Rotary kiln simulation software

Keywords waste combustion, simulation model, rotary kiln, thermal and mass balances, refractory. The simulation yields axial temperature profi les for the. Then the model was imported into the discrete element simulation software of edem 2. Our cement rotary kiln simulator is the most effective tool to train personnel in all aspects of the operation of a rotary klin. Pdf thermal analysis of the rotary kiln through fea. Upper limits on diameter are set by the tendency of the shell to deform under its own weight to an oval cross section. According to the new type of two stall supporting cement rotary kiln designed by ourselves, the key components of the rotary kiln are simulated and analyzed with ansys software.

Cementing the future of rotary kilns through simulation and. The integrated model, the developed software rocks for rotary cement kiln simulator and results presented here will be useful for enhancing our understanding and for enhancing the performance of. The kiln model applied in this work was developed by hatch over a number of years and has been used for several rotary kiln projects. Rotary kiln china henan zhengzhou mining machinery co.

Flow sheet of the pyrolysis plant figure 8 shows a flow sheet of the pyrolysis plant. This paper focuses on simulation of flue gas recirculation system at different recycle ratios for maximum no xreduction in an industrial cement rotary kiln while keeping desired temperature at various rotary kiln zones. The capability of the resultant cfd model was demonstrated by 3d simulation of the bed of a large rotary kiln. Though the technology of rotating drums has been available for over 100 years, it has not been replaced, but remains in active use in many of its traditional applications. Numerical simulation of the influence factors for rotary kiln. A hierarchical simulation methodology for rotary kilns.

Research on control model and simulation platform of. The rotary drum provides an efficient means kilnsimu read more. Research on control model and simulation platform of cement. Longitudinal and transverse mixing in rotary kilns. The integrated model, the developed software rocks for rotary cement kiln simulator and results presented here will be useful for enhancing our understanding and for enhancing the performance of clinker manufacturing. Cfd simulation of flue gas recirculation in a rotary kiln for. Vtt offers a comprehensive set of tools and expertise for modelling and simulation of process and automation concepts. Gaseous and solid phase simulation in 1d in kilnsimu generalpurpose solver for any rotary kiln application gaseous phase simulation in 3d in ansys fluent highperformance multiphase cfd modeling environment hosting a leading selection of combustion submodels chemical reaction modeling, especially in turbulent conditions. Join the grabcad community today to gain access and download. The stress and strain distribution of the rolling ring and riding wheel are obtained, and the weak link of the rotary kiln parts is pointed. For simulation purposes reactors are defined to model all elementary process steps, e. Process simulation of activated carbon production using a rotary kiln. The kiln is a large cylindrical structure where the raw materials are brought together and heated to form clinker, the base material of cement. Kilnsimu is a standalone software that can be used for thermodynamic modelling rotary drum furnaces.

Then, based on the configuration software, the dynamic simulation platform of the cement rotary kiln burning zone temperature is developed. Tell me where i can get rotary kiln simulation software. How can i use aspen plus for rotary kiln simulation for activated carbon production. Rotary kiln is thermal equipment to heat materials. Without affecting the study results, some adjustments will be made to the established structure, material property model, and practical rotary kiln for simulation calculation. Process simulation of activated carbon production using a. Cement kiln is used for making cement clinker and there are dry and wet methods to make cement clinker. By using a 309 stainless steel liner and ceramic fiber insulation, we can shopassemble the largest systems without exceeding the weight and size restrictions of standard freight. Join the community and register for a free guest account to post a reply. While it relies on the calculation routines of chemapp, it is userfriendly and specialized to one specific application. The analysis of rotary kiln thermal characteristics based. The finite element simulation models of the rolling ring and. The finite element simulation models of the rolling ring. Welcome to autodesk s simulation mechanical forums.

