MECH WELL INDUSTRIES LTD.

Driven By Innovation

SERVICES OFFERED
# COMPUTATIONAL FLUID DYNAMICS
# FINITE ELEMENT ANALYSIS

www.mechwell.com 9001: 2015

ISO 27001: 2013
sales@mechwell.in
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 Mechwell’s
COMMITMENT
VISION
To occupy leading
position globally for
Products’ and service
like Expansion Joints,
Gates & Dampers,
APH Spares and CAE
services etc.
QUALITY POLICY
To serve customer
needs by optimizing
resources of designing,
manufacturing,
supplying quality
products providing
services in time and
improving the
customer satisfaction.
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MISSION
♦ To provide CFD
based turn key
solution to power
plants and other
process industries
like Cement,
Petroleum,
Automobile etc.
♦ To help power
plants in reducing
SPM, to meet pre-
vailing Pollution
Control Board
Norms.
♦ To Manufacture and
Supply World Class
Quality Products &
deliver them on
time.
 MECHWELL

CAE Design & Consultancy

CFD is a branch of fluid mechan- FEA is a computerized method

ics that uses numerical analy- for predicting how a product re-
sis and algorithms to solve fluid acts or respond to real-world
flows situations. forces, vibration, heat, and oth-
er physical effects.

♦ MECHWELL provides Reverse engineering service , which is useful in

product development & to make and maintain quality of product.

♦ MECHWELL is working in collaboration with ALTAIR TECHNOLOGIES

to initiate particle analysis by using EDEM software.

♦ MECHWELL’S team consists of the engineering experts from IIT, & Other
reputed engineering institutes having vast experience.

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 COMPUTATIONAL
FLUID DYNAMICS

What is Computational Fluid Dynamics:

Computational fluid dynamics (CFD) is a new

highly recommendable technology to use in
process optimization. Basically, it is a branch of
fluid mechanics that uses numerical analy-
sis and algorithms to solve fluid flows situations.

High-performing computers are used to conduct

the calculations required to simulate the
interaction of liquids and gases with surfaces
defined by boundary conditions.

Advantages :

 Predicts performance before modifying or installing the systems .

 Cost And Time Effective

 Fast And Reliable

 Unlimited level of detail In system

 Virtual modeling with powerful visualization capacity.

 Easily analyze the experiment which are difficult in practical.

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 CFD APPLICATION
DOMAINS

POWER CEMENT

OIL & GAS PROCESS

HVAC AUTOMOTIVE

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 CFD APPLICATION IN
POWER :

MWI offers CFD solution to flow related problems to improve performance and
economize operations of :

1. Boiler : CAVT (Cold Air Velocity Test) + CFD analysis of boiler 2nd pass
helps to suggest measures to reduce the erosion of tubes due to fly ash flying at
high velocity. To reduce and optimize unbalanced temp profile.

2. ESP : CFD + G.D. Test + Stack Emission measurements of ESP help in

evolving solution to reduce particulate emission.

3. Ducts : CFD + Velocity test of duct help in designing flow controls which
help in reducing pressure drop and duct erosion which is directly impact in ID fan
margin.

4. Absorber : To analyze flow distribution to achieve the homogeneity & im-

proving flow distribution to achieve CV within 10 % at absorber inlet.

5. Fans & Stack. To reduce erosion and wear.

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 CFD : BOILER

3 D MODEL MESHING FLOW PATTERN

 Assessing impact of gas firing on

NOx and SOx emission.
 To improvise the flow of secondary
air at the furnace inlet.
 To improve flow distribution inside
the boiler.
 Reduce the turbulence in the hot
air duct.
 Evaluation of GCV range of mix
gas firing in Boiler
 Thermal Modeling of boiler.

