CFD Analysis For Cement Plants

Improve your flow process by simulation in Cement Plant using Computational Fluid Dynamics ( CFD ) Study

Baghouse Analysis :

Efficient operation of fabric filter collection systems is crucial in achieving maximum removal of particulate matter from gas streams, of the factors affecting baghouse performance the equal distribution of flow between individual compartments, the velocity levels at the bottom of the bags and the trajectories of the target particulate are of primary importance.

CFD analyses inlet manifold confirmed equal flow splits to each of the all compartments. Analysis of a single compartment revealed critically high velocities at the bottom of the bags which explained excessive erosion in this area. Modifications in the bag house results in reduced velocity levels at the bottom of the bags. The combined CFD and physical model approach provided the most technically accurate, cost-effective solution in the shortest time.

ESP Analysis for Cement Industries :

Proper flow through an ESP is critical to optimal performance, as evidenced by many case studies. Improper flow can result in high opacity, unwanted dust buildup and erosion. Because of poor flow distribution through an ESP collector plates high velocity regions caused particle momentum to overcome electrostatic forces, resulting in suboptimal capture efficiency.

Preheater System and Downcomer Duct :

Improving the fluid flow distribution through ducts and equipment, which increases efficiency and eliminate persistent maintenance cost. Oscillatory, high turbulent flow can lead to physical vibration problems and thermal stresses in the structure. Ducts because of poor design, may suffer from low efficiency due to air recirculation, flow separation & high turbulence intensity.

The recommended modifications in duct provide a significant improvement in minimizing the turbulent and flow separation regions which in turn results in reduction in pressure drop. Planned maintenance shut down have already shown excellent vane performance those were used to optimize flow through the duct.

Combustion Analysis in Kilns & Calciner

Modern cement plants have Calciner to increase the productivity of the plant. Inside Caliciner have a strong endothermic reaction known as the calcination process, and another process is the combustion of pulverized solid fuels.

By CFD analysis pulverized fuel particles injection & trajectories can be optimized because it directly affects the energy consumption.

In Kiln major problem of the erosion of the castables & Flame length propagation & Emissions from the kiln.

Mech-well provides the solution by studying the various aspects of in Kilns & Calciners

  • Theoretical & excess air requirement for Complete combustion
  • Injection of coal particles & trajectories
  • Cause of erosion of the Castables
  • Flow from the Kiln to Calciner
  • Velocity propagation inside Kiln & Calciner
  • effect of various Coal Blending on combustion
  • Study of Particle residual time inside Calciner
  • Secondary Combustion areas
  • Study of pollutant emissions