Dynamic modelling of a rotary kiln for calcination of titanium dioxide white pigment

Ginsberg, Tobias; Modigell, Michael

doi:10.1016/j.compchemeng.2011.03.029

Cited by 34 publications

(18 citation statements)

References 20 publications

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“…The sulfate method includes a calcination stage [8,9,34] where a "filter cake" is calcined in a rotary kiln at approximately 1000 °C. The kiln heat requirements are provided by combustion of natural gas in a separate chamber [8].…”

Section: Development Of a Process Model For Rutile Tio2 Production Using The Sulfate Methodsmentioning

confidence: 99%

“…They appear in anatase, rutile and brookite form. Notably, rutile white pigment is of significant economic importance [8]. TiO2 pigments are produced from a variety of ores with two different processes: the sulfate process (representing a total of approximately 40% of the total TiO2 production) using concentrated sulfuric acid and the chloride process (comprising a respective 60% of the total TiO2 production) which uses chlorine gas.…”

Section: Introductionmentioning

confidence: 99%

“…During calcination, the material is heated to high temperatures (usually ranging between 800-1200 °C, depending on the pigment), causing changes to its crystal structure and grain size [5]. These temperatures are achieved through the combustion of fossil fuels [5,17] such as natural gas [5,8] and oil [18]. Variations of the traditional ceramic production route have either been implemented or proposed by various patents for Green Cr2O3 pigment production [13][14][15][16][19][20][21].…”

Section: Introductionmentioning

confidence: 99%

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Process Simulation and Life Cycle Assessment of Ceramic Pigment Production: A Case Study of Green Cr2O3

Alifieris¹,

Katsourinis²,

Giannopoulos³

et al. 2021

Processes

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This study presents a combined process modeling—Life Cycle Assessment (LCA) approach for the evaluation of green Cr2O3 ceramic pigments production. Pigment production is associated with high calcination temperatures, achieved through the combustion of fossil fuels. Therefore, it is necessary to evaluate its environmental impact with regards to energy requirements and CO2 emissions. Initially, a process model is developed to simulate the final calcination stage of the traditional pigments production process. It is validated against titanium dioxide (TiO2) white production industrial data and adjusted for Cr2O3 production. Three alternative processes are examined: two for pigment grade (PIGM1, PIGM2) and one for metallurgical (MET) Cr2O3. Heat demand and CO2 emissions computed by the developed process models are used as input in the LCA along with upstream data from the literature using a cradle-to-gate approach. The implementation of the LCA has resulted in calculated Global Warming Potential (GWP100) ranging from 7.9 to 12.8 CO2-eq and fossil Primary Energy Demand (PED) between 91.4–159.6 MJ-eq (all referring to 1 kg of pigment production). It is depicted that the biggest part of the emissions originates from the upstream production and transportation of raw materials (contributing up to 96% of total CO2 emissions) and other sources (electricity, production plant, etc.), rather than the examined calcination stage (contributing from 1.3 to 3.5% of GWP).

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Section: Development Of a Process Model For Rutile Tio2 Production Using The Sulfate Methodsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

See 1 more Smart Citation

Process Simulation and Life Cycle Assessment of Ceramic Pigment Production: A Case Study of Green Cr2O3

Alifieris¹,

Katsourinis²,

Giannopoulos³

et al. 2021

Processes

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“…The study showed that the optimization of a plate dryer should Correspondence concerning this article should be addressed to A. Zakharov at alexey.zakharov@aalto.fi concentrate on maximizing the effective covering ratio of the plates. More recently, Ginsberg and Modigell 19 developed a dynamic model of a rotary kiln used for the calcination of titanium dioxide. The overall heat transfer phenomena and the reactions occurring in the process were described.…”

Section: Introductionmentioning

confidence: 99%

Dynamic modeling of a multiple hearth furnace for kaolin calcination

et al. 2015

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A dynamic model of a multiple hearth kaolin calciner has been developed and is presented in this article. This model describes the physical-chemical phenomena taking place in the six furnace parts: the solid phase, gas phase, walls, cooling air, rabble arms, and the central shaft. The solid phase movement, in particular, is described by a novel mixing model. The mixing model divides the solid bed in a hearth into volumes and the distribution of their contents, after one full central shaft rotation, is identified by the pilot experiments. First, the model is validated by the industrial data, and then the dynamics of the multiple hearth furnace is studied by introducing step changes to the three manipulated variables: the feed rate, and the gas, and air flows supplied. The responses of the gas phase temperature and solid bed component profiles are analysed and the results are discussed. V C 2015 American Institute of Chemical Engineers AIChE J, 61: [3683][3684][3685][3686][3687][3688][3689][3690][3691][3692][3693][3694][3695][3696][3697][3698] 2015

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“…Marias (Marias, 2003) presented a new development in the study of a rotary kiln incinerator using the possible coupling between gPROMS TM and Fluent TM . Ginsberg and Modigel (Ginsberg & Modigell, 2011) established a rigorous onedimensional dynamic model of a rotary kiln for calcination of titanium dioxide white pigment; they considered the heat losses from the kiln outer shell to the environment, and determined useful equations for calculating the convection and radiation heat losses. Sogut et al (Sogut, Oktay, & Karakoc, 2010) performed a complete thermal analysis of a rotary kiln for the cement industry and stated that the energy efficiency of that equipment was 61 %; moreover, they indicated that 5 % of the waste heat can be utilized with a recovery exchanger.…”

Section: Introductionmentioning

confidence: 99%

Energy efficiency of an innovative vertical axial rotary kiln for pottery production

Núñez

López

Vargas

2015

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Colombia es un importante productor y exportador de carbón a nivel mundial. Múltiples sectores utilizan este recurso para la producción de energía térmica y eléctrica, entre los cuales se encuentra la industria cerámica, que en el 2011 tuvo un consumo de 118 590 toneladas. La mayor parte de las industrias de alfarería se encuentran en áreas rurales y utilizan hornos antiguos alimentados con carbón con baja eficiencia energética, generando efectos ambientales considerables a la población circundante. A pesar de la importancia de estas industrias para las pequeñas economías rurales, agencias nacionales gubernamentales han cerrado varias debido a la falta de desarrollo de sistemas más limpios. Este trabajo pretende analizar el comportamiento térmico de un horno rotatorio de eje vertical para la alfarería y su eficiencia energética variando el modo de operación. El horno operó durante siete horas y necesitó tres horas para alcanzar 800 °C en la cámara de sintetización o cocido. Las temperaturas promedio de las cámaras de carga, secado, cocido y enfriamiento, a partir del momento de estabilización fueron 204, 223, 809 y 321 °C respectivamente. Las pérdidas por radiación y convección al ambiente fueron equivalentes al 15%, mientras que las pérdidas relacionadas con los gases de combustión fueron del 18%. Durante la operación en continuo la eficiencia energética del sistema alcanza el 60 %. Este diseño innovador demostró alcanzar las temperaturas requeridas en el proceso de alfarería; más aún permitió el uso de un combustible gaseoso, haciendo el proceso más limpio y eficiente que los sistemas tradicionales alimentados por carbón.

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Dynamic modelling of a rotary kiln for calcination of titanium dioxide white pigment

Cited by 34 publications

References 20 publications

Process Simulation and Life Cycle Assessment of Ceramic Pigment Production: A Case Study of Green Cr2O3

Process Simulation and Life Cycle Assessment of Ceramic Pigment Production: A Case Study of Green Cr2O3

Dynamic modeling of a multiple hearth furnace for kaolin calcination

Energy efficiency of an innovative vertical axial rotary kiln for pottery production

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