Investigation of erosion in an industrial cyclone preheater by CFD simulations

Mirzaei, Mahmood; Clausen, Sønnik; Wu, Hao; Nakhaei, Mohammadhadi; Zhou, Huan; Jønck, Kasper Martin; Jensen, Peter Arendt; Lin, Weigang

doi:10.1016/j.powtec.2023.118424

Cited by 3 publications

(2 citation statements)

References 16 publications

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“…The high turbulence within the five-stage cyclone preheater facilitates complete mixing of the particles, disruption of agglomerates, and repeated mixing and separation of the raw material in multiple stages [ 24 , 25 ]. This process results in a more thorough homogenization of the raw meal.…”

Section: Resultsmentioning

confidence: 99%

Evaluation and Analysis of Cement Raw Meal Homogenization Characteristics Based on Simulated Equipment Models

Cao,

Zhou

2024

Materials

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In recent years, the variability in the composition of cement raw materials has increasingly impacted the quality of cement products. However, there has been relatively little research on the homogenization effects of equipment in the cement production process. Existing studies mainly focus on the primary functions of equipment, such as the grinding efficiency of ball mills, the thermal decomposition in cyclone preheaters, and the thermal decomposition in rotary kilns. This study selected four typical pieces of equipment with significant homogenization functions for an in-depth investigation: ball mills, pneumatic homogenizing silos, cyclone preheaters, and rotary kilns. To assess the homogenization efficacy of each apparatus, scaled-down models of these devices were constructed and subjected to simulated experiments. To improve experimental efficiency and realistically simulate actual production conditions in a laboratory setting, this study used the uniformity of the electrical capacitance of mixed powders instead of compositional uniformity to analyze homogenization effects. The test material in the experiment consisted of a mixture of raw meal from a cement factory with a high dielectric constant and Fe3O4 powder. The parallel plate capacitance method was employed to ascertain the capacitance value of the mixed powder prior to and subsequent to treatment by each equipment model. The fluctuation of the input and output curves was analyzed, and the standard deviation (S), coefficient of variation (R), and homogenization multiplier (H) were calculated in order to evaluate the homogenization effect of each equipment model on the raw meal. The findings of the study indicated that the pneumatic homogenizer exhibited an exemplary homogenization effect, followed by the ball mill. For the ball mill, a higher proportion of small balls in the gradation can significantly enhance the homogenization effect without considering the grinding efficiency. The five-stage cyclone preheater also has a better homogenization effect, while the rotary kiln has a less significant homogenization effect on raw meal. Finally, the raw meal processed by each equipment model was used for clinker calcination and the preparation of cement mortar samples. After curing for three days, the compressive and flexural strengths of the samples were tested, thereby indirectly verifying the homogenization effect of each equipment model on the raw meal. This study helps to understand the homogenization process of raw materials by equipment in cement production and provides certain reference and data support for equipment selection, operation optimization, and quality control in the cement production process.

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Section: Resultsmentioning

confidence: 99%

Evaluation and Analysis of Cement Raw Meal Homogenization Characteristics Based on Simulated Equipment Models

Cao,

Zhou

2024

Materials

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“…Although many researchers have investigated the primary mechanism of erosive wear, they reported that cutting and pitting are the paramount mechanisms of erosion [15,16]. Predicting pipeline erosive wear can help researchers in the hydrocarbon and mineral processing industries to understand the primary causes of therefore prevent erosion damage; several studies have been conducted regarding erosive wear evaluations of different flow devices such as valves [17][18][19][20], pumps [21][22][23][24], turbines [25][26][27][28] and cyclone separators [29][30][31].…”

Section: Introductionmentioning

confidence: 99%

Erosion–Corrosion Failure Analysis of a Mild Steel Nozzle Pipe in Water–Sand Flow

Khan,

Wieczorowski,

Damjanović

et al. 2023

Materials

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Several leaks appeared in a mild steel (MS) pipe jet nozzle installed in a direct impact test rig after a few months of operation in erosive flow at the Centre for Erosion–Corrosion Research. The locations of perforation leaks were primarily upstream, but severe wall thinning was also noticed adjacent to the exit section. In this paper, a failure analysis was carried out on the leaking of a pipe jet nozzle, and the results are discussed in detail. The investigation carried out includes visual observation, scanning electron microscopy, 3D scanning, energy-dispersive spectroscopy, and laser profilometry measurements. In addition, numerical simulations based on computational fluid dynamics (CFD) and the discrete phase model (DPM) were conducted to investigate the root cause of the failure of leaks in the pipe jet nozzle. Further CFD-DPM simulations were performed on three different pipe jet designs for liquid–solid flow conditions, and were compared to find an alternative design to prevent the failure of the pipe jet nozzles. It was found that the increase in turbulence along with multiple impacts of particles on the wall generate leaks and cracks in the pipe jet nozzle. Moreover, the CFD-DPM showed a five-fold reduction in the maximum erosion rate; this was observed in the replacement of failed pipes with the proposed alternative nozzle pipe design featuring a chamfer reducer section. The CFD-DPM analysis of all geometric configurations showed that alteration of reducer section design has the greatest impact on erosive wear mitigation.

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Evaluation of erosion of AISI 1045 carbon steel due to non-cohesive microparticles

Khan,

Wieczorowski,

Mourad

et al. 2024

Journal of Materials Research and Technology

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Investigation of erosion in an industrial cyclone preheater by CFD simulations

Cited by 3 publications

References 16 publications

Evaluation and Analysis of Cement Raw Meal Homogenization Characteristics Based on Simulated Equipment Models

Evaluation and Analysis of Cement Raw Meal Homogenization Characteristics Based on Simulated Equipment Models

Erosion–Corrosion Failure Analysis of a Mild Steel Nozzle Pipe in Water–Sand Flow

Evaluation of erosion of AISI 1045 carbon steel due to non-cohesive microparticles

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