COMBUSTION ANALYSIS
SECOND PASS OF BOILER

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 CFD :ELECTROSTATIC
ELECTROSTATIC
PRECIPITATOR

BEFORE MODIFICATION

AFTER MODIFICATION

WHY CFD ?
 To minimize the system pressure loss.
 To achieve ICAC EP 7 norm.
 To make flow distribution uniform.
 To improve collection efficiency.
 To optimize the ESP & Its associate ducting.

PDPL 1 PDPL 2

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 CFD : Baghouse

VELOCITY PROFILE OF V - PLANE VELOCITY PROFILE AT H - PLANE

BENEFITS :

 To achieve uniform gas flow

distribution through all the bags
in the module.
 To optimize the pressure drop .
 To improve Collection efficiency
of the bag filter.
 To design the Diverter, PDPL
and other flow conditioning de-
vice to Improve flow pattern
with minimum Pressure drop.
 To optimize the baghouse.

VELOCITY PROFILE OF Z - PLANE

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 CFD : FLUE GAS
DUCTING

AH CONNECTING DUCT BEFORE AH CONNECTING DUCT AFTER ANALYSIS

VELOCITY PROFILE OF APH TO ESP INLET DUCT

BENEFITS :
 To make flow distribution uniform.
 Optimize the Pressure Drop.
 Avoid ash concentration in ESP inlet passes.
 Reduce Auxiliary Power Consumption.
 Particle analysis using EDEM.

HONEYCOMB DESIGNED
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 CFD : ABSORBER

SLURRY DISTRIBUTION

MODEL VELOCITY DISTRIBUTION

WHY CFD?

 Pressure drop optimization.

 To know the gas distribution.
 To know slurry distribution.
 Velocity across absorber determined.
 To check turbulence across system.
 To Optimize and improve performance of
the system.

PRESSURE PROFILE ACROSS ABSORBER

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 CFD : COAL MILL

VELOCITY STREAMLINE

VELOCITY PROFILE AT COAL MILL

VELOCITY COUNTERS AT MILL OUTLETS

PARTICLE PROFILE AT COAL MILL RECIRCULATION ZONES AT INSIDE COAL MILL

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 CFD : TURBO
MACHINERY

3 D MODEL VELEOCITY PROFILE

PRESSURE PROFILE ACROSS FAN

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 CFD APPLICATION IN
CEMENT PLANT

PH CYCLONE RAW MILL

RAW MILL CIRCUIT KILN / CALCINER

BAG FILTER WHR BOILER

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 CFD APPLICATION In
CEMENT PLANT

KILN

RAW MILL PRE HEATER SYSTEM

CFD is used in the cement to addressed the problem in the Pre heater such as
improper heat transfer, high pressure drop, low collection efficiencies and high fan
power consumption apart from it CFD is also used to reducing problems in Kiln,
Calciner, Cement Mill and raw mill etc. MWI offers cost effective solution to ce-
ment plant with benefit in line with CFD results.

We use CFD analysis to carry out studies pertaining to

 Single/multiphase Analysis
 Heat Transfer
 Combustion Analysis
 Material/Particle Behavior

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CFD : PH SYSTEM

FLOW SEPERATION

OBJECTIVE:

 To find out flow separation and

recirculation as well as flow
concentrations zones in duct
arrangement using CFD tech-
nique.
 To optimize turbulence by de-
signing the guide plates &
small duct modifications to re-
duce pressure drop .
 Provide temperature and pres-
sure drop profile at every
stage of PH System .
 To optimize the system.

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 CFD : PH CYCLONES

SINGLE CYCLONE PARTICLE ANALYSIS TWIN CYCLONE PARTICLE ANALYSIS

OBJECTIVES:

 Analysis and review of collection

efficiency in PH Cyclone
 Analysis and review of Heat transfer
and temperature profile PH Cyclone.
 To improve of heat transfer and
saving of heat consumption in
system.
 To Optimize the system.

