Perform Computational Fluid Dynamics (CFD) analysis to identify the percentage of combustion of pet coke at the outlet of pyroclone and optimize the design so that overall energy consumption can be minimized to improve the plant performance.
Properties of raw material, pet coke, flue gas and provided flow rates for different cases in the pyroclone are used to simulate combustion and calcination reaction inside the pyroclone for steady state CFD flow analysis . The composition of flue gas at TAD outlet is calculated by doing the mass balance around the Kiln inlet, TAD outlet and pyroclone inlet and the same is incorporated in CFD simulations. The proximate and ultimate analysis of pet coke is used to model the combustion phenomenon in CFD simulations.
A high rotational flow causes higher pressure drop in pyroclone top, also increases the residence time of coal particles.
It is observed that the gases flow along the walls after dispersion of pet coke and raw material in the pyroclone. Also, a high temperature is observed near the burner port. The most of pet coke particles flows along the wall at high velocities. The percentage combustion obtained for different cases are 96.91%, 96.95% and 99.97% respectively. Similarly, the percentage of calcination obtained are 98%, 100% and 98.98% respectively.