Optimization of Fine Material Distribution in a Gas Stream to Maximize Heat Transfer

Overview

Bridge Gap Engineering is a leading company in cement plant designs around the world. Cement manufacturing is completed in a few simple steps. These steps involve grinding raw materials, heating them to make clinker, and mixture the clinker before adding gypsum and limestone. During the preheating stage, a splash plate is used to distribute the ground raw material across a vertical shaft that has hot gas flowing through it. Our group was tasked with testing several different designs of splash plates to determine which plate allows for the greatest heat transfer between the gas and solid particles.

Objectives

Our teams’ objective was to test three different splash plate designs and determine which one would maximize heat transfer between the solid particles and the hot gas.

Approach

– Meet with sponsor and conduct research to learn about the cement manufacturing process and current products that are on the market

– Conduct research on particle distribution and heat transfer in a gas stream

– Determine a substitute for the raw material, a scale for the model, and what materials to use in the design

– Create CAD drawings of splash plates and cyclones that will be used in the test rig

COVID Pivot Adjustments
– Mold splash plates out of clay and let dry

– Build test rig out of wood

– Test the distribution of sand on different splash plates at different angles

– Determine which splash plate distributes the sand evenly across a circular area

Outcomes

Overall, we concluded that using a convex plate at an angle of about 50 degrees would be the most efficient at transferring heat from the hot air to the particles. As shown in the graph, this splash plate spread the material with a very even distribution. which means more surface area would be exposed and a greater amount of heat would be transferred to the material.