Imaging of Flames in Cement Kilns To Study the Influence of Different Fuel Types

Pedersen, Morten Nedergaard; Nielsen, Mads; Clausen, Sønnik; Jensen, Peter Arendt; Jensen, Lars Skaarup; Dam‐Johansen, Kim

doi:10.1021/acs.energyfuels.7b01954

Cited by 16 publications

(19 citation statements)

References 30 publications

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“…A comparison was carried out between the experimental and numerical results reported in [17]. It was assumed that the mass flow rate of the pet-coke supply is about 3 tons/hour.…”

Section: Fds Modeling Of the Combustormentioning

confidence: 99%

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Multiphysics Design of Pet-Coke Burner and Hydrogen Production by Applying Methane Steam Reforming System

Davidy¹

2021

Clean Technol.

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Pet-coke (petroleum coke) is identified as a carbon-rich and black-colored solid. Despite the environmental risks posed by the exploitation of pet-coke, it is mostly applied as a boiling and combusting fuel in power generation, and cement production plants. It is considered as a promising replacement for coal power plants because of its higher heating value, carbon content, and low ash. A computational fluid dynamics (CFD) computational model of methane steam reforming was developed in this research. The hydrogen production system is composed from a pet-coke burner and a catalyst bed reactor. The heat released, produced by the pet-coke combustion, was utilized for convective and radiative heating of the catalyst bed for maintaining the steam reforming reaction of methane into hydrogen and carbon monoxide. This computational algorithm is composed of three steps—simulation of pet-coke combustion by using fire dynamics simulator (FDS) software coupled with thermal structural analysis of the burner lining and a multiphysics computation of the methane steam reforming (MSR) process taking place inside the catalyst bed. The structural analysis of the burner lining was carried out by coupling the solutions of heat conduction equation, Darcy porous media steam flow equation, and structural mechanics equation. In order to validate the gaseous temperature and carbon monoxide mole fraction obtained by FDS calculation, a comparison was carried out with the literature results. The maximal temperature obtained from the combustion simulation was about 1440 °C. The calculated temperature is similar to the temperature reported, which is also close to 1400 °C. The maximal carbon dioxide mole fraction reading was 15.0%. COMSOL multi-physics software solves simultaneously the catalyst media fluid flow, heat, and mass with chemical reaction kinetics transport equations of the methane steam reforming catalyst bed reactor. The methane conversion is about 27%. The steam and the methane decay along the catalyst bed reactor at the same slope. Similar values have been reported in the literature for MSR temperature of 510 °C. The hydrogen mass fraction was increased by 98.4%.

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“…A comparison was carried out between the experimental and numerical results reported in [17]. It was assumed that the mass flow rate of the pet-coke supply is about 3 tons/hour.…”

Section: Fds Modeling Of the Combustormentioning

confidence: 99%

“…It was assumed that the mass flow rate of the pet-coke supply is about 3 tons/hour. The temperature of the air entering the burner was 20 • C (293.15 K) [17].…”

Section: Fds Modeling Of the Combustormentioning

confidence: 99%

Multiphysics Design of Pet-Coke Burner and Hydrogen Production by Applying Methane Steam Reforming System

Davidy¹

2021

Clean Technol.

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“…10−13 However, the use of SRF in industrial units has arisen a number of operational issues, as these alternative fuels have different combustion characteristics compared with fossil fuels. 12,14,15 The high use of SRF results in the high input of chlorine and alkali metals and increased circulation of chlorine and sulfur amounts, facilitating the formation and growth of mineral particle deposits. 16−19 Mineral particle deposition is frequently observed in cement production plants and occurs typically in cyclone preheaters, calciners, and rotary kilns, thereby affecting the production efficiency and stability of operation.…”

Section: Introductionmentioning

confidence: 99%

Experimental Investigation of Mineral Particle Deposition in the Cement Production Process

et al. 2022

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This study aims to improve the understanding of the formation and prevention of deposits caused by the introduction of alternative fuels in the cement industry. Experiments were conducted with cement mineral materials in a laboratory-scale entrained flow reactor. To simulate the temperature conditions in a cement calciner, two different deposit probe systems were used: a high probe surface temperature (HPST) deposit system with a probe surface temperature range of 700–1200 °C and a low probe surface temperature (LPST) deposit system with a probe surface temperature range of 500–700 °C. The effects of fed materials (raw meal, hot meal, bypass dust), flue gas temperature (700–1200 °C), deposit probe surface temperature (550–1200 °C), gas velocity (0.9–2.7 m/s), and experimental duration (5–60 min) on the deposit formation rate were investigated. The results revealed that the concentration of KCl in the fed materials has a large influence on deposit formation. In HPST experiments with furnace temperatures ranging from 700 to 1100 °C, the bypass dust has a higher deposition rate than hot and raw meals, due to a large amount of K and Cl (>10 wt %) in the bypass dust, which forms melts and increases the stickiness between impacting particles and deposits. In LPST experiments, the presence of KCl facilitated the deposit formation rate by providing a sticky layer on the deposit probe via condensation, resulting in a higher deposition rate of bypass dust than the raw meal. An increase in gas velocity showed a negative effect on the deposit formation rate due to an increase in rebound. The present study suggests that keeping the calciner wall temperature at 900–1100 °C and a low level of KCl content would effectively reduce the deposit formation, thereby increasing the equipment life and reducing the operating cost during cement production.

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“…A widespread method to evaluate the rotary kiln flame characteristics is flame thermography with a pyrometric camera 2 . However, under some circumstances like high dust contents the applicability of the method is restricted 3 or such a system is not available. Therefore other sources of information on the flame shape can be very useful.…”

Section: Introductionmentioning

confidence: 99%

Influence of alumina ratio on reactions at the surface of alite crystals during cooling

Böhm¹,

Knöpfelmacher²

2021

Journal of Microscopy

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Microstructural features of industrial Portland cement clinker samples are presented to illustrate the influence of the clinker melt chemistry on the reactions taking place on the surfaces of alite crystals during cooling at high temperatures. While clinker melts rich in Al 2 O 3 are usually undersaturated with respect to CaO, leading to corrosion of alite crystals and formation of secondary belite, clinker melts rich in Fe 2 O 3 are oversaturated with respect to CaO. This leads to a final growth step of alite during cooling, as long as the clinker temperature is still in the stability field of alite (>1250 • C). In the first case, the microstructural features of the alite surface permits conclusions on the length of the precooling zone in the rotary kiln, which is closely connected to the flame shape. In the latter case, such conclusions cannot be drawn.

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Imaging of Flames in Cement Kilns To Study the Influence of Different Fuel Types

Cited by 16 publications

References 30 publications

Multiphysics Design of Pet-Coke Burner and Hydrogen Production by Applying Methane Steam Reforming System

Multiphysics Design of Pet-Coke Burner and Hydrogen Production by Applying Methane Steam Reforming System

Experimental Investigation of Mineral Particle Deposition in the Cement Production Process

Influence of alumina ratio on reactions at the surface of alite crystals during cooling

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