optimising plant operation using cfd modelling
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OptimisingplantoperationusingCFDmodelling
Usingadvancedthree-dimensionalsimulationservicestooptimiseplantefficiencyLargeenergygenerators,mineralsprocessorsandenergyusersfaceextremelycompetitiveandchallengingenvironmentsthatincludeconsiderablepressuretomaximisetheirplant’sperformance.Insuchanenvironmentplantoperatorsfacegrowingpressuretolimittheiremissions,andtominimisetheirfueluseandmaintenancecosts
ChallengesPlantoperatorswishingtooptimiseplantperformancefaceseveralchallengesincluding:• determiningcurrentplantefficiencyandcomparingplant
efficiencytobuildspecificationsorexpectations• identifyingoptionsforimprovingplantperformance• predictingandquantifyingtheexactimpacteachoption
willhaveonplantprocesses• determiningwhichoptionsarethemostcost-effective• inlightofgovernmentpolicytoreducegreenhousegas
emissionsandtheproposedcarbontax,re-evaluatingefficiencyprojectsoriginallyconsideredtobecost-prohibitive
• evaluatinglong-termabatementactionsforcontinuingoperationsinalower-emissions-intensityeconomy.
SolutionsCriticalindeterminingplantperformance–andingainingthebenefitsfromoptimisingthatperformance–isunderstandingexactlywhatishappeninginsideaplant.HRLTechnologyGroup’sexpertprocessmodellingservicecan‘lookinside’anoperatingplant.Usingarangeofsimulationpackages,includingcomputationalfluiddynamics(CFD)modelling,hrl:providesdataandanalysistoassistclientsinidentifyingoptionsforoptimisingprocessesandincreasingplantefficiency.CFDmodellingisapowerfulmethodofproducingcomputer-basedthree-dimensionalmodelsofanyflowsystem.Suchmodellingallowsdifferentcombinationsofoperatingconditions,conceptualdesignsandmodificationstobetestedandprovenbeforetheyareimplemented.CFDmodellingcanbeusedtodeterminetheperformanceofsystemswithtwo-phaseflowandthoseinwhichchemicalreactionsoccur.
hrl:usesthesemodellingtoolstocomplementotherclientservicesincludingevaluatingresourcesandfuel,emissionsandenvironmentalmonitoring,materialsengineeringandprojectimplementation.
hrl:expertprocessmodellingservicecan‘lookinside’anoperatingplantoperatingplant
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CaseStudy
Determiningthesuitabilityofareplacementbiomassfuel
Aleadingcementproducerwasinterestedinreplacingnaturalgaswithbiomassasfuelfortheircombustionprocess.hrl:proposedusingCFDmodellingasanon-invasivemethodtodeterminethealternativefuel’scombustioncharacteristicsandeffectiveness.hrl:personnelalsousedmodellingtoidentifydesignchangestostabiliseflow,changefuel-residencetimeandalterfuel-injectionheightandangletooptimisecombustionoftheproposedbiomassfuel.Themodellingdeterminedthatbiomasswasaviablefuelalternativewithoutanydetrimentaleffectonperformance,aslongasthesuggesteddesignchangesdevelopedfromtheCFDmodelwereimplemented.
Benefits Thebenefitsclientsenjoybydrawingonhrl:extensiveexpertiseinCFDmodellinginclude:• assistanceinunderstandingthecurrentperformanceof
theirplantanditslimitations• modellingalternativemodificationoptionsand
operationalconditions,quantifyingperformanceimprovements,anddeterminingthecost-benefitequationbeforecommittingtoanyplantmodificationwork
• drawingonhighlyskilledtechnologistsusingstate-of-theartmodellingsoftwarewhoemploymethodologies,andproduceresultsandrecommendationsthatwithstandexternalscrutinyandinwhichclientscanhaveconfidence
• providingastrongtheoreticalunderstandingthatisbackedbyyearsofpracticalexperienceandexpertiseinapplyingthetechnology
• drawingontheservicesofasupplierthatlookstoprovidethebestsolution,notjustaresearchprogram.
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Contact AlexBlatchford
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