Also available on Youtube.
About This Webinar
Presented by Pramod Bangalore of CPFD at the 2026 Barracuda Virtual Reactor Users’ Conference.
Cement manufacturing involves complex gas-solid reacting flows where heat transfer, combustion, particle transport, and chemical reactions strongly influence process efficiency, emissions, and product quality. This presentation highlights two Barracuda Virtual Reactor application models that demonstrate how high-fidelity simulation can be applied to key process units within the cement pyro-processing line: the cement calciner and the conditioning tower.
The first application model simulates an industrial-scale cement calciner, capturing coupled gas-solid hydrodynamics, fuel combustion, limestone calcination, heat transfer, and NOₓ formation using a comprehensive reaction framework validated against plant data. Results illustrate temperature, species, oxygen, and calcination distributions throughout the reactor and demonstrate the model’s ability to evaluate alternative fuel scenarios, including municipal sludge co-firing. The second application model focuses on evaporative gas cooling within a cement conditioning tower. Simulations quantify gas cooling, water evaporation, and thermal distributions to evaluate cooling effectiveness, optimize spray nozzle configurations, and protect downstream particulate collection equipment.
Together, these application models demonstrate how Barracuda Virtual Reactor provides a predictive simulation platform for improving cement process design, troubleshooting plant operation, evaluating alternative fuels, reducing emissions, and accelerating process development through physics-based digital engineering.
About the Speaker
Pramod joined CPFD as a Senior CFD Engineer in 2023, bringing experience modeling cement plant units, solid oxide fuel cell systems, consumer power tools, and consumer goods. At CPFD, Pramod has been involved in numerous projects with the development and services teams. He received an MS in Mechanical Engineering from the Missouri University of Science and Technology.