BOTTOM STAGE CYLONE ANALYSIS

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 CFD : CALCINER

FLOW PROFILE INSIDE CALCINER PARTICLE ANALYSIS

OBJECTIVES:

 To illustrate the flow distribution

within Calciner.
 To improve residence time of
particles in Calciner
 To improve temperature uni-
formity by improving combus-
tion in Calciner.

COMBUSTION ANALYSIS

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 CFD : RISER DUCT &
SPREDER BOX

RISER DUCT, SPREDER BOX & FEED PIPE:

RISER DUCT ANLYSIS TO IMPROVE HEAT TRANSFER

SPREADER BOX & FEED PIPE FOR HEAT TRANSFER IMPROVEMENTS

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 CFD : GAS
CONDITIONING
TOWER

Flow patterns of droplets and their velocities .

OBJECTIVE:
 To predict flow pattern.
 Liquid and gas flow in
scrubbers & towers.
 Internal flow characteristics in
spray nozzles
 Gas and liquid mixing in
dual-fluid nozzles
 Improve flow regime of the
gas conditioning tower.

flow patterns with velocities inside the GCT.

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 CFD : PH BOILER

OBJECTIVE:
 To analyze and make flow uniform inside the Boiler.
 To Optimize pressure drop.
 To improve heat transfer.
 To check particle distribution inside the boiler.
 To Optimize its associate ducting..

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 CFD : AQC BOILER

OBJECTIVE:
 To analyze and make flow uniform inside the Boiler.
 To Optimize pressure drop.
 To improve heat transfer.
 To check particle distribution inside the boiler.
 To Optimize its associate ducting..

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 CFD : RAW MILL

NOZZEL RINGS MODEL

PRESSURE PROFILE IN RAW MILL

SEPERATOR MODEL

OBJECTIVES:
 To optimize Pressure drop.
 To Know the flow profile
and particle behavior inside
the raw mill.
 To analyze the separator
and optimize in away that
efficiency of raw mill will
increase.
 To reduce fan power
Consumption.
VELOCITY DISTRIBUTION

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 CFD : RAW MILL
CIRCUIT.

PRESSURE PROFILE

MODEL OF VRM CIRCUIT

OBJECTIVES:
 The check and Optimize flow
distribution in the ducting complex.
VELOCITY PROFILE
 To short out dust accumulation
problem from the circuit.
 To check & optimize collection
efficiency of cyclone.
 To Optimize the pressure drop from the
circuit and cyclones.
 To know the particle distribution inside
the circuit.
 To optimize the raw mill ducting
complex

VELOCITY PROILE WITH PARTICLE

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 CFD APPLICATION In
OIL & GAS

HEATERS FLOW ANALYSIS MULTIPHASE ANALYSIS

CFD (Computational Fluid Dynamic, CFD), is a new technology with the emer-
gence of high-speed electronic computer. The technology allows the numerical
calculation method for solving fluid flow problems as possible, in solving prac-
tical engineering flow, heat transfer problem in practice has been continuously
mature and complete, and has an increasing number of engineering practices
verification.

We analyzes various scopes through

CFD in oil & gas industries such as

 Heat Exchanger Analysis

 Sloshing Analysis
 Multi phase flow Analysis
 Erosion analysis
 Fluid Structure Interaction
 Mixing /separator performance anal-
ysis
Heat Exchangers

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 CFD : COMBUSTION
AIR DUCTING

VELOCITY PROFILE

3 D Model

BENEFITS:

 To Understand fluid flows of

critical areas
 To analyze the pressure drop.
 To make flow distribution
PRESSURE DROP ANALYSIS
uniform across every burner.
 Enhancing the efficiency of
recovery processes and
equipment .
 Optimize the system.

BURNER INLET DUCTING FLOW PROFILE

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 CFD APPLICATION IN
AEROSPACE & DEFENCE

STATIC PRESSURE CONTOUR AT MACH NO. 0.2 & Α = 8O

COMPUTATIONAL MESH CLOSE TO EPPLER 387 AEROFOIL SURFACE BOMB DEPLOYMENT STUDY

DLR F4 WING MESH MODEL DLR F4 WING PRESSURE COUNTER

OBJECTIVES :

 Develop practical modeling guidelines for CFD prediction of high-lift flow

fields.

