Technology

CFD Modelling of Peat Combustion in a standard Duoflex Burner

Published

9 years ago

July 4, 2016

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Using modern techniques like CFD and a few laboratory tools, changing from one fuel to the other in Rotary Kilns has become fairly easy and quite predictable.

The DUOFLEX burner is widely used in rotary kilns with a variety of fuels like pulverized coal, coke, or natural gas. The burner is highly customizable, allowing ease of operation with alternate fuels like plastic chips and sewage sludge. Duoflex burner design is based on the proven concept of fuel flowing in a central duct; which is circumscribed by annular ducts for primary air supply. The annular ducts, one providing radial and the other providing axial flow are mixed at the nozzle tip. The tip is retractable, allowing fine control of the nozzle area. The radial to axial air ratio is also adjustable. Thus the burner allows for a high degree of operational flexibility, and provides a stable flame under a wide variety of process conditions. These factors contribute to Duoflex being the burner of choice for cement installations all over the world.

To demonstrate the universal application of the burner, a study was commissioned to explore the feasibility of burning peat as a primary fuel. Peat is the accumulation of partially decayed organic matter and burning it in kiln is not a standard operating condition. Therefore, a Computational Fluid Dynamics (CFD) study was commissioned to evaluate the burner performance. Peat was tested and compared with coal using Thermogravimetric Analysis/Differential Thermal Analysis(TGA/DTA) tests. Figure 2 shows the results from the TGA/DTA tests.

Crucial analysis of peat was carried out in the laboratory to understand the fuel. Based on the results, a CFD model was developed in ANSYS to simulate the burning of peat in a kiln. In the kiln, the fuel undergoes "fast" combustion, limited only by the mixing of fuel and oxidiser. This was incorporated in the CFD model. There are a large number of reference plants for burning coal in the kiln. Using the reference data from the plants and with in-house experience, the CFD model with coal was validated. In the same model, the fuel was changed to peat and the results were compared with each other. Three scenarios were simulated using the CFD model namely, 100% Coal firing, 100% Peat firing and Peat/Natural Gas combination. The CFD model revealed that peat firing is distinctively different from coal fired systems. Figure 2 shows the flame profiles for the three fuel firing in the kiln system. The conclusions from the CFD results were used to design features for the Duoflex burner that would help sustain continued operation for alternate fuel firing.

What is computational fluid dynamics (CFD)?
Computational fluid dynamics (CFD) is the use of applied mathematics, physics and computational software to visualise how a gas or liquid flows – as well as how the gas or liquid affects objects as it flows past. Computational fluid dynamics is based on the Navier-Stokes equations. These equations describe how the velocity, pressure, temperature, and density of a moving fluid are related.

Computational fluid dynamics has been around since the early 20th century and many people are familiar with it as a tool for analysing air flow around cars and aircraft. As the cooling infrastructure of server rooms has increased in complexity, CFD has also become a useful tool in the data centre for analysing thermal properties and modelling air flow. CFD software requires information about the size, content and layout of the data centre. It uses this information to create a 3D mathematical model on a grid that can be rotated and viewed from different angles. CFD modelling can help an administrator identify hot spots and learn where cold air is being wasted or air is mixing.

Simply by changing variables, the administrator can visualise how cold air will flow through the data centre under a number of different circumstances. This knowledge can help the administrator optimise the efficiency of an existing cooling infrastructure and predict the effectiveness of a particular layout of IT equipment. For example, if an administrator wanted to take one rack of hard drive storage and split the hard drives over two racks, a CFD program could simulate the change and help the administrator understand what adjustments would be needed to be made to deal with the additional heat load before any time or money has been spent.

By Arun Appadurai, CFD Specialist, FLSmidth Pvt. Ltd

Technology

ARAPL Reports 175% EBITDA Growth, Expands Global Robotics Footprint

Affordable Robotic & Automation posts strong Q2 and H1 FY26 results driven by innovation and overseas orders

Published

2 weeks ago

October 15, 2025

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Affordable Robotic & Automation Limited (ARAPL), India’s first listed robotics firm and a pioneer in industrial automation and smart robotic solutions, has reported robust financial results for the second quarter and half year ended September 30, 2025.
The company achieved a 175 per cent year-on-year rise in standalone EBITDA and strong revenue growth across its automation and robotics segments. The Board of Directors approved the unaudited financial results on October 10, 2025.

Key Highlights – Q2 FY2026
• Strong momentum across core automation and robotics divisions
• Secured the first order for the Atlas AC2000, an autonomous truck loading and unloading forklift, from a leading US logistics player
• Rebranded its RaaS product line as Humro (Human + Robot), symbolising collaborative automation between people and machines
• Expanded its Humro range in global warehouse automation markets
• Continued investment in deep-tech innovations, including AI-based route optimisation, autonomy kits, vehicle controllers, and digital twins
Global Milestone: First Atlas AC2000 Order in the US

ARAPL’s US-based subsidiary, ARAPL RaaS (Humro), received its first order for the next-generation Atlas AC2000 autonomous forklift from a leading logistics company. Following successful prototype trials, the client placed an order for two robots valued at Rs 36 million under a three-year lease. The project opens opportunities for scaling up to 15–16 robots per site across 15 US warehouses within two years.
The product addresses an untapped market of 10 million loading docks across 21,000 warehouses in the US, positioning ARAPL for exponential growth.

