The client was facing issues in their plant because of the energy consumption by their equipment. Mechartes was consulted to carry out root cause analysis and CFD for Oil & Gas to minimize power consumption and to improve the plant efficiency. The scope of work was to carry out the root cause analysis using numerical studies, including CFD for Oil & Gas, CFD for power plants Analysis and FEA methods for various equipment in the plant, including the downcomer duct with cyclones, hot air ducting, Kiln Hood, Boiler evaporator bank.
The objective was to demonstrate the flow profile temperature and to estimate the pressure drop for given flow rate conditions for each equipment.
The main objective of the CFD for power plants and CFD for Oil & Gas analysis was to identify the maximum pressure drop locations & recirculated flow regions and to provide recommendations to improve the flow profiles & to reduce the overall pressure drop inside various equipment. The study should enable the improvement of overall energy consumption and plant efficiency. In order to achieve the above objective, the steady state CFD for power plants and CFD for Oil & Gas was carried out using general CFD methodology along with equations, processes & boundaries.
To help the client and to reduce the energy consumption of the plant, Mechartes visited the plant and studied CFD for power plants and CFD for Oil & Gas conditions. Mechartes carried out the root cause analysis using numerical studies for the Duct connected from the outlets to the boiler inlet and to the various stages of the cyclone. By CFD for power plants, CFD for Oil & Gas analysis and FEA studies, Mechartes was able to present the client with the current situation and the reason for the excessive usage of power. Mechartes provided design solutions to reduce the overall energy consumption and to improve the plant efficiency.
