Computer Simulation of Heat Transfer in Alumina and Cement Rotary Kilns

2021 ◽  
pp. 1-57
Author(s):  
Atinder Pal Singh ◽  
P.S. Ghoshdastidar
Keyword(s):  
Heat Transfer ◽  
Computer Simulation ◽  
Rotary Kiln ◽  
Cement Kiln ◽  
Gas Temperature ◽  
Contact Heat ◽  
Dry Process ◽  
Radiation Exchange ◽  
Covered Wall ◽  
Rotary Kilns

Abstract The paper presents computer simulation of heat transfer in alumina and cement rotary kilns. The model incorporates radiation exchange among solids, wall and gas, convective heat transfer from the gas to the wall and the solids, contact heat transfer between the covered wall and the solids, and heat loss to the surroundings as well as chemical reactions. The mass and energy balances of gas and solids have been performed in each axial segment of the kilns. The energy equation for the wall is solved numerically by the finite-difference method. The dust entrainment in the gas is also accounted for. The solution marches from the solids inlet to the solids outlet. The kiln length predicted by the present model of the alumina kiln is 77.5 m as compared to 80 m of the actual kiln of Manitius et al. (1974, Manitius, A., Kurcyusz, E., and Kawecki, W., “Mathematical Model of an Aluminium Oxide Rotary Kiln,” Ind. Eng. Chem. Process Des. Dev., 13 (2), pp. 132-142). In the second part, heat transfer in a dry process cement rotary kiln is modelled. The melting of the solids and coating formation on the inner wall of the kiln are also taken into account. A detailed parametric study lent a good physical insight into axial solids and gas temperature distributions, and axial variation of chemical composition of the products in both the kilns. The effect of kiln rotational speed on the cement kiln wall temperature distribution is also reported.

Computer Simulation of Drying of Food Products With Superheated Steam in a Rotary Kiln

2010 ◽  
Author(s):  
Koustubh Sinhal ◽  
P. S. Ghoshdastidar ◽  
Bhaskar Dasgupta
Keyword(s):  
Heat Transfer ◽  
Computer Simulation ◽  
Flow Rate ◽  
Rotary Kiln ◽  
Rotational Speed ◽  
Gas Flow ◽  
Superheated Steam ◽  
Gas Temperature ◽  
Gas Flow Rate ◽  
Refractory Wall

The present work reports a computer simulation study of heat transfer in a rotary kiln used for drying and preheating food products such as fruits and vegetables with superheated steam at 1 bar. The heat transfer model includes radiation exchange among the superheated steam, refractory wall and the solid surface, conduction in the refractory wall, and the mass and energy balances of the steam and solids. Finite-difference techniques are used, and the steady state thermal conditions are assumed. The false transient approach is used to solve the wall conduction equation. The solution is initiated at the inlet of the kiln, and proceeds to the exit. The output data consist of distributions of the refractory wall temperature, solid temperature, steam temperature, and the total kiln length. The inlet of the kiln is the outlet of the gas (superheated steam), since the gas flow is countercurrent to the solid. Thus, for a fixed solid and gas temperature at the kiln inlet, the program predicts the inlet temperature of the gas (i.e. at the kiln exit) in order to achieve the specified exit temperature. In the absence of experimental results for food drying in a rotary kiln, the present model has been satisfactorily validated against numerical results of Sass [1] for drying of wet iron ore in a rotary kiln. The results are presented for drying of apple and carrot pieces. A detailed parametric study indicates that the influence of controlling parameters such as percent water content (with respect to dry solids), solids flow rate, gas flow rate, kiln inclination angle and the rotational speed of the kiln on the axial solids and gas temperature profiles and the total predicted kiln length is appreciable. The study reveals that a good design of a rotary kiln requires medium gas flow rate, small angle of inclination and low rotational speed of the kiln.

Analysis of Local Heat Transfer in Direct Fired Rotary Kilns

2010 ◽  
Author(s):  
Fabian Herz ◽  
Yogesh Sonavane ◽  
Eckehard Specht
Keyword(s):  
Heat Transfer ◽  
Rotary Kiln ◽  
Local Heat Transfer ◽  
Local Heat ◽  
Internal Diameter ◽  
Transfer Coefficients ◽  
Contact Heat ◽  
Contact Heat Transfer ◽  
Bed Temperature ◽  
Rotary Kilns

Heat transfer in the rotary kiln is a complex phenomenon due to the different modes of heat transfer. In the first part of this study, the local heat transfer coefficients are analysed theoretically, to describe the heat transfer mechanisms in the cross section of the rotary kiln. Furthermore, the axial solid motion along the length of the kiln is considered in the local surfaces which exchanges the heat. A pilot plant drum of length 0.45 m and internal diameter of 0.6 m has been designed and fabricated to measure the contact heat transfer coefficient from the kiln wall to the covered solid bed. The cylinder is heated continuously by means of three electrical heaters fixed externally around the cylinder at various positions. K-type thermocouples have been used to measure the wall and solid bed temperature along the circumferential and the radial direction. Experiments are performed with various materials such as Quartz sand and Copper pellets of different size, shape and thermal conductivity. The effect of the material properties, the rotational speed (1–6 rpm) and the filling degree (10–20%) on the contact heat transfer have been studied thoroughly.

