Energy Efficiency Bulletin

Case Study Bulletins from CII-Sohrabji Godrej Green Business Centre

Bulletin No. 9

Computational Fluid Dynamics (CFD) Analysis & Flow Smoothening in Preheater Down-Comer Duct for Pressure Drop Reduction

September 2007

Company Details Dalmia Cement (Bharat) Limited is one of the oldest cement plants in India, having commenced operations in 1939, with an installed capacity of 250 Tonnes per day. The plant has continuously upgraded the equipment, systems and technology to such an extent that it is one of the most energy efficient units in the country. Also, in the year 1991, a Regional Training Centre sponsored by World Bank was established at the unit to cater to all Cement Plants, located in South India. A major capacity expansion project was taken up by the unit enhancing the capacity to 4200 TPD. Dalmia Cements produces Oil Well Cement, Airstrip Cement, Railway sleeper Cement, and special cements like Coastal Cement,Superoof Cement, Super foundation Cement, Ordinary Portland Cement, Portland Pozzolana Cement. Back ground Fans are major energy consumers in Cement Industry. Fans in the cement industry usually have to handle large gas volumes, high pressure, high temperatures and high dust loading. The various applications of fans include Raw and Cement mill de dusting, Pre heater exhaust, Cooler exhaust, Forced draft, Pre calciner, Turbo separator and Coal grinding plants. One of the major reasons of higher power consumption in fans in the cement industry is the high pressure drop in various ducts. Computational fluid dynamics (CFD) is one of the branches of fluid mechanics that uses numerical methods and algorithms to solve and analyze problems that involve fluid flows. Computers are used to perform the millions of calculations required to simulate the interaction of fluids and gases with the surfaces used in engineering. CFD analysis could be employed to pinpoint high pressure drop zones in ducts. Project details The observations made on the Pre-Heater (PH) down comer duct are as follows:

High pressure drop of 110 mmWg was noticed over a duct length of 136 m.The velocity of gases was found to be optimal at 19 m/sec.The typical pressure drop for a length of 136 m for this velocity should be in the range of 30 40 mmWg only.The power consumed by a fan is directly proportional to the pressure being raised. Therefore, the additional pressure drop of 70 80 mmWg resulted in excess power consumption in both the PH fans. This additional pressure drop of 70 80 mmWg, was equivalent to 10% of the total pressure raised by the fan. Computational Fluid dynamics (CFD) analysis was carried out to find out the exact reason for this excess pressure drop and also identify the methods for reducing the same.
CFD ANALYSIS

Pre-Heater (PH) down comer duct

Simulation of gas flow inside the duct

It was observed that pressure drop was higher near the two bends, one at the top and other at the bottom. It was concluded that these bends cause turbulence due to improper gas flow. After the Computational fluid dynamic study, flow distribution plates were installed at both bends (two at the top and one at the bottom) of the duct. This resulted in smoothening the gas flow resulting in a reduced pressure drop (80 mmWg instead of the previous 110 mmWg).

Replication potential Third Party CFD analysis was carried out for pressure drop minimization, for the first time in the cement industry. Subsequently, at least 10 other plants have carried out similar studies and reaped benefits. There is a high Replication potential for CFD study in other plants as well as well as in other sectors where there are high pressure drops in various ducts. Issues faced during implementation CFD study and analysis was carried out when the plant was running in full capacity. The installation of flow diverter plates inside the ducts was done when the plant was shutdown. Installation of the plates was done in a day. Comments from the plant team The project was implemented by Dalmia Cements, Dalmiapuram in the year 2005 The plant team was aware of the higher pressure drop in the pre heater down comer duct. The CFD analysis pin pointed the exact location where modification needed to be carried out. The modification was done by the plant team. No major issues were faced during the project implementation. Financing of the project The plant invested about Rs 0.5 million for implementation of the project. The investment was taken up fully with internal funds. Results of the project Implementation of the project resulted in an annual energy saving of 0.6 million kWh. The annual cost saving achieved is Rs 1.45 million (0.03625 million USD). The investment made was Rs 0.50 million (0.0125 million USD), with a pay back period of 5 months. Benefits of the project
l Reduction in duct pressure drop l Uniform gas flow l Reduced power consumption of pre-

Cost benefit analysis

l Annual savings Rs 1.45 million

(0.03625 million USD)

l Investment

Rs 0.50 million (0.0125 million USD) 5 months

l Payback

About CII & CII-Godrej GBC CII is a non-government, not-for-profit, industry led and industry managed organisation, playing a proactive role in India's development process. Founded over 112 years ago, it is India's premier business association, with a direct membership of over 6500 organisations from the private as well as public sectors, including SMEs and MNCs, and an indirect membership of over 90,000 companies from around 350 national and regional sectoral associations. Cll-Godrej GBC is a Centre of Excellence in Energy Efficiency, Green Buildings, Renewable Energy, Water, Environment & Recycling and Climate Change activities in India. About 3 Country Energy Efficiency The Project "Developing Financial Intermediation Mechanisms for Energy Efficiency Projects in Brazil, China and India" aimed to substantially increase investments in energy efficiency by the domestic financial sectors in Brazil, China and India. The project was a partnership between the World Bank, the United Nations Environment Programme (UNEP) through the UNEP Risoe Centre on Energy, Climate and Sustainable Development (URC), and institutions in Brazil, China and India. Additional information is available at www.3countryee.org This Energy Efficiency Bulletin comprises of a series of case studies on successful energy efficiency projects implemented by Indian industry. The bulletin is supported under the "3 Country EE" initiative and by USAID.

heater fans

For further details contact

Mr N.Gopalaswamy Whole Time Director Dalmia Cement (Bharat) Ltd Dalmiapuram, Trichy (Dist) 621 651 Phone : 04329-235123 Extn. 503, 203 Fax : 04329-235111 Email : gswamyn@dalmiacement.com

Mr K S Venkatagiri / Mr K Sivaram
Survey No 64, Kothaguda, Near Hitech City Hyderabad - 500 032 Tel: 040-23112971 73, Fax: 040-23112837 Email : k.s.venkatagiri@ciionline.org / k.sivaram@ciionline.org www.greenbusinesscentre.com