JK Cement Ltd., a leading manufacturer of Grey Cement in India and White Cement worldwide, faced operational challenges at its Mangrol unit in Rajasthan and Muddapur unit in Karnataka. These challenges included pressure drops and dust accumulation, significantly impacting their operations and production efficiency.

Mechartes was tasked with conducting a root cause analysis to identify the issues and provide viable solutions to increase production efficiency. Utilizing CFD analysis, which is more cost-effective for testing various operating scenarios and designs than physical onsite tests, Mechartes carried out a detailed steady-state CFD study. This analysis focused on different stages of PH Cyclone and Calciner outlet ducts, aiming to verify and enhance pressure drop, and flow profiles, and minimize material and dust accumulations according to client specifications.

By considering the operating conditions provided by the client—such as flow rate, temperature, pressure, and dust particle details—Mechartes identified necessary modifications. The suggested changes, including the addition of guided vanes, were mutually agreed upon to improve pressure and flow profiles and reduce dust accumulation.