Projects & Case Studies

Featured Study: Use of Hydrogen as a Fuel Input in Cement Manufacturing

A conceptual feasibility, process safety, and combustion dynamics analysis examining 10%–25% thermal energy substitution of fossil coal with industrial hydrogen in high-temperature cement kilns.

Challenge: Clinker calcination requires flame temperatures exceeding 1,450°C. Hydrogen burns with a laminar flame speed 8x faster than methane, has low volumetric energy density, and produces water vapor with lower radiant heat emissivity than luminous coal flames.

Process Safety: Highlights ASME B31.12 hydrogen piping compliance, Class I Div 1 explosion proofing, and burner exit nozzle velocities exceeding 45 m/s to prevent dangerous burner flashback.

Additional Verified Plant Case Studies

• Phosphoric Acid Slurry Pump Cavitation Fix: Reconfigured suction manifold to eliminate short-radius elbows, boosting NPSHa by 1.1m and dropping vibration from 14.2 to 1.8 mm/s.
• Rotary Kiln Main Drive Gearbox Overhaul: Compensated for thermal pedestal lift using cold alignment pre-offsets, improving tooth contact from 42% to 88%.

The 6-Stage Case Study Methodology

1. Define Challenge: Operational baseline and financial impact.
2. Investigate Evidence: Physical records, vibration spectra, and oil assays.
3. Evaluate Options: Technical feasibility and safety trade-offs.
4. Review Risk: Statutory codes, HAZOP, and metallurgy limits.
5. Measure Outcome: Verified measurements vs projections.
6. Share Lessons: Institutionalizing knowledge in CMMS procedures.