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CFD APPLICATIONS
IN
CEMENT INDUSTRIES

CII Green Cementech 2009


Hyderabad

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

Network in India
H.O. & Marketing division
Mumbai
R&D
Nasik

Factory
Igatpuri
Branch Office at
Chandrapur

Korba

Nagpur

Representatives at
U.P.

M.P.

West Bengal

Chattisgarh Tamil Nadu


Gujarat

Delhi

Orissa

Haryana

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

Certifications

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

Major Operational Areas


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

Mech-Wells Manufacturing

Expansion Joints-metallic, non-metallic (Fabric)


Radial, Axial, Modified seals, Basket elements for air heaters
IBR approved tube bends & coils
Fabrication / machining of power plant spares
We also provide turnkey solutions for improving flow profile in duct & ESP
efficiency improvement.

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

CFD Solutions for Cement Industries

Flow analysis of Duct, ESP, Bag-house etc.


Raw Mill and Coal Mill Analysis
Combustion analysis in Kiln
Cyclone Performance Analysis
Noise reduction in Fan using Aero-Acoustic Principle

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CFD Methodology
The sequence of operations required to carry out the projects are as follows:

Collection of Drawings and Data from client.

3-D Modeling of System in ANSYS Workbench.

Grid generation in ICEM CFD and Gambit.

Performing the simulation using CFX and Fluent

Analyzing the results and locating the problematic areas in the existing design.

Iteratively modify the design so as to remove the problematic areas.

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

Bag House Analysis


Equal distribution of flow Efficient.
High velocities at the bottom of the bags which explains excessive erosion.
Cost-effective solution in the shortest time.

(Premodified Baghouse)

(Modified Baghouse)

Coal Mill Analysis

Reduced localized erosion

Reduced band width of coal particles

Reduced power consumption

Coal Mill Analysis

Combustion Analysis

Improved burner design.


Scope for analysis using alternative fuels
in Kiln.

Coal combustion

Gas combustion

CFD Analysis For Turbo Machinery


Efficiency of fan increases with better inlet and outlet flow distribution
Designing flow grid for flow measurement
Without modifying fan, only just small modification in duct improves fan
performance

Aero Acoustic Solution


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

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

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.

Cyclone Performance Analysis

Maximum velocity near to wall and minimum


velocity at the center.
This flow pattern is useful for the designing
of duct connecting cyclones.

Cyclone Connecting Duct Analysis

The new duct design eliminates high velocity region.

Improved flow distribution at the cyclone inlet.

Pre-modified duct

Cyclone Connecting Duct Analysis

Pre-modified Cyclone
analysis with duct

Modified Cyclone
analysis with duct

Achievements- Maihar Cement Industries

Reduced pressure drop by 60 mm WC.


Energy savings 50 KW/h.
Payback period less than 4 months.

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. The benefit achieved after modification is in the
pressure drop across cyclone 4 which results in power saving. 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

Downcomer Duct Analysis


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

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)

Achievements- Dalmia Cement Industries

Reduced pressure drop by 37mm WC.


Energy savings 64 KW/h.
Payback period less than 4 months.

This is to certify that we have provided flow diverter plates ( 3 no.) 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.
We are happy to share that the pressure drop across the duct has reduced
from 70mmwg to 33mmwg resulting in preheater fan power saving.
- DALMIA CEMENT

Benefits to our Clients


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

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List of some of our valued clients


Thermal Power Stations
Nasik, Bhusawal, Parli, Chandrapur, Khaperkheda, Koradi, Uran
Shaktinagar, Rihand, Vindhyachal, Korba, Unchahar, Ramagundam, Dadri,
Auraiyya
Trombay
Other Thermal Power Stations

Cement Plants

Others
JAPAN

TTK LIG Ltd.