Financial Performance – Q2 FY2026 (Standalone)
Net Revenue: Rs 25.7587 million, up 37 per cent quarter-on-quarter
EBITDA: Rs 5.9632 million, up 396 per cent QoQ
Profit Before Tax: Rs 4.3808 million, compared to a Rs 360.46 lakh loss in Q1
Profit After Tax: Rs 4.1854 lakh, representing 216 per cent QoQ growth
On a half-year basis, ARAPL reported a 175 per cent rise in EBITDA and returned to profitability with Rs 58.08 lakh PAT, highlighting strong operational efficiency and improved contribution from core businesses.
Consolidated Performance – Q2 FY2026
Net Revenue: Rs 29.566 million, up 57% QoQ
EBITDA: Rs 6.2608 million, up 418 per cent QoQ
Profit After Tax: Rs 4.5672 million, marking a 224 per cent QoQ improvement

Milind Padole, Managing Director, ARAPL said, “Our Q2 results reflect the success of our innovation-led growth strategy and the growing global confidence in ARAPL’s technology. The Atlas AC2000 order marks a defining milestone that validates our engineering strength and accelerates our global expansion. With a healthy order book and continued investment in AI and autonomous systems, ARAPL is positioned to lead the next phase of intelligent industrial transformation.”
Founded in 2005 and headquartered in Pune, Affordable Robotic & Automation Ltd (ARAPL) delivers turnkey robotic and automation solutions across automotive, general manufacturing, and government sectors. Its offerings include robotic welding, automated inspection, assembly automation, automated parking systems, and autonomous driverless forklifts.
ARAPL operates five advanced plants in Pune spanning 350,000 sq ft, supported by over 400 engineers in India and seven team members in the US. The company also maintains facilities in North Carolina and California, and service centres in Faridabad, Mumbai, and San Francisco.

Technology

M.E. Energy Bags Rs 490 Mn Order for Waste Heat Recovery Project

Second major EPC contract from Ferro Alloys sector strengthens company’s growth

Published

2 weeks ago

October 15, 2025

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M.E. Energy Pvt Ltd, a wholly owned subsidiary of Kilburn Engineering Ltd and a leading Indian engineering company specialising in energy recovery and cost reduction, has secured its second consecutive major order worth Rs 490 million in the Ferro Alloys sector. The order covers the Engineering, Procurement and Construction (EPC) of a 12 MW Waste Heat Recovery Based Power Plant (WHRPP).

This repeat order underscores the Ferro Alloys industry’s confidence in M.E. Energy’s expertise in delivering efficient and sustainable energy solutions for high-temperature process industries. The project aims to enhance energy efficiency and reduce carbon emissions by converting waste heat into clean power.

“Securing another project in the Ferro Alloys segment reinforces our strong technical credibility. It’s a proud moment as we continue helping our clients achieve sustainability and cost efficiency through innovative waste heat recovery systems,” said K. Vijaysanker Kartha, Managing Director, M.E. Energy Pvt Ltd.

“M.E. Energy’s expansion into sectors such as cement and ferro alloys is yielding solid results. We remain confident of sustained success as we deepen our presence in steel and carbon black industries. These achievements reaffirm our focus on innovation, technology, and energy efficiency,” added Amritanshu Khaitan, Director, Kilburn Engineering Ltd

With this latest order, M.E. Energy has already surpassed its total external order bookings from the previous financial year, recording Rs 138 crore so far in FY26. The company anticipates further growth in the second half, supported by a robust project pipeline and the rising adoption of waste heat recovery technologies across industries.

The development marks continued momentum towards FY27, strengthening M.E. Energy’s position as a leading player in industrial energy optimisation.

Technology

NTPC Green Energy Partners with Japan’s ENEOS for Green Fuel Exports

NGEL signs MoU with ENEOS to supply green methanol and hydrogen derivatives

Published

2 weeks ago

October 15, 2025

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NTPC Green Energy Limited (NGEL), a subsidiary of NTPC Limited, has signed a Memorandum of Understanding (MoU) with Japan’s ENEOS Corporation to explore a potential agreement for the supply of green methanol and hydrogen derivative products.

The MoU was exchanged on 10 October 2025 during the World Expo 2025 in Osaka, Japan. It marks a major step towards global collaboration in clean energy and decarbonisation.
The partnership centres on NGEL’s upcoming Green Hydrogen Hub at Pudimadaka in Andhra Pradesh. Spread across 1,200 acres, the integrated facility is being developed for large-scale green chemical production and exports.

By aligning ENEOS’s demand for hydrogen derivatives with NGEL’s renewable energy initiatives, the collaboration aims to accelerate low-carbon energy transitions. It also supports NGEL’s target of achieving a 60 GW renewable energy portfolio by 2032, reinforcing its commitment to India’s green energy ambitions and the global net-zero agenda.