IMPROVING ENERGY EFFICIENCY THROUGH CFD(COMPUTATIONAL FLUID DYNAMICS) PRESENTED BY: DEEP DAVE (SR. ENGG. MARKETING)

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2 IMPROVING ENERGY EFFICIENCY THROUGH CFD(COMPUTATIONAL FLUID DYNAMICS) PRESENTED BY: DEEP DAVE (SR. ENGG. MARKETING) 2

3 INTRODUCTION ESTABLISHED IN 1983, MECHWELL IS A MULTI-DISCIPLINE APPLIED R&D ORIENTED ENGINEERING FIRM. MECHWELL WAS ESTABLISHED TO PROVIDE SOLUTIONS FOR CEMENT, POWER & ALLIED INDUSTRIES FOR FLOW, EMISSIONS & ENERGY CONSUMPTION PROBLEMS. BUSINESS: TURNKEY SOLUTION TO CEMENT, POWER & ALLIED INDUSTRIES INCLUDING CUSTOM ENGINEERING, SPECIALTY SYSTEMS DESIGN (EFIP), MANUFACTURING AND IMPLEMENTATION, AND SUPPORT TO INDUSTRY IN EMISSIONS CONTROL. TO ACHIEVE SPM<30MG, HEAT AND MASS TRANSFER, AND APPLIED ENERGY SYSTEMS. DESIGN, MANUFACTURE & SUPPLY OF EXPANSION JOINTS, DAMPERS & GATES AND EFIP S CFD & FEA CONSULTANCY SERVICES MECHWELL IS WORKING IN COLLABORATION WITH CASTLE. MECHWELL S TEAM CONSISTS OF THE ENGINEERING EXPERTS FROM IIT, & OTHER REPUTED ENGINEERING INSTITUTES HAVING VAST EXPERIENCE.

4 INTRODUCING : MECHWELL INDUSTRIES LTD. Manufacturing Air pollution control Testing & commissioning R&D CENTER FOR INNOVATION 4

5 PRODUCT OFFERING: EXPANSION JOINT (METALLIC & NON METALLIC) - DESIGN AND MANUFACTURE Manufacturing SERVES TO : THERMAL POWER PLANTS, GAS TURBINE POWER PLANTS, CEMENT PLANTS ETC.

6 DAMPERS & GATES - DESIGN AND MANUFACTURE. Manufacturing SERVES TO : THERMAL POWER PLANTS, GAS TURBINE POWER STATIONS, CEMENT PLANTS ETC.

7 AIR HEATER BASKETS & SEALS DESIGN AND MANUFACTURE. Manufacturing SERVES TO : THERMAL POWER PLANTS

8 Air pollution control ESP s Bag Filter AFGC

9 Testing Services Provided REMAINING LIFE ASSESSMENTS OF BOILERS AS PER IBR 391A CLEAN AIR DIRTY AIR TEST GD TEST APH PERFORMANCE TEST ADVANCED NDT SERVICES FOR BOILER & TURBINE DURING AOH VISUAL INSPECTION ULTRASONIC FLAW DETECTION. ULTRASONIC THICKNESS GAUGING. MAGNETIC PARTICLE TESTING LIQUID / DYE PENETRANT TESTING. RADIOGRAPHIC TESTING IN SITU FIBEROSCOPY / VIDEOSCOPY INSPECTION IN-SITU METALLOGRAPHY & PLASTIC REPLICATION. IN-SITU HARDNESS TESTING OXIDE SCALE THICKNESS MEASUREMENT SAMPLING INSPECTION - THESE TESTS WILL BE CONDUCTED AT IBR / NABL APPROVED LABORATORIES.

