Computational Fluid Dynamics (CFD) Application

& Benefits for Cement Plant

Theme: Best Practices in Energy Efficiency in Cement Sector , A KEP initiative

7th-8th July, 2016 at My Home Industry Ltd., Mellachuruvu , Nalgonda
Presented By: Akshay Shah
 Content
Introduction to Mechwell

Introduction to Computation Fluid Dynamics

How CFD works ?

CFD applications in Cement Plants

Pros & Cons of CFD

Benefits of CFD
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 Solutions 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.
Domains :
Research & Development , Testing , Manufacturing & Supply , Air Pollution Control
 R&D – CENTER FOR INNOVATION

What is CFD ?

Fluid dynamics is the science of fluid motion.

Fluid flow is commonly studied in one of three ways:

Experimental fluid dynamics.

Theoretical fluid dynamics.

Numerically: Computational Fluid Dynamics (CFD).

CFD analysis complements testing and experimentation.

– Reduces the total effort required in the laboratory.
 Computational Fluid Dynamics (CFD) is the science of predicting fluid flow, heat

transfer, mass transfer, chemical reactions, and related phenomena by solving the

mathematical equations which govern these processes using a numerical process.

 The result of CFD analyses is relevant engineering data used in:

– Conceptual studies of new designs.

– Detailed product development.

– Troubleshooting.

– Redesign.
 CFD - how it works

1. Analysis begins with a 3D model of a physical problem.

2. Fluid properties are modeled empirically.

3. Conservation of matter, momentum, and energy must be satisfied throughout the

region of interest.

4. Domain is discretized into a finite set of control volumes or cells. The discretized
domain is called the “grid” or the “mesh.”

5. Simplifying assumptions are made in order to make the problem tractable (e.g.,
steady-state, incompressible, in viscid, two-dimensional).
 CFD - how it works
6. Provide appropriate initial and boundary conditions for the problem.

7. CFD applies numerical methods (called discretization) to develop approximations

of the governing equations of fluid mechanics in the fluid region of interest.
– Governing differential equations: algebraic.
– The set of algebraic equations are solved
numerically (on a computer) for the flow field
variables at each node or cell.
– System of equations are solved
simultaneously to provide solution.
8. The solution is post-processed to extract quantities
of interest (e.g. lift, drag, torque, heat transfer,
separation, pressure loss, etc.).
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
 Energy Efficiency Improvement Opportunities

• Use of technology for up gradation & Retrofitting of energy

Existing plants efficient equipment

New plants • Identification and selection of state-of-the-art technologies

• Blending with imported coal for improving average quality

Fuel quality
• Use of pet-coke & other combustible wastes

• Greater use of industrial wastes like flyash and slag for

Blended cement making blended cements

Power supply • Improving quality of power through captive generation.

• Inter-firm comparison and benchmarking

Performance monitoring
• Target setting and monitoring
Where CFD plays major role ?

Cyclone Ducts

Electrostatic
Baghouse
Precipitators (ESP)

Raw Mill/ Coal Mill Kiln/ Calciner

Gas Conditioning
Tower
Thermal Efficiency Improvement in PH System

Recommended Exit Temperature is 310 Deg.C

Normally it is observed that PH exit Temperature is 337
Deg.C, which is on higher side,

Thus Using CFD Analysis

Heat transfer can be improved
 Thermal Efficiency Improvement in PH System

Reasons for High PH Exit Temperature

 Improper material distribution
 Improper flow distribution
 High velocity

Heat Transfer Analysis in Riser Duct for Flue gas with

Particles elaborates the Temperature
 Thermal Efficiency Improvement in PH System

By CFD analysis, the Exit Temperature Can

Reduce & Reduction in Heat consumption about
5-20 kCal / kg clinker is possible.

By means of
 Modification in Riser Duct

 Modification in Spreader Box & Feed Pipe

 Modification in Cyclone

Modification in Riser Duct to improve Heat transfer

Thermal Efficiency Improvement in PH System

Modification in Spreader box & Feed Pipe for Heat transfer Improvements

So by CFD Modification, PH Exit Temperature can be reduced from 5 Deg C to 25 Deg C

Thermal Efficiency Improvement in PH System

Modification in Spreader box & Feed Pipe for Heat transfer Improvements

So by CFD Modification, PH Exit Temperature can be reduced from 5 Deg C to 25 Deg C

 Thermal Efficiency Improvement in PH System

Cyclone performance analysis using CFD allows:

Investigation of the flow situation
Identification of the bottlenecks
Optimization of the flow pattern
Reduction of pressure loss
Improvement of the separation efficiency

Cyclone flow with high dust load:

The interaction amongst particles is considered

The interaction between particles and gas is considered
Different sizes and particle size-distributions are
considered Modification in Cyclones for
efficiency Improvements
 Thermal Efficiency Improvement in Calciner

CFD analysis in the Calciner

 Distributions of Velocities, Temperature

 Concentrations of the reactant products

and trajectories of coal particles

 Particle interaction with the gases can be

predicted

Particle residence time

Nox,Sox & After burn fuel emission determination

All the above factors are assessed for CFD analysis in a

Calciner
 Thermal Efficiency Improvement in Calciner

Benefits by CFD analysis in the Calciner,

 Improvement in flow
Distribution of Velocities
which improves the combustion

 Improvement in coal particle

distribution

 Reduces the high concentration

of Temperature near the wall.

