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Heat Balance Analysis in Cement Rotary Kiln

Received: 7 October 2018     Accepted: 3 December 2018     Published: 26 May 2019
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Abstract

The purpose of this study is optimizing the air and fuel quantities at kiln considering design parameters of the cement plant by keeping adequate safety factors at each level of calculations to assure that neither production rate nor quality of the clinker vary. Analysis of Heat balance was used to determine the sources of heat loss from the kiln system. Based on the collected data, an energy balance is applied to the kiln system. The physical properties and equations can be found in Perry’s handbook. The reference enthalpy is considered to be zero at 0°C for the calculations. The kiln has a capacity of 1000 ton-clinker per day. It found that the major heat loss is Heat losses by the kiln exhaust gas (2.33%), hot air from the cooler stack (7.28%), Radiation from kiln surfaces (11.71%). Some possible ways to recover the heat losses are introduced and discussed and they are Electricity generation, Heat recovery from kiln surface and Pre-heating raw material before the clinkering process.

Published in Advances in Applied Sciences (Volume 4, Issue 2)
DOI 10.11648/j.aas.20190402.11
Page(s) 26-32
Creative Commons

This is an Open Access article, distributed under the terms of the Creative Commons Attribution 4.0 International License (http://creativecommons.org/licenses/by/4.0/), which permits unrestricted use, distribution and reproduction in any medium or format, provided the original work is properly cited.

Copyright

Copyright © The Author(s), 2019. Published by Science Publishing Group

Keywords

Rotary Kiln, Design Parameters, Exhaust Gas, Radiation

References
[1] N. A. Madlool, R. Saidur, M. S. Hossain, and N. A. Rahim, “A critical review on energy use and savings in the cement industries,” Renew. Sustain. Energy Rev., vol. 15, no. 4, pp. 2042–2060, 2011.
[2] A. Atmaca and R. Yumrutaş, “Analysis of the parameters affecting energy consumption of a rotary kiln in cement industry,” Appl. Therm. Eng., vol. 66, no. 1–2, pp. 435–444, 2014.
[3] T. Engin and V. Ari, “Energy auditing and recovery for dry type cement rotary kiln systems––A case study,” Energy Convers. Manag., vol. 46, no. 4, pp. 551–562, 2005.
[4] V. Karamarković, M. Marašević, R. Karamarković, and M. Karamarković, Recuperator for waste heat recovery from rotary kilns,” Appl. Therm. Eng., vol. 54, no. 2, pp.470–480, 2013.
[5] Z. Söğüt, Z. Oktay, and H. Karakoç, “Mathematical modeling of heat recovery from a rotary kiln,” Appl. Therm. Eng., vol. 30, no. 8–9, pp. 817–825, 2010.
[6] L. a. J. & G. M. A. Ramesh, “Energy Audit of Thermal Utilities in a Cement Plant,” Int. J. Mech. Eng., vol. 2, no. 2, pp. 11–22, 2013.
[7] J.-H. Xu, T. Fleiter, W. Eichhammer, and Y. Fan, “Energy consumption and CO2 emissions in China’s cement industry: A perspective from LMDI decomposition analysis,” Energy Policy, vol. 50, pp. 821– 832, 2012.
[8] N. a. Madlool, R. Saidur, N. a. Rahim, and M. Kamalisarvestani, “An overview of energy savings measures for cement industries,” Renew. Sustain. Energy Rev., vol.19, pp. 18–29,2013.
[9] D. Song and B. Chen, “A Life Cycle Modeling Framework for Greenhouse Gas Emissions of Cement Industry,” Energy Procedia, vol. 61, pp. 2649–2653, 2014.
[10] W. Wang, D. Jiang, D. Chen, Z. Chen, W.Zhou, and B. Zhu, “A MFA-based potential analysis of eco-efficiency indicators of China’s cement and cement-based materials industry,” J. Clean. Prod., 2015.
[11] A. M. Radwan, “Different Possible Ways for Saving Energy in the Cement Production,”Adv. Appl. Sci. Res., vol. 3, no. 2, pp. 1162–1174, 2012.
[12] J. A. Moya, N. Pardo, and A. Mercier, “The potential for improvements in energy efficiency and CO2 emissions in the EU27 cement industry and the relationship with the capital budgeting decision criteria,” J. Clean. Prod., vol. 19, no. 11, pp. 1207–1215, 2011.
[13] Equipment, “Energy auditing in cement industry: A case study,” vol. 2, pp. 171– 184, 2014.
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  • APA Style