In this paper, the influence processes in a simulated cement rotary kiln and operating parameters on the output of the study were to develop and. The kiln tyre is mounted on the cylinder body and rotates on the support roller, supporting the full weight of the rotary kiln including the kiln brick and material therefore, the kiln tyre should have sufficient strength and durability production process of chaeng kiln tyrethe firs. A threedimensional steadystate model to predict the flow and heat transfer in a rotary lime kiln is presented. Prediction of the volatile recirculation in cement rotary. The analysis of rotary kiln thermal characteristics based on. The grabcad library offers millions of free cad designs, cad files, and 3d models. About 2000 kgh of wet olive pits at 15% are dried in a rotary dryer up to moisture content of 5%. Particles movement simulation of screw transporting in. The rei combustion simulation tool glacier was used to model the combustion at the burner end of the kiln and to predict the heat flux to the ore bed. In each simulation, theno xemission at kiln outlet as well as the temperature profile along kiln axis was compared. Process simulation software kilnsimu was used to simulate two different cases for lime kiln. Material in the rotary kiln was regarded as particles. China yu hong heavy industry is specialized in producing calcination equipment manufacturers, to provide you with a variety of materials rotary kiln technical advisory services.

Minimizing heat losses through the kiln shell can help lime producers achieve production efficiencies that are essential in todays competitive markets. Rotary kilns are widely used in metallurgical industry. Aug 08, 2018 watch this video to learn the building of 3d geometry and simulation in comsol. The focus is on the effect of the main operating conditions, i. The rotary kiln was invented in 1873 by frederick ransome.

This work aims to propose the use of computational fluid dynamics cfd simulation and known kinetics as an approach to design an indirectfired rotary kiln with a better thermal efficiency for pyrolysis. Therefore, based on hybrid system theory, thermal regulation, and least squares method, the control model of cement rotary kiln burning zone temperature is given. Modelling and optimization of a rotary kiln direct. The rotary kiln as well as the cooler is discretised into several. In the active layer, particles slide over each other in granular flow. Hitemp manufactures rotary kiln systems that will operate at 12 to 100 tons per day. Analytical and numerical analysis of the tire tightening.

Simantics system dynamics is a free, open source system dynamics modelling and simulation software. Rotary dryer kiln of the different types of dryers that there are the most common is the rotary drum dryerkiln, this type of drier is common not only in the mining industry but you will find them in fertilizer plants, cement plants, and peat hogs to name but a few. Using laws of physics and chemistry it simulates in slightly faster than realtime the changing conditions of a rotary klin. Advanced thermochemical process model of rotary kilns. All important phenomena are considered for the preheat and calcination zones including turbulent gas flow, buoyancy, all modes of heat transfer, evolution and combustion of species and granular bed motion with calcination reaction.

Some of the simulated results were used during the periodical maintenance to improve the refractory characteristics in order to reduce the fret and corrosion process. Process technology analysis of chaeng rotary kiln tyre. The rotary kiln is one of the most representatives of the furnace equipment. You will need to put both of these files in your own directory before using them. Cementing the future of rotary kilns through simulation. In finding the optimal gas temperature for the reductive gas environment necessary to the charcoal activation, the outcome gives the amount of. Kilnsimu rotary kiln simulator kilnsimu is used in several industries. Refractory bricks used in rotary lime kilns must meet these challenges as well as help conserve energy. For an example, i have modeled and simulated a piece of circular waveguide. The research on the control model and simulation platform of rotary kiln burning zone temperature is the basis of automatic control and process optimization of cement clinker sintering process. Ab rotary kilns are concurrently used in several industries.

It is widely used in the fields of cement, nonferrous metallurgy, ferrous metallurgy, refractory material, chemical, and papermaking. By using the software of solid edge, the geometric model could be established. Numerical simulation of the influence factors for rotary. Hi bob, first, i have no experience with kilns, so these are just some ideas based on my limited understanding of the process. Iron ore roasting rotary kiln for sale savona equipment. Rotary kilns are a pyroprocessing device used to raise materials to a high temperature calcination in a continuous process. The original software was used to model the operation of a 35 m pilot kiln at the stellco company. Iron ore roasting rotary kiln for sale savona equipment is your supplier for new, used, and rebuilt ore roasting rotary kiln.

