Swirled Jet Flame Simulation and Flow Visualization Inside Rotary Kiln—CFD with PDF Approach

Elattar, H.F.; Specht, Eckehard; Fouda, A.; Rubaiee, Saeed; Al‐Zahrani, Ahmed; Nada, S.A.

doi:10.3390/pr8020159

Cited by 10 publications

(6 citation statements)

References 17 publications

(27 reference statements)

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“…Rotary kilns are long cylindrical furnaces used for the production of cement and other material processing applications [1]. These furnaces have been studied extensively both numerically [2][3][4] and experimentally [5,6].…”

Section: Introductionmentioning

confidence: 99%

Turbulent Non-Stationary Reactive Flow in a Cement Kiln

Talice

Juretić²,

Lahaye

2022

Fluids

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The reduction of emissions from large industrial furnaces critically relies on insights gained from numerical models of turbulent non-premixed combustion. In the article Mitigating Thermal NOx by Changing the Secondary Air Injection Channel: A Case Study in the Cement Industry, the authors present the use of the open-source OpenFoam software environment for the modeling of the combustion of Dutch natural gas in a cement kiln operated by our industrial partner. In this paper, various model enhancements are discussed. The steady-state Reynolds-Averaged Navier-Stokes formulation is replaced by an unsteady variant to capture the time variation of the averaged quantities. The infinitely fast eddy-dissipation combustion model is exchanged with the eddy-dissipation concept for combustion to account for the finite-rate chemistry of the combustion reactions. The injection of the gaseous fuel through the nozzles occurs at such a high velocity that a comprehensive flow formulation is required. Unlike in Mitigating Thermal NOx by Changing the Secondary Air Injection Channel: A Case Study in the Cement Industry, wave transmissive boundary conditions are imposed to avoid spurious reflections from the outlet patch. These model enhancements result in stable convergence of the time-stepping iteration. This in turn increases the resolution of the flow, combustion, and radiative heat transfer in the kiln. This resolution allows for a more accurate assessment of the thermal NO-formation in the kiln. Results of a test case of academic interest are presented. In this test case, the combustion air is injected at a low-mass flow rate. Numerical results show that the flow in the vicinity of the hot end of the kiln is unsteady. A vortex intermittently transports a fraction of methane into the air stream and a spurious reaction front is formed. This front causes a transient peak in the top wall temperature. The simulated combustion process is fuel-rich. All the oxygen is depleted after traveling a few diameters into the kiln. The thermal nitric oxide is formed near the burner and diluted before reaching the outlet. At the outlet, the simulated thermal NO concentration is equal to 1 ppm. The model is shown to be sufficiently mature to capture a more realistic mass inflow rate in the next stage of the work.

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Section: Introductionmentioning

confidence: 99%

Turbulent Non-Stationary Reactive Flow in a Cement Kiln

Talice

Juretić²,

Lahaye

2022

Fluids

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“…The continuity equation [25] is given as where r 1) and u refer to the density and velocity, respectively. The source term S m is the mass change due to the reactions.…”

Section: Model Developmentmentioning

confidence: 99%

“…Radiation is an important mode of heat transfer in the rotary kiln. The P-1 radiation model is intensively used due to its simplicity [25]. The P-1 model considers the effect of absorption and of emitting and scattering media, which is based on the expansion of the radiation intensity into an orthogonal series of spherical harmonics.…”

Section: Model Developmentmentioning

confidence: 99%

Modeling a Rotary Kiln Retrofitted by Energy Recovery for CO₂ Capture

Wang

Zhang

et al. 2023

Chem Eng & Technol

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Calcium looping has been used for CO2 capture. High‐temperature calcination is needed to decompose CaCO3. To reduce the energy consumption of CaCO3 decomposition in calcium looping, a CaCO3 decomposition system integrating a rotary kiln, waste heat recovery by a single‐atom fluid, and the CaO carbonization process is proposed. The waste heat recovery produces the electric field to intensify CO2 capture. A computational fluid dynamics model is established to study the effects of various parameters on the performance of the rotary kiln. It is found that the electric field enhances the mass transfer and CO2 capture. The system temperature is increased, resulting in significantly enhanced CO2 capture with increased feeding temperature. This provides an alternative way for CO2 capture.

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“…Apart from these, issues related to combustion instability are an area of interest in the literature. In this area, the static instability of the plasma arcs [8] and the combustion imbalances in the annulus burners of rotary kiln [9] are studied experimentally for swirl flame. In the case of thermo-acoustic instability [10,11], numerical and experimental methods [12][13][14], experimental flame transfer functions [15,16], large eddy simulations [17,18], fast random particle method [19] and nonlinear network models [20,21] are used.…”

Section: Introductionmentioning

confidence: 99%

Performance Identification of a Steam Boiler Burner via Acoustic Analysis

2022

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Almost all systems generate acoustic signals when operating or when a process is being performed. These signals contain certain data related to the operating performance of systems. In this study, acoustic data were used to study the performance and to identify the optimum operating points of natural gas burners that are used in steam boilers. The sound recordings of burners obtained under different operating conditions were examined with acoustic analysis methods. The impact of various operating parameters on acoustic values was determined using time series analysis, frequency spectrum data and then power spectral density values. When the excess air coefficient and emission and efficiency values of boilers were compared with the acoustic data, it was determined that the Yule–Walker algorithm contained distinct and explanatory values. The steam boiler and the natural gas burner within were considered a system for the analysis. Measurement results showed that operating parameters and acoustic analysis results were correlated. Moreover, the results were confirmed with the emission measurement results. Finally, it was deduced that the acoustic values can be used for obtaining the optimum operating points in similar systems where inlet and outlet parameters cannot be measured, and the related principles were revealed.

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Swirled Jet Flame Simulation and Flow Visualization Inside Rotary Kiln—CFD with PDF Approach

Cited by 10 publications

References 17 publications

Turbulent Non-Stationary Reactive Flow in a Cement Kiln

Turbulent Non-Stationary Reactive Flow in a Cement Kiln

Modeling a Rotary Kiln Retrofitted by Energy Recovery for CO₂ Capture

Performance Identification of a Steam Boiler Burner via Acoustic Analysis

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Swirled Jet Flame Simulation and Flow Visualization Inside Rotary Kiln—CFD with PDF Approach

Cited by 10 publications

References 17 publications

Turbulent Non-Stationary Reactive Flow in a Cement Kiln

Turbulent Non-Stationary Reactive Flow in a Cement Kiln

Modeling a Rotary Kiln Retrofitted by Energy Recovery for CO2 Capture

Performance Identification of a Steam Boiler Burner via Acoustic Analysis

Contact Info

Product

Resources

About

Modeling a Rotary Kiln Retrofitted by Energy Recovery for CO₂ Capture