Improvement in residual time

of the Particle

Overall improvement in
calcinations
Thermal Efficiency Improvement in Kiln Hood & Kiln

By CFD Analysis in the Kiln Hood & Kiln,

 Secondary/Tertiary air Splits

Distributions of Velocities, Temperatures
 Flow through the Hood
 Size & shape of the flame in the kiln
Erosion pattern in the kiln Hood

Schematic of kiln with kiln Hood

 Thermal Efficiency Improvement in Kiln Hood & Kiln

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

Temperature profile in Kiln

 Thermal Efficiency Improvement in Waste Heat Recovery System

Benefits of CFD in WHRS

 Improvement in Flow distribution inside the WHRS, which enhance the Thermal efficiency of the boiler
 Proper distribution of particles to avoid erosion of the tubes.
Optimization in the pressure drop in WHRS
Cyclone Performance Analysis – Maihar Cements

Pre-modified duct
Cyclone Performance Analysis – Maihar Cements

Pre-modified Cyclone analysis with duct Modified Cyclone analysis with duct
Cyclone Performance Analysis – Maihar Cements

Reduced pressure drop by 60 mm

WC(10% reduction in Fan Power).
Energy savings 50 KW/h.
Payback period less than 4 months.
CFD Model of PH System – J.K. Cements
OUTLET
OUTLET

Cyclone III Stage

Riser Duct

Cyclone IV Stage

Elevation INLET Side View

INLET
CFD Model of PH System – J.K. Cements

Project Completed and analysis report shows

pressure drop up to 20mm WC

Streamlines plot at the inlet duct of III stage cyclone

CFD Model of PH System – J.K. Cements

Project Completed and analysis report shows pressure drop up to 25mm WC

Cyclone with PH down Comer Duct Analysis – Dalmia Cements

Velocity profile on plane (Premodified Duct)

Velocity profile on plane (Premodified Duct)

 Cyclone & Duct Analysis

Reduced pressure drop by 37mm WC.

Energy savings 64 KW/h.

Payback period less than 4 months.

Cyclone & Duct Analysis – Maihar Cements

Cyclone

Premodified design

Modified design
PH Fan Inlet
Cyclone & Duct Analysis – Maihar Cements

Minimum pressure drop reduction of 12

mmWc

Payback period less than 5 months

Cyclone & Duct Analysis – India Cements

Cyclone

Minimum pressure drop reduction of 12

mmWc

Payback period less than 5 months

PH Fan
inlet
PH system CFD results – Sagar Cements

Streamlines illustrate Velocity magnitude for air preheater Cyclone 6, 5, 4, 3 system

 Raw Mill Circuit Analysis Sagar Cement

To RABH Inlet

PH Fan Outlet To VRM Inlet

Grid for Raw Mill Circuit – Sagar Cements
CFD Results of Existing Raw Mill Circuit - Sagar Cement

Stream lines and planes show the flow distribution across cyclones
for pre-modified case.

Power Saving by 100KW HR

Performance Certificate - Sagar Cements

VRM CA Fan Savings-110 KW-Hr

Pay Back Less than 10 months

 Air & Flue Gas Ducts

The flue gases in ducts carry coarse ash/ material particles,

which under certain operating conditions hit the duct
walls and other physical surfaces present within the ducts
causing erosion on wall ducts.

Turbulence is another problem that results in increase in

pressure drop, noise, vibration etc.

Flow separation occurs when a bend or expansion is too

severe to allow the flow to follow the contour of the duct.
This causes a wake to form, resulting in an effective
reduction in the ducts cross sectional area This area
reduction results in a pressure loss that can be significant.
 Air & Flue Gas Ducts

The main objective while carrying out CFD analysis of

ducts is:

To design turning vanes for ducts in order to reduce pressure

drop, reduce turbulence and minimize erosion of duct walls,
caused due to high velocity of flow.

Reducing erosion of duct walls results in reduction of

leakages in the ducting.