    Shihab Ali Khalifa, Doha Yahia Alsadig. (2019). Heat Balance Analysis in Cement Rotary Kiln. Advances in Applied Sciences, 4(2), 26-32. https://doi.org/10.11648/j.aas.20190402.11

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    ACS Style

    Shihab Ali Khalifa; Doha Yahia Alsadig. Heat Balance Analysis in Cement Rotary Kiln. Adv. Appl. Sci. 2019, 4(2), 26-32. doi: 10.11648/j.aas.20190402.11

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    AMA Style

    Shihab Ali Khalifa, Doha Yahia Alsadig. Heat Balance Analysis in Cement Rotary Kiln. Adv Appl Sci. 2019;4(2):26-32. doi: 10.11648/j.aas.20190402.11

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  • @article{10.11648/j.aas.20190402.11,
      author = {Shihab Ali Khalifa and Doha Yahia Alsadig},
      title = {Heat Balance Analysis in Cement Rotary Kiln},
      journal = {Advances in Applied Sciences},
      volume = {4},
      number = {2},
      pages = {26-32},
      doi = {10.11648/j.aas.20190402.11},
      url = {https://doi.org/10.11648/j.aas.20190402.11},
      eprint = {https://article.sciencepublishinggroup.com/pdf/10.11648.j.aas.20190402.11},
      abstract = {The purpose of this study is optimizing the air and fuel quantities at kiln considering design parameters of the cement plant by keeping adequate safety factors at each level of calculations to assure that neither production rate nor quality of the clinker vary. Analysis of Heat balance was used to determine the sources of heat loss from the kiln system. Based on the collected data, an energy balance is applied to the kiln system. The physical properties and equations can be found in Perry’s handbook. The reference enthalpy is considered to be zero at 0°C for the calculations. The kiln has a capacity of 1000 ton-clinker per day. It found that the major heat loss is Heat losses by the kiln exhaust gas (2.33%), hot air from the cooler stack (7.28%), Radiation from kiln surfaces (11.71%). Some possible ways to recover the heat losses are introduced and discussed and they are Electricity generation, Heat recovery from kiln surface and Pre-heating raw material before the clinkering process.},
     year = {2019}
    }
    

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  • TY  - JOUR
    T1  - Heat Balance Analysis in Cement Rotary Kiln
    AU  - Shihab Ali Khalifa
    AU  - Doha Yahia Alsadig
    Y1  - 2019/05/26
    PY  - 2019
    N1  - https://doi.org/10.11648/j.aas.20190402.11
    DO  - 10.11648/j.aas.20190402.11
    T2  - Advances in Applied Sciences
    JF  - Advances in Applied Sciences
    JO  - Advances in Applied Sciences
    SP  - 26
    EP  - 32
    PB  - Science Publishing Group
    SN  - 2575-1514
    UR  - https://doi.org/10.11648/j.aas.20190402.11
    AB  - The purpose of this study is optimizing the air and fuel quantities at kiln considering design parameters of the cement plant by keeping adequate safety factors at each level of calculations to assure that neither production rate nor quality of the clinker vary. Analysis of Heat balance was used to determine the sources of heat loss from the kiln system. Based on the collected data, an energy balance is applied to the kiln system. The physical properties and equations can be found in Perry’s handbook. The reference enthalpy is considered to be zero at 0°C for the calculations. The kiln has a capacity of 1000 ton-clinker per day. It found that the major heat loss is Heat losses by the kiln exhaust gas (2.33%), hot air from the cooler stack (7.28%), Radiation from kiln surfaces (11.71%). Some possible ways to recover the heat losses are introduced and discussed and they are Electricity generation, Heat recovery from kiln surface and Pre-heating raw material before the clinkering process.
    VL  - 4
    IS  - 2
    ER  - 

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Author Information
  • Nile Cement Company Ltd, Rabak, Sudan

  • Nile Cement Company Ltd, Rabak, Sudan

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