Computer Simulation of Drying of Food Products With Superheated Steam in a Rotary Kiln

2012 ◽  
Vol 4 (1) ◽  
Author(s):  
Koustubh Sinhal ◽  
P. S. Ghoshdastidar ◽  
Bhaskar Dasgupta
Keyword(s):  
Heat Transfer ◽  
Computer Simulation ◽  
Flow Rate ◽  
Rotary Kiln ◽  
Gas Flow ◽  
Superheated Steam ◽  
Food Products ◽  
Gas Temperature ◽  
Refractory Wall ◽  
Solid Temperature

The present work reports a computer simulation study of heat transfer in a rotary kiln used for drying and preheating food products such as fruits and vegetables with superheated steam at 1 bar. The heat transfer model includes radiation exchange among the superheated steam, refractory wall and the solid surface, conduction in the refractory wall, and the mass and energy balances of the steam and solids. The gas convection is also considered. Finite-difference techniques are used, and the steady state thermal conditions are assumed. The false transient approach is used to solve the wall conduction equation. The solution is initiated at the inlet of the kiln and proceeds to the exit. The output data consist of distributions of the refractory wall temperature, solid temperature, steam temperature, and the total kiln length. The inlet of the kiln is the outlet of the gas (superheated steam), since the gas flow is countercurrent to the solid. Thus, for a fixed solid and gas temperature at the kiln inlet, the program predicts the inlet temperature of the gas (i.e., at the kiln exit) in order to achieve the specified exit temperature of the gas. In the absence of experimental results for food drying in a rotary kiln, the present model has been satisfactorily validated against numerical results of Sass (1967, “Simulation of the Heat-Transfer Phenomena in a Rotary Kiln,” Ind. Eng. Chem. Process Des. Dev., 6(4), pp. 532–535) and limited measured gas temperature as reported by Sass (1967, “Simulation of the Heat-Transfer Phenomena in a Rotary Kiln,” Ind. Eng. Chem. Process Des. Dev., 6(4), pp. 532–535) for drying of wet iron ore in a rotary kiln. The results are presented for drying of apple and carrot pieces. A detailed parametric study indicates that the influence of controlling parameters such as percent water content (with respect to dry solids), solids flow rate, gas flow rate, kiln inclination angle, and the rotational speed of the kiln on the axial solids and gas temperature profiles and the total predicted kiln length is appreciable. The effects of inlet solid temperature and exit gas temperature on the predicted kiln length for carrot drying are also shown in this paper.

Particle Scale Heat Transfer Analysis in Rotary Kiln

2012 ◽  
Author(s):  
Amit Ravindra Amritkar ◽  
Danesh Tafti ◽  
Surya Deb
Keyword(s):  
Heat Transfer ◽  
Rotary Kiln ◽  
Granular Media ◽  
Particle Surface ◽  
Convection Heat Transfer ◽  
Heat Transfer Analysis ◽  
Convection Heat ◽  
Bed Temperature ◽  
Rotary Kilns ◽  
Pass Through

Rotary furnaces have multiple applications including calcination, pyrolysis, carburization, drying, etc. Heat transfer through granular media in rotary kilns is a complex phenomenon and plays an important role in the thermal efficiency of rotary furnaces. Thorough mixing of particles in a rotary kiln determines the bed temperature uniformity. Hence it is essential to understand the particle scale heat transfer modes through which the granular media temperature changes. In this study, numerical simulations are performed using coupled Discrete Element Method (DEM) and Computational Fluid Dynamics (CFD) to analyze heat transfer in a non-reacting rotary kiln. The microscopic models of particle-particle, particle-fluid, particle-surface and fluid-surface heat transfer are used in the analysis. The heat transfer simulations are validated against experimental data. The effect of particle cascading on the bed temperature is measured and contributions from various modes of particle scale heat transfer mechanisms are reported. Particles are heated near the rotary kiln walls by convection heat transfer as they pass through the thermal boundary layer of the heated fluid. These particles are transported to the center of the kiln where they transfer heat to the cooler particles in the core of the kiln and back to the cooler fluid at the center of the kiln. It is found that 90% of the heat transferred to particles from the kiln walls is a result of convection heat transfer, whereas only 10% of the total heat transfer is due to conduction from the kiln walls.

COMPUTER SIMULATION OF HEAT TRANSFER DURING DRYING AND PREHEATING OF WET IRON ORE IN A ROTARY KILN

2002 ◽  
Vol 20 (1) ◽  
pp. 19-35 ◽  
Author(s):  
P. S. Ghoshdastidar ◽  
G. Bhargava ◽  
R. P. Chhabra
Keyword(s):  
Heat Transfer ◽  
Computer Simulation ◽  
Rotary Kiln ◽  
Iron Ore

Heat Transfer in the Non-reacting Zone of a Cement Rotary Kiln

1996 ◽  
Vol 118 (1) ◽  
pp. 169-172 ◽  
Author(s):  
P. S. Ghoshdastidar ◽  
V. K. Anandan Unni
Keyword(s):  
Heat Transfer ◽  
Flow Rate ◽  
Rotary Kiln ◽  
Gas Flow ◽  
Transfer Model ◽  
Temperature Profiles ◽  
Gas Temperature ◽  
Gas Flow Rate ◽  
Steady State Heat ◽  
Steady State Heat Transfer

This paper presents a steady-state heat transfer model for a rotary kiln used for drying and preheating of wet solids with application to the non-reacting zone of a cement rotary kiln. A detailed parametric study indicates that the influence of the controlling parameters such as percent water content (with respect to dry solids), solids flow rate, gas flow rate, kiln inclination angle and the rotational speed of the kiln on the axial solids and gas temperature profiles and the total predicted kiln length is appreciable.

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