Wet process rotary cement kilns: modeling and simulation

Abstract

The knowledge of wet process kilns design and operation in the cement industry has not been improved substantially during the last decades since the pre-calcination process has been developed to become the technological standard. In spite of the tendency to replace wet process rotary kilns for cement production by modern dry process kilns with pre-calcination, there are still a substantial number of wet process kilns in operation. Their efficient operation requires an individually designed chain system to enhance the kiln performance. Currently the design of chain systems for wet process rotary cement kilns depends strongly on experience. Systematic theoretical and experimental investigations for the dimensioning of chain systems are not known. Based on a one-dimensional cell model, a simulation program for wet process rotary cement kilns with chain systems has been developed. With the aid of this simulation tool, the influence of chain systems on solid composition and temperature profiles, clinker throughput and fuel requirement is predicted and the design of chain systems can be optimized.