Avinash Mechwell

CFD APPLICATIONS IN

CEMENT INDUSTRIES

CII Green Cementech 2009Hyderabad

About UsAbout 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 IndiaNetwork in India

H.O. & Marketing division Mumbai

R&DNasik

FactoryIgatpuri

Branch Office atChandrapurKorba Nagpur

Representatives at

U.P. M.P. Chattisgarh Tamil Nadu Orissa

West Bengal Gujarat Delhi Haryana

ResourcesResources

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

CertificationsCertifications

9 S.S.I.

9 ISO 9001/2000

9 N.S.I.C

9 Indian Boiler Regulations (IBR).

Major Operational AreasMajor 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

MechMech--WellWells Manufacturings 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 SolutionsCFD 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.

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CFD Solutions for Cement IndustriesCFD 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

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.

CFD MethodologyCFD Methodology

Computational Model

Pre-modified model Modified model

Raw Mill ESP AnalysisRaw Mill ESP Analysis

Streamlines illustrate fluid flow pattern in Duct and ESP & after

Modification Flow through ESP has been improved

CFD ResultsCFD Results

Streamline Plot forPre-modified model

Streamline Plot forModified model


Velocity pattern illustrate the flow distribution at ESP Fan inlet

Velocity Plot for Existing model at ESP Fan Inlet

CFD ResultsCFD Results

Velocity Plot for Modified model at ESP Fan Inlet


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)

Bag House AnalysisBag House Analysis

Coal Mill AnalysisCoal Mill Analysis

Reduced localized erosion

Reduced band width of coal particles

Reduced power consumption

Coal Mill AnalysisCoal Mill Analysis

Combustion AnalysisCombustion Analysis

Improved burner design.

Scope for analysis using alternative fuels

in Kiln.

Gas combustion

Coal combustion

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

CFD Analysis For Turbo Machinery CFD Analysis For Turbo Machinery

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.

Aero Acoustic Solution Aero Acoustic Solution

Case study 1 Case study 1

Aim:- To analyze Cyclone connecting duct design to reduce pressure drop across it.

Maihar Cement Industries

Poor flow distribution to the cyclone inlet affects the performance of the cyclone.

CFD was used to design the connecting duct between cyclones.

Cyclone Connecting Duct AnalysisCyclone Connecting Duct 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 Performance AnalysisCyclone Performance Analysis

The new duct design eliminates high velocity region.

Improved flow distribution at the cyclone inlet.


Pre-modified duct


Pre-modified Cyclone analysis with duct

Modified Cyclone analysis with duct

AchievementsAchievements-- Maihar Cement IndustriesMaihar 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

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

2. Improve flow at the fan inlet.

DowncomerDowncomer Duct AnalysisDuct Analysis

Down Comer Duct AnalysisDown Comer Duct Analysis

Velocity profile on plane (Premodified Duct)

Velocity profile on plane (Modified Duct)

Case study 2Case study 2

Dalmia Cement Industries

Down Comer Duct AnalysisDown Comer Duct Analysis

Velocity profile on plane (Premodified Duct)

Velocity profile on plane (Modified Duct)

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

AchievementsAchievements-- DalmiaDalmia Cement IndustriesCement Industries

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Benefits to our ClientsBenefits 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.

List of some of our valued clients List of some of our valued clients

Nasik, Bhusawal, Parli, Chandrapur, Khaperkheda, Koradi, Uran

Shaktinagar, Rihand, Vindhyachal, Korba, Unchahar, Ramagundam, Dadri, Auraiyya

Trombay

Thermal Power Stations

Other Thermal Power Stations

Cement Plants

Others

JAPAN TTK LIG Ltd.

Documents

Avinash Mechwell