10 R&D CENTER FOR INNOVATION THE USE OF A RANGE OF ADVANCED TOOLS INCLUDING COMPUTATIONAL FLUID DYNAMICS (CFD), FINITE ELEMENT ANALYSIS (FEA) COMPUTER AIDED DESIGN (CAD) AND OTHER SIMULATION TECHNOLOGIES. MECHWELL PROVIDES COMPUTER AIDED ENGINEERING SERVICES TO A HOST OF INDUSTRIES, MOST NOTABLY THE POWER, CEMENT, AVIATION, OIL AND GAS, RENEWABLE ENERGIES AND AUTOMOTIVE SECTORS. 10

11 CAE - APPLICATION DOMAINS & FOCUS AREAS 11

12 CAE- R&D CENTER FOR INNOVATION Why CFD Computational Fluid Dynamics? It s the numerical analysis method involving large computerized iterations for predicting fluid flow patterns. Time efficient & Optimized Solutions Process for Design Optimization Computerized 3D CAD model is developed with Actual Site Drawings High Quality Mesh is prepared for the model After confirmation from client fluid flow simulation is proceeded to Analyze flow patterns Optimum of design Changes for Ideal fluid flow across the system Mechwell Industries Ltd. 12

13 COMPUTATIONAL FLUID DYNAMICS : STEPS IDENTIFICATION OF PROBLEM DATA COLLECTION MODELING MESH GENERATION BOUNDARY CONDITION EVALUATION MODIFICATION/ ANALYSIS SIMULATION Verification 13

14 We use CFD analysis to carry out studies pertaining to Single Phase/Multi Phase Flow Analysis Heat transfer Combustion Analysis Material/Particle behavior As part of our FEA service, we carry out studies pertaining to Thermal studies Vibration Analysis Stress Analysis (static, dynamic, non-linear, impact) Fatigue Analysis

15 3D MODELING SERVICES Pre Heater System (Cement Industry) Boiler (Power Plant Industry)

16 3D MODELING SERVICES McDonnell Douglas F-15 Eagl (Aerospace Industry)

17 3D MODELING SERVICES Chevrolet Camaro (Automotive Industry)

18 MESH GENERATION Mesh Generation ICEMCFD

19 MESH GENERATION Mesh Generation ICEMCFD

20 MESH GENERATION Mesh Generation - Hypermesh

21 CFD & FEA ANALYSIS Combustion Analysis Multi Phase Flow FEA Analysis

22 POWER SECTOR PROJECTS: PERFORMANCE IMPROVEMENT IN COAL MILL CFD ANALYSIS OF FLUE GAS DUCTS CFD ANALYSIS OF BOILER CFD ANALYSIS OF ELECTRO STATIC PRECIPITATOR PERFORMANCE IMPROVEMENT IN WIND BOX ACOUSTICS FINITE ELEMENT ANALYSIS OF COAL BUNKER

23 PARTICLE TRACKING IN COAL MILL Particle size -200 mesh: % of Particle leaving %

24 CFD ANALYSIS FOR -LANCO POWER ANPARA-660MW Existing CFD Results Figure illustrates the gas velocity streamlines at LTSH/LTRH

25 LTRH CFD RESULTS - STREAM LINE Modified CFD Results Figure illustrates the gas velocity streamlines at LTSH/LTRH

26 3D Model Confirmation Pre Modified arrangement Modified arrangement 26

27 Erosion Control Devices (ECD) ECD s are designed to protect the boiler tube from erosion due to impingement of high velocity ash particles. The C.A.V.T. data and CFD analysis results are used to optimize the design of ECDs to get the best results Existing Results Modified Results

28 Normalised ave. vel. - m/s Normalised ave. vel. - m/s Erosion Control Scheme For Boilers Comparison of Pre & Post installation velocities Bottom of LTSH Lower Bank from FRONT Wall Bottom of LTSH Lower Bank From Left Wall Pre Post 1.00 Pre Post

29 AS-IS Analysis

30 AS-IS Analysis

31 Modified CFD Results

32 Comparison Between Pre and Post CFD

33 Sr.No Modification Benefits in Power Saving 1. Design of Duct for Nashik TPS 210 MW Mahajenco 200 KWh Saving 2. Design of Deflectors in DUCT for Rajghat TPS 62.5 MW BHEL 3. Auxillary Power Saving- Gandinagar TPS, GEB 4. Pressure Drop Reduction in flue gas Duct- TATA Power 5. Auxillary Power Savings in Ducts- Jindal Power 100 KWh Saving 6.6 KV 53 mm WC 6.6 KV

