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Modeling and Simulation
Cement Processes
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Particle Size Analysis
Classifier Analysis
Ball Mill Simulation
Rotary Dryer Simulation
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Technical Services Offered

  1. Particle size distribution and prediction of powder properties from your measured data from any one instrument, namely a Sieving set, Microscope, Coulter counter, Photosedimentometer, X-ray Sedigraph, Laser-based instruments etc.  We provide weight, area and number distributions, all the important particle diameters like volume diameter, surface diameter, surface-volume diameter, Stokes diameter, all the important average diameters of the distribution, specific surface area, steepness quality factor etc.  The results are provided using our comprehensive award-winning software SIZEANAL.

  2. Classifier performance analysis for which the basic data required  are the size distributions of streams around the classifier.   These "raw data" are first "corrected" using a Lagrangian technique to remove the inherent inconsistencies and then, the "corrected distributions" are used to estimate the classifier performance parameters namely, the direct bypass fraction (Rf), cut-particle diameter (d50), sharpness index of cut (SI) and the complete Tromp curve.  The results are provided using our software CLASANAL.

  3. Cyclone performance analysis for which the basic data required are the principal cyclone dimensions, the flow rates of gas and solids, solids specific gravity, feed solids concentration, plant elevation from sea level etc.   The predictions furnished by us include the cut-particle diameter of the cyclone, the complete Tromp curve, the overall collection efficiency and pressure drop.  The results are provided using our software CYCLONE.

  4. Cyclone design for which the required data are as mentioned in 3. above except the obvious cyclone dimensions!  A few design combinations can be furnished for specific entrance velocities.  The results again are provided by our software CYCLONE.

  5. Fertilizer granulation plant performance analysis and suggestions for improving throughput, reducing fuel and electrical energy consumptions, improving quality parameters like moisture content, moisture re-absorption due to relative humidity exceeding a critical value depending upon the material CRH, heat balance validations etc. using our exhaustive software GRAND.

  6. Rotary dryer optimisation and design using our software RDSIMUL which is one module in the above software GRAND.  We can furnish comprehensive predictions of product moisture content, outlet gas and solids temperatures, power and fuel consumptions, the complete profiles of moisture content, gas and solids temperature along the dryer length, entrainment and collection rates, heat balance tables, absolute and relative humidities and dew points at various locations etc.

  7. Ball mill circuit analysis and optimisation using our comprehensive software BMSIMUL .

  8. Hydrocyclone optimisation and design using our softwares HCYCLONE and CLASANAL.  The predictions would include the direct bypass fraction (Rf), cut-particle diameter (d50), sharpness index of cut (SI) and the complete Tromp curve for any combination of hydrocyclone dimensions, feed pressure and feed pulp density.

  9. Raw-mix design and optimisation for cement industries using our detailed software RAWMEAL, which includes the prediction of some important kiln operation parameters as well.

  10. Fractional composition analysis to determine the homogeneity of raw-mix in cement plants using our proprietary software FRACO.   The method involves determination of particle size distribution (psd) and chemical composition of individual size fractions of raw-mix.  The LSF, SR, AR, Minimum Burning Temperature (MBT) etc. of individual size fractions would be different and this variability gives clues about raw-mix heterogeneity and differential grinding in the raw mill which are useful for raw mill as well as raw-mix optimisation.

  11. Estimation of fan flow rate from known power consumption and impeller rpm using fan characteristic curves, and mathematical correlation of fan characteristic curves for ready reference, back-calculation and forecasting.

  12. Estimation of filter efficiency curve and Filter Micron Rating at different efficiencies (FMR95, FMR99 etc.) from measured particle size distributions (psd) of feed and product (or collected dust) streams using our proprietary software FILTER.  This is especially useful for cartridge filters used in process plants.

  13. Mathematical modeling of heat balance calculation of cement kiln circuit including rotary kiln, pre-heater cyclones, pre-calciner and grate cooler.  This would enable optimisation of heat consumption in the kiln circuit.

  14. Study and optimisation of boilers, thermic fluid heaters, incinerators etc. for optimisation of their operation and design.

  15. Study and optimisation of packed bed, fluidized bed and spouted bed reactors and dryers.

  16. Study and optimisation of spray dryers including collection cyclones and dedusting equipment.

  17. Design and optimisation of pneumatic conveying pipelines, collection cyclones and dedusting equipment.

  18. Powder characterisation advice regarding particle shape determination and correlation.

  19. Quarry planning including bore-hole composition data management and analysis, semi-variogram curve estimation, spherical (or other) model fit, reserve estimation based on inverse square law and kriging.

  20. Multivariable, multinomial equation determination for forecasting, Theory of Regionalised Variables-based forecasting (especially for quarry planning), and any other mathematical forecasting services using our in-house library functions or new developments, if needed.

  21. Technical forecasting which includes data analysis and determination of the best correlation (or best curve) between any x and y, where the relation is known to be monotonic (either continuously increasing or continuously decreasing).  The mathematical equation will be determined by the software GITA.  The predictions along with the data shall be shown on Linear, Log-log and Semi-log graphs.

  22. Sale forecasting for FMCG, pharmaceutical companies etc. based on past sales figures.  The data required will be sales figures for say 20 weeks which will be used to determine a mathematical relationship using GITA.  This relation will then enable us to forecast sales figures for future weeks, say 21 onwards.

  23. Mathematical model development for your specific requirements of process simulation, optimisation and equipment design, and software development for the above.

Address :  Dr. K. Viswanathan, B-113/2 East of Kailash, New Delhi 110065, INDIAPh : 91 11  26830345, Mob: 9818803624.   
  Email:  ptcsoftware@softhome.net, ptcsoftware@rediffmail.com.