Case Study - Ecka Granules Right click here and choose "save target as" to download a printable pdf file of this page.... Finite Elements (Australia) Pty Ltd provided design development services which fundamentally altered the design of a new aluminium chiller chamber plant extension. The computational Fluid Dynamics Analysis cost less then $55,000. The Finite Element Analysis cost less then $20,000. Finite Elements provided: Computational Fluid Dynamic Analysis (CFD), Finite Element Analysis (FEA), and redesign advice. p   613 + 6264 2975 f   613 + 6264 3130 info@finiteelements.com.au Finite Elements (Australia) Pty Ltd established since 1993. ABN: 36 060 076 806 If it is worth spending between $30,000 and $60,000 to resolve process problems with your industrial plant then it is well worth spending it on some computer based Computational Fluid Dynamics (CFD) analysis. Ecka Granules is a producer of aluminium powders, pigment pastes, and aluminium granules. With a growing need in the market for a more diverse range of aluminium powders, and with a need to improve their own production quality and volumes, Ecka decided to add a new, redesigned, atomising plant to their existing plant at Bell Bay in northern Tasmania. The two sections of the atomising plant requiring design development were the high temperature atomising head and the chiller chamber. A mix of molten aluminium and compressed air are sprayed into the Chiller Chamber at high temperature and pressure, through the atomising head. The Chiller Chamber is a vessel which contains the atomising head and collects and cools the molten aluminium particles. The particles then enter a lean phase conveying system through which they are transported to the cyclones that sperate the particle sizes. As the aluminium particles pass through the chamber from the supersonic region at the atomising head to the exit duct, they cool down and pass through their lower explosive limit. At this time the process poses an explosion risk. The design posed a challenge for a number of reasons. Firstly, the new plant had to be capable of dealing with the substantially higher temperature, air flow and aluminium flow conditions than the existing plant. Secondly, the cooling molten aluminium particles had to flow efficiently through the chiller chamber to avoid powder build up in dead flow zones, as well as ensure particles did not impact and stick to the chamber walls before solidifying. Prior to engaging Finite Elements, Ecka Granules prepared a preliminary design of their new chamber based in the performance of their existing chamber and that of other chambers throughout the Ecka Worldwide Group. The design also incorporated new ideas to overcome known shortfalls in existing designs. In an attempt to better understand the dynamics of their original chamber, traditional air flow testing techniques using ambient air and water sprays had been employed. In an attempt to better understand the dynamics of their original chamber, traditional air flow testing techniques using ambient air and water sprays had been employed. These test were very limited in their application. The conditions inside the chamber were a far more complex combination of factors than could be modelled with air and water. A more sophisticated modelling technique, capable of dealing with molten high temperature sprayed aluminium with heat transfer between the sprayed particles and the surrounding gases, high pressure supersonic atomisation air and ambient cooling and conveying air, was required. Finite Elements (Australia) Pty Ltd chose, for this study, to use CFX-5 Computational Fluid Dynamics software for its advanced multi-physics capabilities. setup.                     next.....