Cfd simulation of the preheater cyclone of a cement plant and. Correlation between entry velocity, pressure drop and. Index terms air pollution, cyclone, pm particulate. It uses the suspension preheating method to preheat and partially decompose the raw material to shorten the length of the rotary kiln, and at the same time make the raw material and the hot gas flow in the kiln full. This manual is an integral part of the cyclone separator and must be kept with it until its decommissioning as a reference for all future updates.
Depending on the existence of mutual, significant interaction between particles, two different regimes. Such heat as escapes the preheater is used to heat the rawmill. Additional cooling through injection into the top cyclone of the preheater gives you various advantages. In the preheater tower at a cement industry for example, a reduction in pressure drop is fundamental for reduction in the cost of cement where each kcal of energy saved per kilogram of product plays an important role in the success of the cement plant. The model can also be used while selecting a new type of surface geometry for optimising the design of air preheater. Mechanical department chaitanya bharathi institute of. Additionally, the lucy preheater s top stage cyclones are designed for maximum dedusting efficiency. Cyclone preheater, also known as suspension preheater, is the main cement equipment commonly used in the new dry process cement production line.
Cyclone separator and the assembly, use and maintenance instructions that are necessary for operating the cyclone separator with maximum safety for the operators. Pdf cfd simulation of the preheater cyclone of a cement. Cyclone geometry d there are a number of different forms of cyclone but the reverse flow cyclone represented in figure 1 is the most co mmon design used in the industry. Cyclone is considered to be cheaper having low maintenance cost. Computational fluid dynamics cfd models provide an economical means of understanding the complex fluid dynamics and how it is influenced by changes in both design and operating conditions. The lv cyclone is a high efficiency cyclone, which reduces the pressure loss, thus achieving a considerable reduction in fan.
The gassolid contact mode and time depend on particle movement in cyclones, which has previously been studied by positron emission particle. Heat transfer analysis of recuperative air preheater. Fabrication and installation of preheater tower equipment. Design of high efficiency cyclone for tiny cement industry niki gopani and akshey bhargava international journal of environmental science and development, vol. Inner pipe or central pipes for preheater cyclone in the cement industry 1 duration. Easy operation due to high excess air percentage in kiln. Alley, 1986 typically, a particulateladen gas enters tangentially near the top of the cyclone, as shown schematically in the left figure.
Detailed calculations and experienced engineering are necessary to find the optimized solution. Cyclonic separation is a method of removing particulates from an air, gas or liquid stream, without the use of filters, through vortex separation. Cyclone and riser ducts are specially shaped to have smoother flow, good collection efficiency with lesser pressure drop. Cfd simulation of the preheater cyclone of a cement plant and the optimization of its performance using a combination of the design of experiment and multigene genetic programming. The msc multi stage combustion process is based on the split feeding of fuel, tertiary air and raw meal. Therefore, a suitable, tailormade design combined with a superior alkaliresistant brick quality will prove to be an economical solution and prolong the service life of cyclones. When removing particulate matter from liquid, a hydrocyclone is used. Cyclone design basic parts of the preheater are cyclones with low pressure loss. Bottleneck analysis when reengineering the kiln plant, all effects of the complete kiln system must be considered. The present work is based on the performance of flour mill cyclone for different flow rates. Cyclones have often been regarded as lowefficiency collectors. Hence, the above design of cyclone is safe, as the designed efficiency is more than 90%.
Attention was paid by designers of preheaters to the geometry of cyclones and their. The calcined material from preheater is then fed to kiln where it is further calcined and sintered. The computeraided design cad files and all associated content posted to this website are created, uploaded, managed and owned by third party users. Analytical techniques do not permit variations in the geometry to be readily assessed. Pdf optimization of the preheater cyclone separators used. Pdf cfd simulation of the preheater cyclone of a cement plant. Optimization of the preheater cyclone separators used in the cement industry article pdf available in international journal of green energy 101 january 2012 with 3,569 reads. The recuperative air preheater is a general term used to describe any device designed to heat air before another process with the primary objective of increasing the thermal efficiency of the process. Full text of holderbank cement engineering book internet archive.
