Model of Mass and Energy Transfer in a Clinker Rotary

Kiln
J.A. Guirao
S. Iglesias
Numerical Analysis TEChnologies S.L.
J. Pistono
Universidad de Oviedo
R. Vzquez
IMASA Div. Internacional
Abstract
The purpose of this report is the development of an application allowing the precise simulation of the
processes which are involved in the operation of a rotary cement kiln, either wet or dry. This will be in use
during cement production in existing kilns and in the design stage of new kilns, including other processes,
such as preheating and precalcining. The length of the furnace is divided into as many sections as desired,
the last face of the first section being equal to the first face of the second section, and so on. In each section
it is considered: (1) heat transfer by conduction, convection and radiation (2) chemical reactions, including
vaporization of the water content in the wet process (3) entrance and exit of flows of each chemical
specimen. Every physical property and transfer depends on local (point) conditions. The results are
complete maps of temperature and composition together with their variations during stages of kiln feeding
and fuelling.

Introduction
The development of an application allowing the strict simulation of the processes taking place in a rotary
kiln for clinker production will be an important advance in the design procedures for this equipment.
The project initial objectives are summarized as follows:

To build a design tool: development of an application capable of predicting all the variables,
chemical as well as thermo-physical in the complete kiln length. Traditionally, the design of rotary
kilns is mainly supported on the knowledge derived from previous constructive experience. A tool
such as that hereby proposed will constitute the technical basis for decision taking concerning
design, such as length to be assigned to each stretch, chain mass, etc.

To build a supporting tool for other design stages as mechanical analysis.

To build a simulation tool for prediction of the behavior of the equipment in its working
conditions, which will allow making a sensitivity analysis, predicting its behavior in the case of
foreseen changes.

The construction of such a tool requires a detailed analysis of the heat and mass transfer mechanisms
occurring inside the kiln. For that, a sequential analysis methodology has been developed, consisting in the
division of the equipment in parts of a given length. The finite elements method applied to each part of the
kiln allows establishing the starting conditions for the following element, obtaining therefore a sequential
resolution.
In each analyzed part the effects derived from the three heat transmission mechanisms (convection,
conduction and radiation), are considered in a coupled way. The convergence conditions in each element
are therefore based on the accomplishment of the energy balance in the element.

Parallel to the heat transmission model, development of a detailed model of the chemical and physical
transformations (the evaporation is treated as an equivalent reaction kinetics) inside the kiln, and evolution
of the different species in function of the thermo-dynamical parameters. This model interacts with the
preceding one, since the chemical reactions are either exo- or endo-thermic, and these contributions must
be taken into account in the energy balance of each element.
Finally, a model capable of predicting the product evolution is also needed. Since the kiln is rotating, and
the thermo-physical characteristics of the product vary along the kiln, the product longitudinal speed also
varies, resulting in variations of the product resident time in each element, of filling index1, etc. All these
circumstances are again coupled with the thermal, chemical and particle dynamics models.
At present, the three models have been developed, but some parameters of the different models are pending
of adjustment, from experimental data.
The three models described are implemented within the environment of the ANSYS application, and they
interact with a fully parameterized and realistic generation of the kiln geometry itself.

Transfer phenomena
In the simulation the following energy transfer mechanisms are included:

Conduction
In order to analyze the conduction in a cement rotary kiln, its cross section has two parts, depending on the
presence of product, as shown in Figure 1, and the heat flows also through the product, when present; this
is a particular type of conduction in porous solid.

Figure 1. Considered conduction phenomena

Area filled with product related to total cross section

All the conduction phenomena are characterized by the conductivities proper to each material present as a,
function of its temperature.

Convection
The heat transfer associated to convective phenomena has been included by use of transfer correlations for
the evaluation of the film coefficients, function of the non-dimensional numbers that control the transfer
processes. These APDL TABLE functions depends of two variables (local surface temperature and average
flluid bulk temperature). In that way the film transfer coefficients have been taken as depending of the local
temperature of the exchange surfaces applying boundary conditions in table form, i.e. non-linear analysis.
Internal convection is forced convection in circular cross section ducts (figure 2) and external is taken as
natural convection outside of rotating cylinders (figure 3).

Figure 2. Inside convection phenomena considered

Figure 3. Outside convection phenomena considered

Radiation
Radiation from the kiln outside shell to the atmosphere, an equivalent simple transfer coefficient is
considered, according to:

Q gs = A s hr Tg Ts

)(

hr = s Tg2 + Ts2 Tg + Ts

In the preceding equations, a view factor of 1 has been considered, because the shell surface is fully
surrounded by the atmosphere.
Concerning the inside radiation, we have a far more complex situation, since there exists radiation between
a gas and a surface, the gas being highly participative. It is also necessary to estimate the radiation between
surfaces, and therefore to calculate the shape factors between the several radiant surfaces.

Figure 4. Inside radiation phenomena

As a first approach, and in the aim of not making it too complex, it has been assumed that, as the kiln is
continuously rotating, the inside surface temperatures in the same section are not very different; so, in this
stage of the study, we neglect the value of the radiant energy transmitted between inside surfaces.
Nevertheless, we are at present working in the development of an algorithm for the determination of the
shape factors for each couple of model elements (finite elements), and the solution of the heat transmission
by radiation trough participating media, considering the gas as a mixture of CO2, H2O, N2 y O2.
For the modeling of the transfer equipment by inside radiation, the AUX12 Radiation Matrix Method has
been used.

