Gr id gener ation in ICEM CFD and Gambit. Ø This flow pattern is useful for the designing of

Ø Performing the simulation using CFX and Fluent duct connecting cyclones.

Ø Analyzing the r esults and locating the pr oblematic ar eas in the existing d esign.

Ø Iter atively modify the design so as to r emove the pr obl ematic areas.
 Case study - Maihar Cement Cyclone Connecting Duct Analysis

Aim:- To analyze Cyclone c onnecting du ct design to r educe pr essure dr op acr oss it. Poor flow distribution to the cyclone inlet affects the performance of the cyclone.

CFD was used to desi gn the conn ecting duct between cyclon es.

Cyclone Connecting Duct Analysis Cyclone Connecting Duct Analysis

Ø The new duct desi gn eliminates high velocity region.

Ø Impr oved flow distr ibution at the cyclone inlet.

Pre-modified Cyclone analysis Modified Cyclone

with duct analysis with duct
Pre-modified duct

Achievements- Maihar Cement Industries Performance Certificate

Ø Reduced pr essure drop by 60 mm WC

Ø Energy savings 50 KW/h.

Ø Payback period l ess than 4 months.

The suggested modifications as per your drawin gs 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
approxim ate values in the respect are pressure drop reduction of 60 mm
WC across cyclone 4 and power saving of 50 KW
- MAIHAR CEMENT
 Downcomer Duct Analysis Case study - Dalmia Cement Industries

D own Comer D uct Analysis

Aim:- 1. To reduce pressure drop across down comer duct.

2. Improve flow at the fan inlet.

Velocity pr ofile on plane Velocity pr ofile on plane

(Pr emodified Duct) (Pr emodified Duct)

Case study - Dalmia Cement Industries Performance Certificate

Achievements-
ements -

Ø Reduced pressure drop by 37mm WC.

Ø Energy savin gs 64 KW/h.

Ø Payback period less than 4months.

This is to c ertify that we have provided flow diverter plates ( 3 no .) in our KHD kiln
pre heater down comer du ct as p er the C FD analysis c arried out by M /s
MECHWELL INDUSTRIES LTD MUMBAI to r educe the pr essure dr op acr oss the duct
fr om top stage cyclone to pre h eater fan inlet.
We are h appy to sh are that the pressure drop across the duct has reduce d by
37mmwc result ing in pr eheater fan power saving .
- DALMIA CEMENT

Case study 3 - Ambuja Cement Performance Certificate

Benefits:-
Power savings more than 40 kWh

Pay back period:- Down Comer Duct

Analysis
Less than 5 months
 Case study 4 - Maihar Cements Performance Certificate

Cyclone

Benefits:-
Minimum pressure drop reduction of 12 mmWc

Down Comer
Pay back period:-
Less than 5 months

PH Fan Inlet

Case study - India Cements Case Study – IB Thermal

Cyclone

Benefits:-
Minimum pressure drop reduction of 12
mmWc

Pay back period:-

Less than 5 months Down Comer
Duct

PH Fan inlet Str eamline Plot for Str eamline Plot for
Pre-modified duct Modified duct

Case Study – Nasik TPS Unit # 3 Case Study – Nasik TPS Unit # 3

In pre-modified duct d esign, distribution of flow was p oor resulting in high er osion Duct Design
and pressur e drop.
Mech-Well pr ovided new duct design for Nasik power plant unit III which reduce d
ID fan current
the pr essure dr op and er osion and ma de e qual the distr ibution in all the passes.
Load (Amp.)
A Pass B Pass

Before 180 MW 140 140

Modif icat ion

After 215 MW 112 122

modificat ion

Design and er ection by Mech-well

Pre-Modified Modi fied
 Case Study – Nasik TPS Unit # 3
Cas e Study – Gandhinagar TPS Unit # 3

AH Outlet

ESP ESP

3D-ComputationalModel considered
for CFD Analysis

Str eamline Plot for Streamline Plot for

Pre-modified model Modified model
ID Fan Inlet

Cas e Study – Gandhinagar TPS Unit # 3 Cas e Study – Gandhinagar TPS Unit # 3

Pre modifiedCFD Results

Performance Evaluation

2009-10
Sr . No. Parameters
Pre Installation Post Installation
Date 11.09.2009 06.11.2009
1 Load MW 210 210
2 ID Fan A curr ent (amp) 123 Stand By
Streamline Plot
3 ID Fan B current 126 134
4 ID Fan C curr ent 120 130
5 FD Fan current A 50 45
CFD Plot :Marked Portion showing the
6 FD Fan current B 50 43
very high turbulence with
recirculation & highest velocity at the 14 SPM 138.73 113.225
back surface of the duct, which will Velocity plot
cause highest pressure drop in the
duct.

