Numerical optimization of VRM Cyclone Geometry for Enhanced Energy efficiency

Abstract

The cement industry, which is a highly energy-intensive industry as well as a rapidly growing sector, is grappling with various challenges like increasing power, fuel, and raw material costs which are leading to diminishing profit margins. In order to survive and sustain and expand profit margin, plant went for capacity enhancement by increasing the feed of the Vertical roller mill. However, it led to an increased pressure drop of 200-210 mmWG across the cyclone against the typical value of 120-130 mmWG. This paper unveils the deliberation of reduction in pressure drop with the help of Computational Fluid Dynamics (CFD) across the cyclone to reduce power consumption of raw mill fan. CFD was employed to understand the flow patterns across the cyclone separator. Non-uniform flow of flue gas at the inlet of the cyclone was observed. To make the uniform flow pattern, guide plates were installed and the cyclone’s inlet area was enlarged, and the modification resulted in the pressure drop reduction of 40 mmWG and savings of 0.18 kWh/t material in the raw mill fan.