Energy Efficiency in Cement Plant using Computational Fluid ...
Computational Fluid Dynamics Simulation in the Cement Industry
Transcript of Computational Fluid Dynamics Simulation in the Cement Industry
Computational Fluid Dynamics Simulation in
the Cement Industry
Kyle CobleMaintenance Engineer
CalPortland
CFD Overview
Fluid Flows
• Fluid States• Chemistry• Boundary Conditions• Navier-Stokes Equations
Heat Transfer
• 3 Heat Transfer Methods• Cement Pyro Process
Combustion
• Proven Capabilities• Combining Flow, Heat, & Chemical Reactions
Discrete Phase Model (DPM)
• Multiple States• Particle Tracking• Coupled Solving• Evaporation
Discrete Element Method (DEM)
• Bulk Material Flows• Numerous Applications• Particle Size Distributions• Specialized Software
Steady State and Transient Analysis
• Steady vs Transient• Screw Compressor
Geometry and Mesh
• Simulation Foundation• Collection of Cells• Cell Calculations• Cell Size, Count, & Quality
Solution Method• Simultaneous Calculations• Neighboring Cells• Iterative Process• Scaled Residuals• Convergence
Residual Examples• Velocity• Continuity• Energy
Advantages of CFD in the Cement Plant
Process Energy Savings
• Process Improvements• Other Resources• Gas Conditioning Tower Example
Wear Reduction
• Identify Heavy Wear Areas• Implement Protections• Design to Minimize Wear
Process Education and Understanding
• Visualizations• Animations• Incoming Employee Education• More Complex Equipment
Equipment Design and Selection
• Compare Designs• Size Fans and Pumps• Fan Rotor Optimization
Practical Applications of CFD in the Cement Plant
Gas Conditioning TowerOverview
Flow Direction
Inlet FromTower
Water SprayerLocation
Outlet ToID Fan
• Extended Downcomer• Laminar Flow• Pressure Drop
FlowStraighteners
Old Design
Gas Conditioning TowerPareto Optimization
• Flow Straightener Removal• Pareto Front Optimization• Design Points
Gas Conditioning TowerResource Savings
• 0.4 inH2O• 20 GPM
Clinker Cooler Takeoff DuctOverview
Inlet from Cooler
Outlet to Baghouse
AmbientInlet Flow Direction
Forced Air Inlet
• Outlet Temperature Distribution• 16 Compartment Baghouse
Outlet to Coal Mill
Clinker Cooler Takeoff DuctHanging Chain Solution
Kiln Chain Cylinder ApproximationTight Corners
• Conventional Practice• Geometry Approximation• Ineffective Solution
Clinker Cooler Takeoff DuctSlanted Plate Solution
Inlet from Cooler
Outlet
AmbientInlet
• Vertical Temperature Distribution• Forced Mixing
Slanted Plate
Preheater Tower Simulation
• Understand Our Process• Replace Top Stage• Test Vessel Designs
Coal Silo Wall Stresses
• Asymmetrical Loading• Low Pressure Zone• Wall Stresses• DEM or Viscous Fluid
Dryer Design• DEM with DPM
Raw Mill Feed
Hot AirFlow
Lessons Learned
Validate and Refine the Results
• Collect Base Case Data• Anticipate Measurements• Model Base Case• Model Changes• Trend & Compare Results• Multiple Iterations
Verify the Drawings
• “Existing”• “Field Fit”• Measure• Relines
Meshing, Meshing, Geometry, Meshing
• Simulation Foundation• Many Meshing Methods• Chain Approximation
In-House vs. Contracting
Fixed vs Variable Costs
• In House Labor• Variable Pyro Process• Numerous Cases• Charge per Case
More Opportunities for Simulation
Raw MillDryer ID Fan
Design PreheaterVessels
CementStorageDome
Cross FlowHeat
Exchanger
• Applications Everywhere• Growing List
In-House Expertise
• Interpretation• Validation• Verification
Future Possibilities
Pneumatic Transport
• Wear Identification• Pressure Drop• Piping Design and Changes
Mixing of Bulk Materials
• Shoot Design• Effective Mixing• Uniform Distribution
Whole Plant Processes Linked
Coolerto
Coal Mill
TA Ductto
Calciner
• Process Changes• Accurately Predict Effects• Upstream and Downstream
Calcination
• Proven Combustion Capabilities• Calcination Potential• Large Undertaking• Immense Benefit
Thank You• Special Thanks:
o Steve Coppinger – VP Engineering Serviceso Dave Carichner – Director of Project Engineeringo Hartmut Riess – Chief Process Engineero Brandon Schirmer – Mechanical Engineer