ESP Flow A nalysis Case study – Clair Engineers Pvt. Ltd.

Electrost at ic Precipit at or (ESP)

Proper flow through an ESP is critical for optimal p erformance. Improper flow
can result in high op acity, unw anted dust buil dup an d erosion. Be cause of poor
flow distribution through an ESP , hi gh vel ocity regions cause p article momentum
to over come electr ostatic for ces, r esulting in suboptimal ca pture efficiency.
High efficiency per for mance of the ESP requires uniform flow andmass distribution
acr oss the pr ecipitator plates. This is achieved by optimal design of flow contr ol
devices and PDPL (scr eens) at a ppr opr iate loc ation.

Simulation demons t rates t he

improved flow dis tribu tion
thro ugh a n E SP.
 Case study - Shree Cements Ltd., Beawar Case Study -
Hamon Shriram Cottrell

Raw Mill ESP Analysis - CFD Results ESP Analysis - CFD Results

Str eamline Plot for Streamline Plot for Velocity Contours for Velocity Contours for
Pre-modified model Modified model Pre-modified ESP Modified ESP

Streamlin es illu strate fluid flow pattern in Duct and ESP & after Modification
Flow through ESP has been im proved

Optimization Of ESP – Other ESP Projects Carried Out..

Hamon Shriram Cottrell
PDPL Configuration

1. Hindalco
2. NTPC, Vindhyachal
3. Chandrapur TPS, Unit III
4. Rajghat, Unit II
5. Parli TPS, Unit III, IV & V
6. Bhusawal, Unit II & IV.
7. Khaperkheda TPS, Unit I, II & III.
8. Nasik TPS, Unit I & II.
9. Alstom, Renusagar, Unit IV & Many more……………

Case study – Clair Engineers Pvt. Ltd. (1) Case study – Clair Engineers Pvt. Ltd. (2)

Bag House Analysis

Bag House Analysis
Ø Equal distribution of flow Efficient.
Ø High velocities at the bottom of the bags which explain s excessive
erosion.
Ø Cost-effective solu tion in the shortest tim e.

(Premodified Baghouse) (Modified Baghouse)

(Premodified Baghouse) (Modified Baghouse)

 Case study – ACC Ltd. Aero Acoustic Solution

Bag House Analysis

Ø Prediction & Testing of noise generated due to fan .

Ø Study of existing probl em

Ø Suggestion for noise contr ol

Ø Design, Analysis & Manufacture of Silencer .

Inle t

Comp utational
Mod el of Bag h ous e
Out le t

Case study – Jaypee Rewa, CPP Case study – Jaypee Rewa, CPP

Original Silencer CFD Designed Silencer

Turnkey Solutions For Coal Mill Combustion Analysis

Ø Reduce d loc alized erosion

Ø Reduce d b and wi dth of coal par ticles
Ø Reduce d pow er consumption
Ø Impr oved bur ner design.

Ø Scope for analysis using alter native fuels

in Kiln. Coal combustion

Streamline illus tra tes flow Ve loc ity c ontour ill us trate s flow Vec tor plot illus trates flow
dis tribution i n Coal Mill dis tribution i n Coal Mill dis tribution i n Coal Mill Gas combustion
 Benefits to our Clients Manufacturing Capabilities

Ø Improved performance of ESP, Bag-House, Cyclone, Raw mills, Coal

mills and auxiliary.

Ø Meet the emission legislation by increasing equipment collection

Expansion Joints -
efficiency. Metallic & Non-metallic

Ø Lower noise brings plants n

i to statutory environmental compliance.

Ø Drive down the operational cost with m

i proved quality.

Ø And themost important - cost effectiveness.

Silencers All types of Dampers & Gates

43

List of some of our valued clients

Cement Plants

Thermal Power Stations

Nasik, Bhusawal, Parli, Ch andrapur , Kh aperkheda, K oradi, Uran

Shaktinagar, Rihan d, V indhyachal , Kor ba , Unch ahar, Rama gundam,

Dadr i, Auraiyya
Tr ombay
Other Thermal Power Stations

Others
J APAN