Profiting from better air flow in baghouses

Computational Fluid Dynamics (CFD) tools provide a means for predicting -in great detail -the flow patterns that can be expected within process equipment at concrete plants. This information enables significant plant improvements through the implementation of oftentimes minimal modifications. CFD tools can also be used during the plant's design phase to ensure proper operation after commissioning. The paper will discuss several areas of plant design where CFD tools have been implemented to provide operational benefit. Topics to be discussed include: (a) reducing pressure drop through process components, (b) improving the distribution of particle-laden flows into hoppers, resulting in less bag wear, (c) reducing/eliminating tube sheet scouring in clinker coolers, (d) improving utilization of existing equipment, (e) the use of Lagrangian modeling techniques to predict dust loading paths and to size and place reaction injectors, and (f) implementing reaction chemistry to model combustion dynamics. While the primary focus of the paper is baghouse operation, discussion will also be provided concerning kiln dynamics, clinker coolers and injectors for NOx and mercury reduction in flue gas.