Both these factors mainly, reduced turbulence and reduced

erosion, result in reduction in pressure drop across the duct
which in turn results in saving of power consumption.
Baghouse Analysis

Good flow distribution inside the baghouse is very

essential to increase the bag life, improved collection
efficiency & minimize pressure drop.
Adhering to ICAC standards & desired performace,
Mechwell can improve baghouse flows by:
−Ensuring a uniform flow distribution of the gas to each
baghouse compartment.
−Ensuring that flows entering each baghouse
compartment are evenly distributed and that all bags are
utilized within a given compartment.
−Preventing gas velocities that are high enough to
damage a bag.
−Minimizing pressure losses throughout the baghouse.
Bag House Analysis – Clair Engineers Pvt Ltd

(Premodified Baghouse) (Modified Baghouse)

Bag House Analysis – Clair Engineers Pvt Ltd

(Premodified Baghouse) (Modified Baghouse)

Bag House Analysis – ACC ltd

Inlet

Computational Model of Bag

house
Out let
Bag House Analysis – ACC ltd

Inlet 1
(GCT outlet)

Inlet 2
(FLASH DRYER)
Out let
Fan Inlet
Combustion Analysis

Combustion analysis using CFD allows:

to improve the combustion air flow pattern
to the burners in order to smooth the
combustion.
to compare the influence of different
burner designs on flame shape.
to understand the influence of several inlet
parameters concerning either the fuel used,
or the kiln geometrical dimensions, the
position of the burner in the kiln, the
various velocities.
 Aero Acoustic Solutions

 Prediction & Testing of noise generated due to fan.

 Study of existing problem

 Suggestion for noise control

 Design, Analysis & Manufacture of Silencer.

Aero Acoustic Solution – Jaypee Rewa , CPP
 Conclusion
Computational Fluid Dynamics (CFD) technology is very much help full for analysis for
single phase & multiphase flow, combustion, heat transfer, prediction of erosion
patterns.
Mechwell has applied CFD technology successfully in Cement industry for process /
efficiency improvement in following areas.

Thermal Efficiency Improvement in Pre-Heaters

Material Deposition study in PH System
CFD analysis of Cyclones
CFD analysis of Kiln Castables
CFD analysis of Separators/ Particle Tracking
CFD analysis of Raw Mills
Combustion Analysis
Credentials
Major Projects carried out by Mechwell Industries Limited
Sl
No. Name of the Company Projects carried out.
1 Sagar Cements Limited CFD Analysis
CFD Analysis for Raw Mill (2) fan inlet, Cement Mill (1) fan inlet and
2 Ramco Cements Ltd outlet, Cement Mill (2) fan outlet
3 Dalmia Cements Ltd CFD Analysis of PH Cyclone in KHD & FLS
4 Sanghi Cements CFD Analysis of Raw Mill Cyclone with Ducting
5 J.K.Cements CFD Analysis of PH Cyclone System
6 Sanghi Cements CFD Analysis of Alkali Bypass system (As Is Condition)
7 Saurashtra Cements CFD Analysis for the Cooler ESP Inlet Duct
8 Sagar Cements Limited CFD Analysis of Calciner with Pre-heater
9 Century Cements CFD Analysis of Economiser
10 Saurashtra Cements CFD Analysis of Sepex Filter Outlet Duct to Sepex Fan Inlet Duct
CFD Analysis To Resolve The Wear Out Problem in Rawmill Outlet
11 Saurashtra Cements Duct
12 Dalmia Cements Ltd CFD Analysis for Raw Mill Circuit
13 NLC Industries Limited PH Cyclone System 3D Model
14 Zuari Cements Email CFD For PH Cyclone
15 India Cements ltd-dalavoi CFD analysis for GCT bypass duct
16 Zuari Cements CFD Analysis of Duct of The C-line Bag House Outlet Duct
17 Shree Cements Ltd. CFD Analysis in AQC-9 and AQC-5 Boiler
18 India CementsLtd-Tirunelveli CFD Analysis of PH Cyclones
19 Orient Cements CFD Analysis of PH Down Comer Duct
20 GEA Process Engineering (India) Pvt. Ltd. CFD Analysis Service of Bag Filter forCement Mill
21 GEA Process Engineering (India) Pvt. Ltd. CFD Analysis Service of Waste Gas ESP
22 Ambuja Cement Ltd. CFD Analysis of cooler ESP Inlet Duct
23 Dalmia Cements Ltd-Ariyalur CFD Analysis of Cements mill & Raw mill ducting
24 J.K.Lakshmi Cements. CFD Analysis of Duct
25 Century Cements-Raipur CFD Analysis of Economizer Region
26 Shree Digvijay Cement Co Ltd. CFD Analysis of cooler ESP& Inlet Duct
27 Dalmia Cements Ltd-Dalmiapuram CFD Analysis in FLS PH system in Line-2 PH
28 Dalmia Bharat Enterprises Ltd-Ariyalur. CFD Analysis of Flue gas Ducting
 These Customers Trusts US:
Cement Plants

Thermal Power Stations

Others

JAPAN

MECHWELL INDUSTRIES LTD. | Driven By Innovation

 THANK YOU
Contact us at: Mr. Akshay Shah
Engineer Marketing
+918275016434 , +912532453556
akshay@mechwell.org
nasik@mechwell.com

MECHWELL INDUSTRIES LTD. | Driven By Innovation 14