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

Abstract

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.

Numerical analysis of the thermal profile inside the wall of a rotary cement kiln

“…Measured (this study) Measured (reference study [20] [36], and output stream of an industrial clinker kiln (wt% calculated from molar fraction data in [37]).…”

“…[Tabela A-I -Composição química de tijolo refratário Magkor A1 (% mássica) [36] e corrente de saída de forno de clínquer industrial (% mássica calculada a partir de dados de fração molar em [37]). ] APPENDICES…”

Efeito da reação de calcinação nas análises energética e exergética de um forno rotativo empregado na produção de clínquer

“…Em vista disso, infere-se que é relevante um estudo que analise a utilização da energia disponibilizada para este sistema. O forno rotativo de clínquer faz parte da unidade de piroprocessamento [3,[6][7][8]. Essa unidade é composta pela torre de ciclones, onde ocorre o pré-aquecimento, pelo forno e por um resfriador [8], conforme o esquema ilustrado na Fig.…”