 Advance the understanding of high-lift flow physics to enable development of

more accurate prediction methods and tools. Enhance CFD prediction
capability for practical high-lift aerodynamic design and optimization.
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 CFD APPLICATION
IN HVAC..

TEMPERATURE DISTRIBUTION AT
DATA CENTER

By using Computational fluid dynam-

ics (CFD), we helps engineers to visual-
ize flow velocity, density, thermal impact
and chemical concentrations for any re-
gion where the flow occurs. This in-turn WORKSHOP AREA- FACTORY HVAC
helps HAVC industries to analyze the
problem areas and we suggest the
best solutions.

OFFICE AREA STUDY

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 CFD APPLICATION
IN STEEL PLANT

3 D MODEL OF FUME EXTRACTION SYSTEM FOR STEEL PLANT

Smoke propagation Velocity contour at vertical plane

OBJECTIVE:
 To evaluate the existing fume extraction system .
 Analyse the secondary ducting system
 To find out the probable solution so that the fume inside the shop can be
minimised .
 To evaluate the performance of the proposed arrangement during , charging/
taping Operations.

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 FINITE ELEMENT
ANALYSIS

WHAT IS FEA?
The finite element analysis (FEA) is a computing technique that is used to
obtain approximate solutions to the boundary value problems in engineer-
ing. It uses a numerical technique called the finite element method (FEM)
to solve boundary value problems.

PROCESS INVOLVED :

Application of
FEA:
 AEROSPACE
HEAD LIGHT SUSPENSION RING
 AUTOMOTIVE
 BOIMEDICAL
 CONSUMER GOODS
 DEFENCE
 ELECTRONICS
BOMB SHELL PIN RACK

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 FINITE ELEMENT
ANALYSIS

FE ANALYSIS OF COAL BUNKER:

DEM ANALYSIS OF COAL BUNKER:

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 FEA : AUTOMOTIVE

 Suspension system design and

analysis.
 Engine and mounting system
development.
 Mechanism development
 Modeling and development of
Intake Manifold
Active systems like Electric Power
 Assistance System (EPAS), ABS
(Anti-lock Braking System), Trac-
tion Control (TC), Autonomous
Emergency Brake (AEB).
 Full vehicle ride and handling
tuning.
 FE meshing support to Durability,
CFD, Passive Safety and NVH. Charge Air Cooler

HEAD LIGHT

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 FEA : LOCOMOTIVE

CAD MODEL OF LOCOMOTIVE CONTAINER

MODAL & FATIGUE ANALYSIS

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 FINITE ELEMENT
ANALYSIS

VALVE:

 For SEISMIC ANALYSIS.

 To determine fatigue
 To find stress & residual Life.

MESHING

STRESS AT DIFFERENT LOCATIONS

PIN: STRESS PLOT

 To Determine fatigue
 To find Stress & Structural Life.

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 TESTING
SERVICES

OUR OTHER SERVICES INCLUDE:

\

 FESEABILITY STUDY FOR BIOMASS

COFIRING
 COLD AIR VELOCITY TEST
 GAS DISTRIBUTION TEST IN ESP
 GAS DISTRIBUTION TEST IN DUCT
 CLEAN AIR TEST
 DIRTY AIR TEST
 ISO KINETIC SAMPLING
 THERMOGRAPHY
 O2 TESTING
 NDT TESTING

For more details please visit our website

www.mechwell.com

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Marketing, Manufacturing and R&D
Gat No.178, Shinde Naygaon Road,
Brahmanwada, Tal.: Sinnar,
Dist.: Nashik – 422103
Maharashtra, India

Tel.: (+91)9130093941
Cell: (+91)8275016387

Email us
sales@mechwell.in

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