Simulation of Gas-solid Flow and Design Modifications of Cement Plant Cyclones

The paper presents Design development of cement industry cyclone based on CFD along with pilot plant trials. Based on simulation of laboratory scale cyclone as expressed in literature and in-house pilot plant experiments, Reynolds stress model has been found to predict the turbulent flow field, pressure drop and particle collection efficiency closely as compared to other standard turbulence models. Using the methodology developed, coal mill cyclone of one of the cement plant in India was simulated by CFD. The predicted pressure drop and separation efficiency were compared with measured data to show good agreement. Using the CFD model, the cyclone dimensions were optimized to improve the cyclone separation efficiency without any major change in pressure drop. The new design was successfully implemented in the plant.