Home  About us  Contact
 

Rotary Cement Kilns (rotary + cement_kiln)

Distribution by Scientific Domains
Chemistry100%

Selected Abstracts

CFD modeling of rotary cement kilns

ASIA-PACIFIC JOURNAL OF CHEMICAL ENGINEERING, Issue 2 2008
Kaustubh S. Mujumdar
Abstract Rotary cement kilns are widely used to convert calcineous raw meal into cement clinker, and are key components in the cement industry. In this article, we report a comprehensive computational fluid dynamics (CFD)-based model to capture key transport processes in rotary cement kilns. Separate but coupled computational models were developed for the bed and the freeboard regions of the rotary kiln. The complex swirling airflow produced by kiln burners, coal combustion, gas-phase combustion of volatile matter and radiative heat transfer in the freeboard region were modeled. The clinkerization reactions in the bed region were modeled assuming solids as pseudo fluids. Coating formation in cement kilns (for both bed and freeboard regions) was considered. Appropriate source and sink terms were developed to model transfer of CO2 from the bed to the freeboard region due to calcination reaction in the bed region. The developed bed and freeboard models were coupled by mass and energy communication through common interface. These coupled computational models were able to quite satisfactorily predict the available data from industrial kilns and previously published results. The computational models were also able to capture the intricacies of the burning zones of rotary cement kilns for changing burner-operational parameters like axial to swirl ratio and oxygen enrichment. The developed approach, computational models and simulation results will not only help in developing better understanding of cement kilns but also provide quantitative information about influence of burner design and other design parameters on kiln performance. Copyright © 2008 Curtin University of Technology and John Wiley & Sons, Ltd. [source]

Solid-solid reactions in series: A modeling and experimental study

AICHE JOURNAL, Issue 9 2009
A. K. Suresh
Abstract Reactions among particulate solid phases are important and abundant in many materials, chemical, and metallurgical process industries. Many of these are reaction networks, and not single-step reactions as normally assumed. There is no theoretical framework available for the analysis of such systems, and single-reaction models derived from the gas,solid literature continue to be used. Formation of cement clinker in the rotary cement kiln is a prime example of the genre, in which mechanistic aspects play an important role in determining energy efficiency and the composition and nature of the phases that form. In the present study, we formulate a model within the ambit of the "shrinking core" class of models, for reactions in series among solid phases. The model shows the presence of one or two moving fronts in the reacting particle, depending on the relative rates of the processes involved. A single Thiele-type parameter controls the model behavior, at once describing the relative rates of the intermediate formation and consumption processes, and the diffusion-reaction competition for the product formation step. The model has been shown to reduce to the well known single reaction models at the limits of low and high values of the Thiele parameter. Experimental data have been obtained on the calcia-alumina system, an important one in cement manufacture, in the temperature range 1150,1250°C. The model has been fitted to these data and the kinetic parameters determined. The comparison bears out the salient features of the theory, and shows that a degree of diffusion limitation exists for the intermediate conversion step under these conditions. The diffusivity values estimated are in the range of 10,19 to 10,18 m2/s and agree with values found in the literature for similar systems. The rate constant for the intermediate conversion step is of the order of 10,6 s,1. This being among the first such determinations, this value awaits confirmation from other studies. © 2009 American Institute of Chemical Engineers AIChE J, 2009 [source]

CFD modeling of rotary cement kilns

ASIA-PACIFIC JOURNAL OF CHEMICAL ENGINEERING, Issue 2 2008
Kaustubh S. Mujumdar
Abstract Rotary cement kilns are widely used to convert calcineous raw meal into cement clinker, and are key components in the cement industry. In this article, we report a comprehensive computational fluid dynamics (CFD)-based model to capture key transport processes in rotary cement kilns. Separate but coupled computational models were developed for the bed and the freeboard regions of the rotary kiln. The complex swirling airflow produced by kiln burners, coal combustion, gas-phase combustion of volatile matter and radiative heat transfer in the freeboard region were modeled. The clinkerization reactions in the bed region were modeled assuming solids as pseudo fluids. Coating formation in cement kilns (for both bed and freeboard regions) was considered. Appropriate source and sink terms were developed to model transfer of CO2 from the bed to the freeboard region due to calcination reaction in the bed region. The developed bed and freeboard models were coupled by mass and energy communication through common interface. These coupled computational models were able to quite satisfactorily predict the available data from industrial kilns and previously published results. The computational models were also able to capture the intricacies of the burning zones of rotary cement kilns for changing burner-operational parameters like axial to swirl ratio and oxygen enrichment. The developed approach, computational models and simulation results will not only help in developing better understanding of cement kilns but also provide quantitative information about influence of burner design and other design parameters on kiln performance. Copyright © 2008 Curtin University of Technology and John Wiley & Sons, Ltd. [source]