Each cad and any associated text, image or data is in no way sponsored by or affiliated with any company, organization or realworld item, product, or good it may purport to portray. An accurate prediction of cyclone pressure drop is very important because it relates directly to operating costs. Aug 10, 2012 the simulated fluid phase is air 20c, 1 atm, inlet velocity 12. A gassolid heat exchange design, called the twodimensional heat exchanger 2dhx, has. They optimized the cyclone performance by changing the four parameters of diameter, vortexfinder length, velocity inlet, and the concentration of particles. The gas flow is forced into a downward spiral simply because of the cyclones shape and the tangential entry. The number of cyclone stages determines the specific fuel consumption. On the one hand, it supports subsequent cooling in the duct or gas cooling tower, while temperature peaks can be compensated on the other. March 2006 replacing or modifying existing top stage cyclones installing hurriclon or hurrivane installing hurrivane in 2nd stage cyclones modifying existing cyclone geometry, mainly inlet portion and inlet spiral modifying dip tubes in. Design of high efficiency cyclone for tiny cement industry. Accordingly, a classification based on the importance of the interaction mechanisms has been proposed elghobashi, 1994. A cyclone preheaters basic equipment design is rarely a decisive factor for the functioning of the kiln plant, but rather the numerous details in the cyclone stages, the calciner and the lower preheater area. Gaseous emissioncontrol technologies airquality technology. The concept of the suspension preheater gradually emerged when, from the 1920s onward, some kilns started to be fitted with cyclones to remove most of the dust from kiln exhausts, and to return it to the kiln.
Mechanical department chaitanya bharathi institute of technology hyderabad,india. The cyclone preheater is the core equipment of the new dry process cement production technology. The effects of vortex finder on the pressure drop in cyclone. For cyclone raw mix preheaters of soviet design, a gas velocity in the gas ducts of 1520 msec is applied. In phase ii a process design with regard to the application of full oxyfuel technology.
Hydrodynamic simulation of cyclone separators 245 of the interactions between the two phases. The design of cyclonic preheaters in suspension cement kilns. Gassolid heat exchanger for cement production dtu orbit. Its a very uncomplicated and effective way to create low no x emissions with only one firing location, one meal split and one tertiary air stream entering tangentially to the calciner. Finally, it has been recommended to further investigate and optimize the design, to realize the full potential of the 2dhx concept. Download as pdf file european cement research academy. Ferrite and ari optimized the preheater cyclone by means of the taguchi method. Heat transfer analysis of recuperative air preheater ijerm. Our design is based on dividing the meal from the secondlowest stage cyclone to the kiln riser and the calciner. The efficiency achieved with this design is of the order of 91. The grate preheater consists of a chamber containing a chainlike hightemperature steel moving.
Cyclone calculator solving for radial velocity given particle, gas and air density, radial distance, rotational velocity, diameter and air viscosity cyclone design equations formulas calculator radial velocity. Furthermore, a sliding suspension of the cyclone dip tube is recommendable to avoid heat deformation of the cyclone dip tube and eventual damage, both of which. Preheater refractories ipreheater cyclone protection. This broad application of cyclones is due to their. Design and analysis of cyclone seperator ijert journal. In 2000 lvt introduced a new cyclone design which has been successfully installed in plants all over the world, both in the top stage preheater and as collecting cyclones for raw mills, coal mills and cement mills. By modernizing the design of cyclone preheaters, significant energy saving can be achieved. An air preheater aph is a general term used to describe any device designed to heat.
Preheater in cement plant cyclone preheater agico cement. The cyclone preheater can take full advantage of heat in the cement rotary kiln, reduce the heat consumption of clinker production, and reduce the room occupied. There is a small clearance gap between the tubes and the thermal plate and leakage is possible through this gap. To optimise air preheater design for better performance. Design and analysis of cyclone dust separator 1muhammad i. Cyclone protection against alkali and abrasion hoganas bjufs viking 330, a drypressed. A company polysius of thyssenkrupp technologies tk prepolmsc the prepolmsc calciner is the standard calcining system for reducing nox emissions. Dry process kiln systems 5 special advantages most economical solution for small and medium capacities. Cyclone dip tube a tec innovative technologies for tailor.
A device that separates particulate from gas fluid by centrifugal force. It is a oneway eulerianlagrangian simulation, so only. The number of cyclone stages in a preheater system largely. It is the main gassolid reaction unit of the cement raw meal predecomposition system, which makes full use of the hightemperature exhaust gas discharged from the kiln tail and the hightemperature flue gas generated by the combustion at the bottom. The associated temperature reduction decreases the operating gas flow rate.
Pdf optimization of the preheater cyclone separators. The cyclone dip tube length and diameter are naturally the most important design factors. Preheater in cement plant, cyclone preheater, cement. To meet ideal effect, agico cement design preheater in the cement plant according to different regions and scale of production. Pdf optimization of the preheater cyclone separators used in the. Cyclone is most commonly used device to separate dust particles from gas and dust flow. These parameters are the collection efficiency of particle and pressure drop through the cyclone dirgo and leith, 1985. Additionally, the lucy preheaters top stage cyclones are designed for maximum dedusting efficiency. Pdf hurriclon cyclone is a specially designed preheater cyclone with two outlet connector pipes of cleaned gas in the cement industry. The present paper aims at designing of high efficiency cyclone by using stairmand method for a tiny cement plant. Cyclone design equations formulas calculator radial velocity. Cyclone design adapted from air pollution control by c.