34 CEMENT SECTOR PROJECTS: THERMAL EFFICIENCY IMPROVEMENT IN PRE- HEATERS MATERIAL DEPOSITION STUDY IN PH SYSTEM CFD ANALYSIS OF CYCLONES CFD ANALYSIS OF KILN CASTABLES CFD ANALYSIS OF SEPARATORS/ PARTICLE TRACKING CFD ANALYSIS OF RAW MILLS

35 THERMAL EFFICIENCY IMPROVEMENT IN PH SYSTEM Modification in Spreader box & Feed Pipe for Heat transfer Improvements

36 MODIFICATION TO PH SYSTEM TO AVOID MATERIAL ACCUMULATIONS Expected Benefit : Reduction in Material Deposition

37 BENEFITS BY CFD ANALYSIS IN THE KILN, Cold CFD Simulation: to predict the flow pattern & Improvement in flow for combustion CFD simulations in combustion: To predict the Flame length propagation Reduction in Kiln hood Erosion

38 SUMMARY: Sr.No Project Benefits 1. Thermal Efficiency Improvement in PH system JK Cement 2. Thermal Efficiency Improvement in PH system Sagar Cement 5% Increase In Production 100 KWh Saving & Heat Rate Improvement by 5 deg celcius 3. Duct Design for Maihar Cement 50 KWh Saving 4. Deflector Design in Down comer For Dalmia Cement Tamilnadu 5. Duct Design in Raw Mill- Shree Cement 30 KWh Saving Pressure drop reduction by 18 mmwc

39 OIL & GAS PROJECTS CFD ANALYSIS OF COMBUSTION AIR DUCTS CFD ANALYSIS OF HRSG SYSTEM CFD ANALYSIS OF OIL & GAS SEPARATION CFD ANALYSIS OF FLARE GAS SYSTEM

40 HVAC PROJECTS CFD ANALYSIS OF DATA CENTER CFD ANALYSIS OF BASE MENT/ CAR PARKING FIRE DYNAMIC SIMULATION OF BASEMENT CFD ANALYSIS OF HVAC SYSTEM Air flow & temperature distribution pattern over the server rack

41 AUTOMOTIVE SECTOR PROJECTS EXPLICIT & IMPLICIT ANALYSIS CAR CRASH ANALYSIS CFD ANALYSIS OF CAR FOR COOLING Interior Airflow Pattern

42 CASE STUDY FOR PROCESS INDUSTRIES FAR FIELD SOUND NOISE PREDICTION CFD ANALYSIS OF RUBBER LATEX MIXTURE Less Velocity Zone

43 CFD ANALYSIS OF TURBO MACHINERY: CFD results of NAS600 Fan JAPAN

44 PERFORMANCE CERTIFICATES:

45 RECENT R&D PROJECT : JINDAL STEEL AND POWER LTD. DESCRIPTION : 1. DEVELOP 3D MODEL OF CFBC BOILER WITH TOTAL TUBES CONSIDERING MIX GAS FIRINGS STRUCTURES WITH THE HELP OF THE DETAIL DRAWINGS PROVIDED BY JSPL 2. ASSESSING IMPACT OF GAS FIRING ON NOX AND SOX EMISSION. 3. EVALUATION OF GCV RANGE OF MIX GAS FIRING IN BOILER. 4. EVALUATION OF MAXIMUM AND MINIMUM FLOW OF MIX GAS (BF AND CO GAS) FIRING IN BOILER AND STUDY OF BOILER CRITICAL PARAMETERS 5. THERMAL MODELING OF CFBC BOILER EVALUATION OF REDUCTION OF COAL CONSUMPTION WITH UTILIZATION OF MIX GAS IN BOILER

46 JSPL,ANGUL 135MW, U#3 - CFBC BOILER Cad Model CFBC Boiler Cyclone Cold Flow Simulation 46

47 CFBC BOILER- SIMULATION & COMBUSTION ANALYSIS 47

48 THESE CUSTOMERS TRUST US OEM s Thermal Power Stations

49 THANK-YOU!! R&D Center for Innovation Contact us At : Mr. Deep Dave Sr. Engineer Marketing Mech-Well R & D Division, Mobile: deep.dave@mechwell.org,nasik@mechwell.com 49