Abstract
Cement is one of the most used building materials in the world. The process of cement production involves numerous and complex reactions that occur under different temperatures. Thus, there is great interest in the optimization of cement manufacturing. Clinker production is one of the main steps of cement production and it occurs inside the kiln. In this paper, the dry process of clinker production is analysed in a rotary kiln that operates in counter flow. The main phenomena involved in clinker production is as follows: free residual water evaporation of raw material, decomposition of magnesium carbonate, decarbonation, formation of C3A and C4AF, formation of dicalcium silicate, and formation of tricalcium silicate. The main objective of this study was to propose a mathematical model that realistically describes the temperature profile and the concentration of clinker components in a real rotary kiln. In addition, the influence of different speeds of inlet gas and solids in the system was analysed. The mathematical model is composed of partial differential equations. The model was implemented in Mathcad (available at CCA/UFES) and solved using industrial input data. The proposal model is satisfactory to describe the temperature and concentration profiles of a real rotary kiln.
Highlights
Some of the challenges facing the cement industries are the high energy demand of production, the continuous increase in fuel prices, process complexity and environmental impact (Atmaca and Yumruta 2014, Tsamatsoulis 2014, Kaddatz etThe best-known type of cement is called Portland cement, which is defined as a hydraulic cluster that is basically obtained by grinding a mixture of clinker and gypsum (Copertaro et al. 2015)
This paper considers the dry clinker production, which is the most used process in Brazilian production of cement (Kihara and Visedo 2014)
The mathematical model proposed in this paper does not require advanced computing to be solved, and it is adaptable to new industrial realities
Summary
Some of the challenges facing the cement industries are the high energy demand of production, the continuous increase in fuel prices, process complexity and environmental impact (Atmaca and Yumruta 2014, Tsamatsoulis 2014, Kaddatz etThe best-known type of cement is called Portland cement, which is defined as a hydraulic cluster that is basically obtained by grinding a mixture of clinker and gypsum (Copertaro et al. 2015). Some of the challenges facing the cement industries are the high energy demand of production, the continuous increase in fuel prices, process complexity and environmental impact One of the main steps of the process for obtaining cement is the synthesis of the clinker (Atsonios et al 2015, Saidur et al 2011). Synthesis occurs inside the rotary kiln and involves complex physical (phase changes) and chemical (endothermic and exothermic reactions) processes (Lourenço et al 2013, Saidur 2011, Silva 2007, Boateng and Barr 1996). The main clinker components are C3S (3CaO.SiO2), C2S
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