Numerical Modeling of Rotary Kilns
Miguel Romero (COSSE student, double degree with TU Berlin)

Supervisor: Domenico Lahaye

Site of the project:
Theemsweg 30
3197 KM Botlek Rotterdam

Supervisor Almatis: Rudy Sadi

start of the project: December 2011

The Master project has been finished in September 2012 by the completion of the Masters Thesis and a final presentation has been given.

For working address etc. we refer to our alumnipage.

Summary of the master project:

A numerical combustion model for the heat and gas flow in the rotating oven was build and validated using temperate measurements in the oven's isolating surface. This model revealed that under in the standard production configuration of the oven, the zone in the kiln where rings are typically formed coincides with areas maximal radiative heat transfer. This key insight allowed us to alter the operating conditions and to avoid ring formation. The new configuration was implemented at the plant in Rotterdam at the end of August 2011 and our kiln has not been affected by ring formation ever since. This new configuration also proved beneficial for the overall quality of the produced cement and provides insight in the production of toxic NOX gasses.

In a subsequent stage of the project, we aim at further optimizing the production process by gaining a better understanding of the phase changes and chemical reactions that the raw material undergoes. This requires extending our numerical model with either particle or porous media modeling capabilities. We are currently investigating the advantages and disadvantages of both approaches.

The long term goal of project is to formulate guidelines for the design of a completely new rotary kiln to be installed at the plant in Rotterdam. Project progress documents and further details are given here.

A rotary kiln

Contact information: Kees Vuik

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