Mathematic simulation of heat transfer and operating optimization in alumina rotary kiln

Yi, Zhengming; Xiao, Hui; Song, Jialin; Guang-bai, MA; Zhou, Jiemin

doi:10.1007/s11771-013-1796-0

Cited by 9 publications

(6 citation statements)

References 17 publications

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“…Although higher temperatures can be achieved with less oxygen and coal flow in an oxygen-rich combustion state, the amount of flue gas generated will also decrease. Convective and radiative heat transfer are the methods used in the rotary kiln to transmit heat from the flue gas to the raw material [40,41]. Insufficient flue gas carries less enthalpy, which has a detrimental effect on clinker production.…”

Section: Effect Of O 2 /Co 2 Atmosphere On the Systemmentioning

confidence: 99%

Coupled Oxygen-Enriched Combustion in Cement Industry CO2 Capture System: Process Modeling and Exergy Analysis

Wang,

Shi

2024

Processes

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The cement industry is regarded as one of the primary producers of world carbon emissions; hence, lowering its carbon emissions is vital for fostering the development of a low-carbon economy. Carbon capture, utilization, and storage (CCUS) technologies play significant roles in sectors dominated by fossil energy. This study aimed to address issues such as high exhaust gas volume, low CO2 concentration, high pollutant content, and difficulty in carbon capture during cement production by combining traditional cement production processes with cryogenic air separation technology and CO2 purification and compression technology. Aspen Plus® was used to create the production model in its entirety, and a sensitivity analysis was conducted on pertinent production parameters. The findings demonstrate that linking the oxygen-enriched combustion process with the cement manufacturing process may decrease the exhaust gas flow by 54.62%, raise the CO2 mass fraction to 94.83%, cut coal usage by 30%, and considerably enhance energy utilization efficiency. An exergy analysis showed that the exergy efficiency of the complete kiln system was risen by 17.56% compared to typical manufacturing procedures. However, the cryogenic air separation system had a relatively low exergy efficiency in the subsidiary subsystems, while the clinker cooling system and flue gas circulation system suffered significant exergy efficiency losses. The rotary kiln system, which is the main source of the exergy losses, also had low exergy efficiency in the traditional production process.

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Section: Effect Of O 2 /Co 2 Atmosphere On the Systemmentioning

confidence: 99%

Coupled Oxygen-Enriched Combustion in Cement Industry CO2 Capture System: Process Modeling and Exergy Analysis

Wang,

Shi

2024

Processes

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“…But the measurement of this maximum temperature is extremely difficult due to the high combustion temperature (up to 1500 o C), heavy dusty environment, and large temperature fluctuation in the rotary kiln. Hence, only a few successful industrial applications of the kiln process control are reported on the open literatures [3,5,6].…”

Section: Introductionmentioning

confidence: 99%

A Mathematical Model for Control and Optimization of Industrial Rotary Alumina Kiln Process

Peng

Mayorga

2020

Wseas Transactions on Systems

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Temperature is a crucial factor for clinker quality in the Industrial Rotary Alumina Kiln Process(IRAKP). However, the characteristic of the high temperature, complex kinetics, multivariable, non-linearreaction kinetics, long-time delayed reaction and various raw materials make it difficult to accurately controlthe temperature in IRAKP through an existing control technology. This paper proposes a dual-responsesurface-based process control (DRSPC) system for the IRAKP in a novel manner. In the DRSPC, instead ofthe more precise and complicated nonlinear equations, the dual response surface models are fitted to describethe reaction kinetics in the IRAKP and track their standard deviations for stable operation purpose. Because asimultaneous consideration of multiple control targets could address the problem of unstable operation inkilns; the objectives of the DRSPC study are designed as optimizing product quality, minimizing energyconsumption and temperature fluctuations. Therefore, the proposed DRSPC goals are to achieve a uniformquality clinker, a high fuel efficiency, and a long refractory life. A weight optimization approach is used tohandle these multiple objective functions. The proposed DRSPC can estimate the working conditions of a kilnand predict some optimal manipulated variables to the control system in each control time interval forimproving the efficiency of IRAKP. The DRSPC is applied to a real IRAKP for demonstrating itsapplicability and advantages.

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“…These control methods include fuzzy control (Guo et al, 2010), neural networks (Yang and Ma, 2011), expert systems (Wang et al, 2012) and hybrid intelligent control strategies (Stadler et al, 2011; Zhang and Gao, 2013; Zhang et al, 2013), and so forth. Furthermore, the distributed control system applied in current rotary kiln production of alumina can only fulfill regular monitoring and certain simple control conditions, and the flame information is not fully used (Yi et al, 2013b; Zhang et al, 2008). Because calcination zone temperature of the rotary kiln is a complex control system, these control methods also have some deficiencies (Tian et al, 2017).…”

Section: Introductionmentioning

confidence: 99%

An alumina rotary kiln monitoring system based on flame image processing

Lin

Jiang

2018

Transactions of the Institute of Measurement and Control

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In order to monitor the combustion condition and improve the product material quality, a digital image acquisition and processing method is adopted in alumina-sintering process. Two digital properties of flame grade and material grade are obtained by image data analyzing and smooth filtering, which provide reliable reference for operational optimization and automatic control of rotary kilns. This image acquisition system improves the operation of kiln effectively and reduces the working intensity and the manufacture cost.

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Mathematic simulation of heat transfer and operating optimization in alumina rotary kiln

Cited by 9 publications

References 17 publications

Coupled Oxygen-Enriched Combustion in Cement Industry CO2 Capture System: Process Modeling and Exergy Analysis

Coupled Oxygen-Enriched Combustion in Cement Industry CO2 Capture System: Process Modeling and Exergy Analysis

A Mathematical Model for Control and Optimization of Industrial Rotary Alumina Kiln Process

An alumina rotary kiln monitoring system based on flame image processing

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