Numerical modelling of calcination reaction mechanism for cement production

Mikulčić, Hrvoje; Berg, Eberhard von; Vujanović, Milan; Priesching, Peter; Perković, Luka; Tatschl, Reinhard; Duić, Neven

doi:10.1016/j.ces.2011.11.024

Cited by 60 publications

(33 citation statements)

References 30 publications

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“…The understanding of the complex nature of combustion and calcination processes in experimental investigation is limited and can be significantly improved by computer simulation tools. Numerical models developed for cement calciners [10], can be used for numerical simulations of process and combustion emissions. Numerical simulations can be used to gain detailed knowledge and required information about operation of devices in order to help cement manufactures to operate in a more energy efficient way.…”

Section: Numerical Investigation Of a Cement Calcinermentioning

confidence: 99%

“…With the aim of improving the operating conditions, different calciners, as well as the chemical and physical processes occurring inside the calciner [10], have been studied. Huanpeng et al [11] using a two-dimensional model and the kinetic theory of granular flow to represent the transport properties of the solid phase, studied the influence of different parameters on the dynamics of the two-phase flow in a calciner.…”

Section: Introductionmentioning

confidence: 99%

“…These scenarios show that there is a possibility for a more sustainable development of this industrial sector in Croatia. In addition, a previously developed mathematical model of the calcination process [10], which contains the relevant physical and chemical processes as, e.g., Arrhenius rate approach, pressure limitation, diffusion resistance, porosity, tortuosity, pore size and pore efficiency, was used for the numerical investigation of a cement calciner. By using this detailed mathematical model, a progress in understanding of the thermo-chemical processes occurring inside a calciner was made.…”

Section: Introductionmentioning

confidence: 99%

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Reducing the CO2 emissions in Croatian cement industry

2013

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a b s t r a c tCement industry is one of the largest carbon emitting industrial sectors. It is responsible for about 5% of anthropogenic CO 2 in the world. Therefore, it is a relevant industrial sector for CO 2 emission regulation strategies. Bearing in mind the importance of cement industry in Croatia, and because of the fact that Croatia will soon become an EU member state, the present paper analyses the potential to reduce CO 2 emission in the Croatian cement industry. There are several measures that can reduce CO 2 emissions from the cement manufacturing process: the use of waste heat as an alternative source of energy; CO 2 capture and storage technologies; reduction of clinker to cement ratio; the use of alternative and biomass fuels; the use of alternative raw materials; an energy efficient combustion process. The most energy efficient technology for cement manufacturing today is the use of a rotary kiln together with a multi-stage preheater and a calciner. Since the use of cement calciners is a relatively new technology, further improvement of their operating conditions is still needed. This paper also highlights the results of research in the field of computational fluid dynamic (CFD) simulations that are used for the investigation of process and combustion emissions. The above mentioned measures together with numerical investigations can reduce the effect of cement manufacturing in Croatia on the environment and can make it more competitive with cement manufacturers from the EU.

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Section: Numerical Investigation Of a Cement Calcinermentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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Reducing the CO2 emissions in Croatian cement industry

2013

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“…3D CFD modeling of a full scale rotary cement kiln with a multi-channel coal burner can be found in another paper, in which ANSYS FLUENT has been used withal zone-wise heat flux model to study the effect of swirl angle on combustion characteristics [26]. An implementation and validation of the calcinations reaction mechanism of limestone in a CFD code can also be found [27].…”

Section: Introductionmentioning

confidence: 99%

CFD Modeling of Meat and Bone Meal Combustion in a Rotary Cement Kiln

Ariyaratne¹,

Malagalage²,

Melaaen³

et al. 2014

IJMO

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Abstract-This paper presents a three-dimensional computational fluid dynamics (CFD) modeling study carried out for a rotary cement kiln withal multi-channel burner with swirl and high momentum air components. The simulations are performed using the commercial CFD software ANSYS FLUENT, version 13.0, and are carried out for coal as well as for meat and bone meal (MBM) combustion using the eddy-dissipation model for combustion. Steady-state solutions are obtained using the Lagrangian approach for the particle phase and the Eurasian approach for the continuous phase. The turbulence is modeled by the RNG k-ε model, and gas-phase radiation is modeled by the P1 radiation model. The effect of MBM fuel properties on combustion characteristics such as temperature, fuel devolatilization, volatiles and char burning, in comparison with coal, are presented and discussed. It was found that MBM combustion products temperatureis300K lower than that of coal, and the char burnout of MBM is 83%. This poor burnout is mainly due to bigger MBM particles.Index Terms-CFD, combustion, meat and bone meal, rotary cement kiln.

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“…Mikulcic [6] presented a numerical modeling of the calcination reaction mechanism for cement production using a CFD code to simulate turbulent flow, temperature, concentration fields of the reactants and products, as well as the interaction of particles with the gas phase. In his review he found that the first mathematical model for calcination mechanisms was developed by Borgwart [7], who concluded that the reaction rate is determined by heat and mass transfer inside a particle.…”

Section: Introductionmentioning

confidence: 99%

A discrete-continuous approach to describe CaCO3 decarbonation in non-steady thermal conditions

et al. 2015

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In cement production, direct measurements of thermal and chemical variables are often unfeasible as a consequence of aggressive environments, moving parts and physical inaccessibility, and therefore prediction models are essential tools in these types of industrial applications. This article addresses the problem of the numerical prediction of the CaCO 3 calcination process, which is the first and the most energy expensive process in clinker production. This study was conducted using the Extended Discrete Element Method (XDEM), a framework which allows a Eulerian approach for the gas phase to be combined with a Lagrange one for the powder phase. A detailed validation of the numerical model was performed by comparison to non-isothermal TG curves for mass loss during the CaCO 3 decarbonation process. The complex three-dimensional predictions for solid and gas phases are believed to represent a first step towards a new insight into the cement production process. Thus, the high accuracy and detailed description of the problem addressed, serve as a basis to assess the uncertainty of more simplified models such as those used in soft sensors.

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Numerical modelling of calcination reaction mechanism for cement production

Cited by 60 publications

References 30 publications

Reducing the CO2 emissions in Croatian cement industry

Reducing the CO2 emissions in Croatian cement industry

CFD Modeling of Meat and Bone Meal Combustion in a Rotary Cement Kiln

A discrete-continuous approach to describe CaCO3 decarbonation in non-steady thermal conditions

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