Rotary Cement Kiln Simulator (RoCKS): Integrated modeling of pre-heater, calciner, kiln and clinker cooler

This paper presents the one dimensional modeling of rotary kilns used for energy intensive production processes. Raw material is fed into an inclined rotating kiln and heated by counter current gas flow. Chemical reactions take place in the bed of raw material as well as in the gas phase. Heat and mass transfer between the bed and the gas phase are implemented. Also the heat transfer to the environment is taken into account. As a benchmark, the process of limestone calcination is chosen. Results are compared with computational fluid dynamic simulations.

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“…Limestone calcination can be modeled as a shrinking core process with surface reaction control according to equation (27) [7].…”

Section: Introduction Of the Cfd Rotary Kiln Modelmentioning

confidence: 99%

Modeling of Rotary Kilns and Application to Limestone Calcination

Küssel¹,

Abel²,

Schumacher³

et al. 2009

Linköping Electronic Conference Proceedings

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“…A particular case is the model of the kiln, in which the discretization in cells is done with respect to the profile of chemical species concentration inside the unit, which is related with temperature levels. The reaction kinetics concerning the clinker process (Mujumdar, 2007) are accounted in the piecewise linearization. At the same time the separation of carbon dioxide generated by calcination reaction is modeled assuming that the calcination reaction takes place for 65% in the in-line calciner and that it is completed in the rotary kiln.…”

Section: Process Description and Modeling Methodologymentioning

confidence: 99%

“…The process generates hot and CO 2 rich exhaust streams. Fin order to study energy efficiency of the process, authors like Mujumdar et al (2006Mujumdar et al ( , 2007 developed detail models of process units, while others highlighted energy and exergy performances of plants (Kolip et al 2010). Some authors have studied the integration of cogeneration units in cement industry as an option of waste heat recovery (Wang et al 2008).…”

Section: Introductionmentioning

confidence: 99%

Energy Integration in the cement industry

Mian

Bendig

Piazzesi

et al. 2013

Computer Aided Chemical Engineering

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“…Some of the challenges facing the cement industries are the high energy demand of production, the continuous increase in fuel prices, process complexity and environmental impact (Atmaca and Yumruta 2014, Tsamatsoulis 2014, Kaddatz et al 2013, Gartner and Macphee 2011, Schneider et al 2011, Mujumdara et al 2007). To address these challenges, there is great interest in optimising the cement production process (Copertaro et al 2015, Utlu et al 2006.…”

Section: Introductionmentioning

confidence: 99%

Dynamic Analysis of the Temperature and the Concentration Profiles of an Industrial Rotary Kiln Used in Clinker Production

Rodrigues

Soares

Junior

et al. 2017

An. Acad. Bras. Ciênc.

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Cement is one of the most used building materials in the world. The process of cement production involves numerous and complex reactions that occur under different temperatures. Thus, there is great interest in the optimization of cement manufacturing. Clinker production is one of the main steps of cement production and it occurs inside the kiln. In this paper, the dry process of clinker production is analysed in a rotary kiln that operates in counter flow. The main phenomena involved in clinker production is as follows: free residual water evaporation of raw material, decomposition of magnesium carbonate, decarbonation, formation of C 3 A and C 4 AF, formation of dicalcium silicate, and formation of tricalcium silicate. The main objective of this study was to propose a mathematical model that realistically describes the temperature profile and the concentration of clinker components in a real rotary kiln. In addition, the influence of different speeds of inlet gas and solids in the system was analysed. The mathematical model is composed of partial differential equations. The model was implemented in Mathcad (available at CCA/UFES) and solved using industrial input data. The proposal model is satisfactory to describe the temperature and concentration profiles of a real rotary kiln.

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Rotary Cement Kiln Simulator (RoCKS): Integrated modeling of pre-heater, calciner, kiln and clinker cooler

Cited by 98 publications

References 16 publications

Modeling of Rotary Kilns and Application to Limestone Calcination

Modeling of Rotary Kilns and Application to Limestone Calcination

Energy Integration in the cement industry

Dynamic Analysis of the Temperature and the Concentration Profiles of an Industrial Rotary Kiln Used in Clinker Production

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