In order to utilize indirectfired rotary kiln for pyrolysis application in a larger scale, its thermal efficiency has to be improved. The computed results are used to find the optimal operation condition. Of the different types of dryers that there are the most common is the rotary drum dryerkiln, this type of drier is common not only in the mining industry but you will find them in fertilizer plants, cement plants, and peat hogs to name but a few the theories behind these machines are very simple, heat an air space up, and then tumble the material to be dried through this space. Cement production is a highly energyintensive process, and the rotary kiln is the most important part of the process. You can find attached a rapid sketch that represent the. Regardless of the floating of the screw in the cylinder, the rotation speed of cylinder. It has its roots in a fortran program that was developed by venkateswaran 1978 to study the reduction of iron ore. How can i use aspen plus for rotary kiln simulation for. An approach to utilize the computational fluid dynamics cfd simulation and the pyrolysis kinetics for the design of pyrolysis rotary kilns with a better thermal. In this paper, the influence processes in a simulated cement rotary kiln and operating parameters on the output of the study were to develop and validate the systems using the same batch. The rotary cement kiln forms a major part of any cement works. This is made from rolled mild steel plate, usually between 15 and 30 mm thick, welded to form a cylinder which may be up to 230 m in length and up to 6 m in diameter. The author found that predicted kiln length by simulation close to the actual kiln length 1.

Heat loss through the kiln shell is of growing concern to lime kiln operators. The rotary kiln used for the activation of charcoal is simulated using mass and energy balances to obtain the temperature distributions of environmental gas and solid in the kiln. Additionally, the cement industry contributes around 5% to 8% of all manmade co 2 emissions. Introduction in todays world, powering along the supply of raw materials, cement production is the most important factor. Establishment of the 3d model of the rotary kiln is mainly to define each components structure and material properties. Kilnsimu rotary kiln simulation program the rotary kiln is concurrently used in several industries. Physiochemical and thermochemical reactions involved in cement kilns are still not well understood because of. To ensure production plant reliability and product quality an understanding and evaluation of the kiln design parameters is of paramount importance. Particles movement simulation of screw transporting in rotary. They are returned to the top part of the bed in the passive layer, where particles move as a solid mass concentrically around the axis of the kiln. Share your knowledge, ask questions, and explore popular simulation mechanical topics. Dynamic simulation of a pilot rotary kiln for charcoal. That is, the new designed equipment has the characteristics of the optimal energy consumption and stable performance.

The cement industry is one of the most intensive energy consumers in the industrial sectors. Watch this video to learn the building of 3d geometry and simulation in comsol. The energy consumption represents 40% to 60% of production cost. An indirectfired rotary kiln was suggested to be a suitable choice subject to the need for a better thermal efficiency.

Modelling and optimization of a rotary kiln direct reduction. Longitudinal and transverse mixing in horizontal rotary kilns has been studied, using a threedimensional discrete element method approach. This paper presents a dynamic simulation system dss and a simulation study of a pilot scale rotary kiln for activated carbon manufacture. The kiln and rotary kiln of gas temperature field is calculated and then imported into the ansys software as an initial condition to complete the reconstruction of the temperature field and using the node interpolation method to carry out. Metallurgy chemical kiln is widely used for magnetic roasting of poor iron ore and oxidizing roasting of chrome and. Dss has been developed by using the simulinkmatlab framework, based on a dynamic mathematical model. Commercial software packages factsage and simusage have been used and linked with borland delphi. Stress simulation on a cantilever in a rotary kiln. A heat transfer steadystate model was developed by ghosdastidar and unni for nonreacting zone of the rotary kiln, which was used for drying and preheating of wet solids. The rotary drum provides an effi cient means for both heat and mass transfer in the processing of.

Modelling and simulation for process industry simulationstore. Cfd study on the application of rotary kiln in pyrolysis. Several ways for reducing energy consumption were computationally investigated. Having a comprehensive model of the kiln in order to reduce manufacturing costs, better performance can be created.

Modelling and optimization of a rotary kiln direct reduction process 55 figure 3. System dynamics is a methodology for understanding the behaviour of complex dynamic systems belonging to different domains. Reacting twophase flow within the firing zone of a rotary kiln used to process raw ore was simulated in order to predict and improve kiln performance. Cfd simulation of flue gas recirculation in a rotary kiln. The kiln diameter is 3 meters, and the probe length around 35 cm. Kilnsimu is versatile simulation software that can handle many different kind of rotary kiln applications with chemical systems consisting of hundreds of phases and species.