Validation of a one-dimensional kiln heat transfer model against a pilot kiln

Marcus Nigel Campbell Bannerman, T. Hanein, Fredrik P. Glasser

Research output: Chapter in Book/Report/Conference proceedingConference contribution

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Abstract

The thermal energy required for cement manufacture is primarily utilised within the rotary kiln where clinkerization occurs. To optimise this key stage in cement production, accurate kiln process models are required. In this work, a simple yet powerful one-dimensional kiln model is presented. The thermal aspects of the presented kiln model have previously been partially validated [1,2]; however, new data from trials in a 7-meter pilot kiln are used to validate the thermal model at scale in the development of a novel C$A cement formulation. This process is challenging as it requires careful atmospheric and temperature control. A thermodynamic database is used to calculate the thermal properties of the gas and solid. Gibbs free energy minimisation is used to predict the stable phases at each stage within the process. The developed model is fully predictive and only the kiln configuration, fuel, excess air, and solid inlet composition are required as inputs. Even without an accurate flame model, the model presented accurately tracks the external and produced solids temperatures. The model is then used to successfully diagnose production issues and demonstrates its value in redeveloping the cement process.
Original languageEnglish
Title of host publicationProceedings of the 37th Cement and Concrete Science Conference
Publication statusPublished - 11 Sep 2017
Event37th Cement & Concrete Science Conference - UCL, London, United Kingdom
Duration: 11 Sep 201712 Sep 2017
http://www.ucl.ac.uk/aim/conference-info/37ccs

Conference

Conference37th Cement & Concrete Science Conference
Abbreviated title37th CCSC
CountryUnited Kingdom
CityLondon
Period11/09/1712/09/17
Internet address

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Kilns
Heat transfer
Cements
Cement manufacture
Rotary kilns
Gibbs free energy
Thermal energy
Temperature control
Thermodynamic properties
Thermodynamics
Air
Chemical analysis
Gases

Cite this

Campbell Bannerman, M. N., Hanein, T., & Glasser, F. P. (2017). Validation of a one-dimensional kiln heat transfer model against a pilot kiln. In Proceedings of the 37th Cement and Concrete Science Conference [058]

Validation of a one-dimensional kiln heat transfer model against a pilot kiln. / Campbell Bannerman, Marcus Nigel; Hanein, T.; Glasser, Fredrik P.

Proceedings of the 37th Cement and Concrete Science Conference. 2017. 058.

Research output: Chapter in Book/Report/Conference proceedingConference contribution

Campbell Bannerman, MN, Hanein, T & Glasser, FP 2017, Validation of a one-dimensional kiln heat transfer model against a pilot kiln. in Proceedings of the 37th Cement and Concrete Science Conference., 058, 37th Cement & Concrete Science Conference, London, United Kingdom, 11/09/17.
Campbell Bannerman MN, Hanein T, Glasser FP. Validation of a one-dimensional kiln heat transfer model against a pilot kiln. In Proceedings of the 37th Cement and Concrete Science Conference. 2017. 058
Campbell Bannerman, Marcus Nigel ; Hanein, T. ; Glasser, Fredrik P. / Validation of a one-dimensional kiln heat transfer model against a pilot kiln. Proceedings of the 37th Cement and Concrete Science Conference. 2017.
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N2 - The thermal energy required for cement manufacture is primarily utilised within the rotary kiln where clinkerization occurs. To optimise this key stage in cement production, accurate kiln process models are required. In this work, a simple yet powerful one-dimensional kiln model is presented. The thermal aspects of the presented kiln model have previously been partially validated [1,2]; however, new data from trials in a 7-meter pilot kiln are used to validate the thermal model at scale in the development of a novel C$A cement formulation. This process is challenging as it requires careful atmospheric and temperature control. A thermodynamic database is used to calculate the thermal properties of the gas and solid. Gibbs free energy minimisation is used to predict the stable phases at each stage within the process. The developed model is fully predictive and only the kiln configuration, fuel, excess air, and solid inlet composition are required as inputs. Even without an accurate flame model, the model presented accurately tracks the external and produced solids temperatures. The model is then used to successfully diagnose production issues and demonstrates its value in redeveloping the cement process.

AB - The thermal energy required for cement manufacture is primarily utilised within the rotary kiln where clinkerization occurs. To optimise this key stage in cement production, accurate kiln process models are required. In this work, a simple yet powerful one-dimensional kiln model is presented. The thermal aspects of the presented kiln model have previously been partially validated [1,2]; however, new data from trials in a 7-meter pilot kiln are used to validate the thermal model at scale in the development of a novel C$A cement formulation. This process is challenging as it requires careful atmospheric and temperature control. A thermodynamic database is used to calculate the thermal properties of the gas and solid. Gibbs free energy minimisation is used to predict the stable phases at each stage within the process. The developed model is fully predictive and only the kiln configuration, fuel, excess air, and solid inlet composition are required as inputs. Even without an accurate flame model, the model presented accurately tracks the external and produced solids temperatures. The model is then used to successfully diagnose production issues and demonstrates its value in redeveloping the cement process.

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