Air Pollution Control Flow Modeling
Complete Product Approach
Neundorfer takes a unique, integrated approach to using flow modeling as a tool for improving the efficiency of air pollution control (APC) equipment. We combine many years of experience with in-depth capabilities, tying together all aspects of flow modeling into a complete product with eight phases. We work with you through each of the phases to lower total project cost, address your unique requirements, and achieve predictable results.
Neundorfer is the only provider of this integrated, holistic approach in North America. Our approach to APC flow modeling has saved some customers millions of dollars, and can result in 30-40 percent improvement in particulate collection efficiency.
1. In Situ Testing
establishes baseline picture of actual gas flow distribution
First, during a planned outage, our technicians use anemometers to internally map air flow velocity and distribution, at various elevations of the equipment inlet and outlet. Data from this test—combined with “as-built” drawings and, sometimes, physical inspection reports—are used to determine if gas flow distribution is contributing to efficiency or collection problems.
2. Computational Fluid Dynamics (CFD)
used to create a virtual model of equipment and test out modifications
Second, a computational fluid dynamics (CFD) program is used to create accurate 3D renderings of your equipment, based on test data and engineering drawings. This virtual model includes flow profiles of the inlet and outlet ductwork. CFD modeling saves time and money by determining, up front, the most cost-effective improvements.
3. Mathematical Performance Prediction
takes the guesswork out of achieving desired results
Next, a mathematical performance prediction program is used to complement CFD results, further clarifying which changes will have the desired results.
4. Physical Model
enables testing of modifications in three dimensions
Construction - Next, a scale physical model of your equipment is constructed in our model shop. An appropriate volume of air is pulled through the model by a fan to duplicate flow path and velocities during normal operations. Technicians use precision probes to test the flow at different locations and elevations within the model.
Modifications - Following each round of physical model testing, results are checked to ensure Institute of Clean Air Technologies (ICAC) criteria are met, and results are compared with the CFD model and the performance predictor for verification. Proposed flow modifications are reviewed with Neundorfer's engineers, fabricators and construction experts to ensure that components can be built and installed at a reasonable cost. The model is then disassembled, modified and re-assembled for another round of testing.
5. Customer Review of Proposed Modifications
demonstrate the effect of flow improvements
After determining the most cost-effective modifications, we invite the customer to visit our headquarters lab in Willoughby, Ohio to review physical model performance and recommended solution. Effects of the modifications are demonstrated using theatrical smoke and helium bubbles under high-intensity light.
6. Engineering: Fabrication and Installation Plans
takes real-world conditions into account
After the best overall solution is selected based on model results, detailed engineering plans and drawings are created for fabrication and installation.
7. Fabrication and Installation
ensures precise construction and positioning in the field
After the best overall solution is selected based on model results, components are fabricated in Neundorfer's shop or under Neundorfer’s direction. These components are then shipped to the customer's plant and installed with Neundorfer supervision.
8. Follow-up In Situ Testing
verifies effectiveness of modifications
After modifications are installed, another round of in situ testing can be performed to confirm results.