Parametric Studies of Cement Production Processes

John, John P.

doi:10.1155/2020/4289043

Cited by 23 publications

(13 citation statements)

References 35 publications

(50 reference statements)

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“…Energy consumption in the Industrial sector ranges from 30-70% of the total energy used in some selected countries as previously reported by [1]. The cement sub-sector utilizes nearly 12-15% of entire industrial energy usage [1,2] due to the high temperatures required in the kilns. Cement is a vital product used in society for constructing modern infrastructure as well as safe and comfortable buildings.…”

Section: Introductionmentioning

confidence: 75%

Energy and Economic Comparison of Different Fuels in Cement Production

Fadayini¹,

Madu²,

Oshin³

et al. 2021

Cement Industry - Optimization, Characterization and Sustainable Application

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Cement clinkerisation is the major energy-consuming process in cement manufacturing due to the high-temperature requirement. In this paper, energy data including specific energy consumption, forms, and types of energy used at different units of cement manufacturing processes were analyzed and compared for effectiveness, availability, cost, environmental, and health impact. Data from three different cement industries in Nigeria labeled as A, B, and C were used for the analysis in this study. The results of this research work established that coal is the cheapest energy source but environmental issues exonerate it from being the choice energy source. LPFO and Natural gas give better production output while minimizing pollution and health issues. When benchmarked against each other, Factory B was found to be the most energy-efficient in terms of output and cost of production. Although coal is cheaper compared to fuel oil and supposed to contribute a share of fuel used in cement industries, the industries are moving towards the use of alternative and conventional fuels to reduce environmental pollution. It is therefore recommended that deliberate effort to achieve appreciable energy-efficient levels should be the priorities of the cement industries in Nigeria.

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Section: Introductionmentioning

confidence: 75%

Energy and Economic Comparison of Different Fuels in Cement Production

Fadayini¹,

Madu²,

Oshin³

et al. 2021

Cement Industry - Optimization, Characterization and Sustainable Application

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“…This process is known as calcination and is treated in the literature as a two-step process that corresponds to endothermic reactions. The technical literature [1] reported that the first stage starts at around 80 o C and extends to a temperature in the order of 160 o C.…”

Section: Zone 3 Zone Formed By the Gypsum Bedmentioning

confidence: 99%

“…Gypsum is obtained from the chemical dehydration process of gypsum, which occurs between 80 °C and 160 °C, called calcination, and, usually, for this purpose, it uses rotary kilns [1]. Preferably, when fuels are used that, when burned, generate particulates, they use indirect burning furnaces.…”

Section: Introductionmentioning

confidence: 99%

“…It should be noted that the existing studies, even in different application areas, provide technical subsidies and also essential data that can be applied to the plaster calcination process, which is the main focus of this article. In general, heat transfer in rotary kilns was studied with a view to better uniformity in the temperature of the kiln housing [14], better chemical transformation process in plasterboard [1], optimized development of performance control [15], evaluation profiles of internal and external temperatures in steady-state [16] and simplified analysis of operations in transient regimes [17]. Therefore, this work intends to fill the absence of studies involved in the heat transfer processes in rotary kilns for calcining plaster in a transient regime, considering all three spatial positions, to have a real projection of the oven temperature profile, also contributing to its dimensioning and control process regarding the use of the conditions of non-homogenization and homogenization of the bed in the production of calcination plaster.…”

Section: Introductionmentioning

confidence: 99%

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Dynamic modeling of the heat transfer process in rotary kilns with indirect oil heating: Parametric analysis of gypsum calcination case

et al. 2022

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This work proposes a mathematical modeling and numerical simulation of a gypsum rotary kiln with indirect oil heating in a three-dimensional transient regime. The mathematical model was based on Fourier's Law as a constitutive relationship and the principle of energy conservation, applied to a control volume in cylindrical coordinates. Furthermore, a bed homogenization model was used to represent the most realistic condition of the physical phenomenon since some rotary kilns have internal fins that aim at homogenizing the gypsum temperature during calcination. This work intends to fill the gap found in heat transfer processes on rotary kilns in transient regime considering three dimensions positions, to have an accurate projection of the temperature profile of the kiln and also, given by the numerical model, the possibility of a tool that can be used to the optimization of the control system of rotary kilns considering the actual demand of the material in production, leading to the best energy performance of the equipment's activation source, as well as reaching the temperatures and processing time of the product. The numerical simulation results revealed reasonable agreement with the experimentally determined calcination process in rotary kilns. Furthermore, a parametric analysis of the influence of the mixture on the temperature fields and the calcination time was carried out to verify the energetic balance of the rotary kiln.

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“…The concrete sector faces many problems to meet the high demand for OPC due to restricted reserves of limestone, slow production growth, and increasing carbon taxes. OPC is considered one of the predominant building materials investigated in the construction industry and reported as 4.2 billion tons (short scale) production in 2019 [ 3 ]. During the manufacturing of OPC, numerous gases affect the environment in series of ways [ 4 ].…”

Section: Introductionmentioning

confidence: 99%

Prediction of Geopolymer Concrete Compressive Strength Using Novel Machine Learning Algorithms

Ahmad

Chaiyasarn

et al. 2021

Polymers

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The innovation of geopolymer concrete (GPC) plays a vital role not only in reducing the environmental threat but also as an exceptional material for sustainable development. The application of supervised machine learning (ML) algorithms to forecast the mechanical properties of concrete also has a significant role in developing the innovative environment in the field of civil engineering. This study was based on the use of the artificial neural network (ANN), boosting, and AdaBoost ML approaches, based on the python coding to predict the compressive strength (CS) of high calcium fly-ash-based GPC. The performance comparison of both the employed techniques in terms of prediction reveals that the ensemble ML approaches, AdaBoost, and boosting were more effective than the individual ML technique (ANN). The boosting indicates the highest value of R2 equals 0.96, and AdaBoost gives 0.93, while the ANN model was less accurate, indicating the coefficient of determination value equals 0.87. The lesser values of the errors, MAE, MSE, and RMSE of the boosting technique give 1.69 MPa, 4.16 MPa, and 2.04 MPa, respectively, indicating the high accuracy of the boosting algorithm. However, the statistical check of the errors (MAE, MSE, RMSE) and k-fold cross-validation method confirms the high precision of the boosting technique. In addition, the sensitivity analysis was also introduced to evaluate the contribution level of the input parameters towards the prediction of CS of GPC. The better accuracy can be achieved by incorporating other ensemble ML techniques such as AdaBoost, bagging, and gradient boosting.

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Parametric Studies of Cement Production Processes

Cited by 23 publications

References 35 publications

Energy and Economic Comparison of Different Fuels in Cement Production

Energy and Economic Comparison of Different Fuels in Cement Production

Dynamic modeling of the heat transfer process in rotary kilns with indirect oil heating: Parametric analysis of gypsum calcination case

Prediction of Geopolymer Concrete Compressive Strength Using Novel Machine Learning Algorithms

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