Chemical model
The cement production is obtained by operating a kiln at high temperature, where different chemical
reactions take place until a dry solid called clinker is obtained. Not all these reactions are fully known,
therefore it cannot be ascertained exactly what happens inside the kiln. Given the kiln feed, an approximate
reaction model can be established, with some accuracy, resulting in a quite complex behavior. To simplify,
it has been assumed that six main reactions take place:

H2O (L) H2O (G)

CaCO3 (S) CaO (S) + CO2 (G)
2 CaO (S) + SiO2 (S) SiO2. 2 CaO (S)
SiO2. 2 CaO (S) + CaO (S) SiO2. 3 CaO (S)
Fe2O3 (S) + 4 CaO (S) + Al2O3 (S) Fe2O3. 4 CaO . Al2O3 (S)
3 CaO (S) + Al2O3 (S) Al2O3. 3 CaO (S)
Some of the reactions occur simultaneously, what adds difficulties to their study.
The evolution of the several chemical species is adjusted to the reaction kinetics of the equations present in
the chemical model, each one having a prevalence interval controlled by the temperature of the gas
mixture. At the same time, the thermodynamic characterization of the preceding equations is included in
the kiln energy balances analyzed. This is affected by APDL programming, integrating it within the
solution iterative process of each kiln element.

Figure 5. Chemical Model

The following stages are considered from the chemical point of view:

Evaporation or drying.

Calcining.

Sintering.

Figure 5 shows the evolution of the typical species according to the adopted model.

Figure 6. Zones of the kiln chemical model

Model of solid material dynamics

The mass flow speed of the material along a rotary kiln is not constant. However, in an approximate way,
the time of permanence of the material within the kiln can be obtained by the following equation, U.S.
Bureau of Mines.

t=

1.77 l
F
pd n
t: stay time (min)
l: kiln length (m)
: natural slope of the dry material ()
p: kiln slope ()
d: kiln diameter (m)
n: rotating speed (r.p.m.)
F: factor considered in section reductions ( =1, for constant diameter)

Control of stay time by variations in kiln diameter has shown to give irregular shifting and material
retentions in the transitions; therefore rotary kilns are built with a constant diameter in the whole length. As
it can be observed in the preceding equation, by modifying the slope and the rotation speed of the kiln the
stay time may be controlled.
As already said, the passage speed inside a kiln is not constant and is conditioned by the thermo-chemical
processes and material transport occurring inside the kiln, with strong influence by the raw material
physical characteristics.
Driving the kiln at constant speed, the material shifts at different speed in the different areas, namely
draying, transition, calcining and sintering. Essays have confirmed this with tracers, in which radioactive
isotopes have been used (Na24 and Mn26). The following image show the estimated average speeds of the
material in the direction of the kiln longitudinal axis.
The speed indicated values are average values obtained by the relation between the length of the considered
area and the stay time of the product in the same. That is to say, that speed is taken as a vector in axial
direction, when in fact, since the kiln is turning, the product is continuously recirculated. On the other hand,
a part of the product that has already passed by a point of the kiln can pass again because there may be a
small return of product, due to the dragging effect of the gas current.
The complexity of the study of the possible flow recirculations inside the kiln, especially in the drying area,
where there are chains mixing the product, advised not to consider these recirculations in this first model.

The simplified alternative, is a constant speed supposed in each zone, together with the net material balance
of a stationary process. In future studies, it is foreseen to develop models describing with greater
approximation the dynamic behavior of the raw material inside the kiln.

Figure 7. Stages of the solid dynamics in the kiln

Resolution algorithms
Calculation hypothesis
The general hypotheses considered in the calculation are the following:
Stationary process: it is supposed that in any given kiln point the same processes occur, independently
of the time. In general, a cement kiln operates in a continuous way, so that the transitory periods are
restricted to situations where the operation conditions are varied (until reaching another nearly stationary
state). So this hypothesis is quite close to reality. Nevertheless, in later studies is intended to include the
simulation of transitory processes with sensitivity analysis.
The analysis of the radiation inside the kiln is complex. Therefore, it is considered, as a starting point,
that the gas inside the kiln is not fully participative and that the inside surfaces do not interchange net
radiation. This simplification, as previously explained, cannot give big errors because the radiant
temperatures involved are very similar. The gas has been taken as a focus of emission, due to its higher
temperature, but not absorbing any energy coming from the inside surfaces.
The chemical processes, very complex and partially unknown, has been modeled in a simpler way,
which will have to be revised in later analysis.
A study of the flame is not carried out and therefore it is supposed that the gas average temperature in
each point characterizes it.
No product recirculations or returns caused by the gas current are considered.

General resolution algorithm

The simulation of the heat transfer processes that occur in a cement rotary kiln is undertaken by means of
the division of the same in a number of finite elements, on which the heat transferred and chemical
processes are studied in detail. After solving an element, the next is solved by applying, as initial contour
conditions, those obtained at the end of the preceding element, and continuing this procedure along the
whole length of the kiln, until the last element. As a final checking, it is necessary to do a global energy
balance and compare it with actual data. If there are substantial differences with the measured data, the
starting hypotheses have to be corrected.

In the next figure gives the schema of the general calculation algorithm. The main program module
generates a complete model of the kiln. It includes a full set of algorithms to carry out analysis and
calculation.

Initial data
For the development of the main algorithm, it is necessary to know, as starting actual data, those defined
below; however, for each kiln division, it is necessary to adopt more additional data, which are enumerated
in the following paragraphs:
Kiln geometrical data
Product data.
Initial concentrations. Product massic flow
Gas data.
Mass flow.
Temperature data
Product temperature at kiln inlet.
Outlet gas temperature
Ambient temperature.
Flame average temperature.

Figure 8. General resolution algorithm

Kiln division
For the complete kiln calculation, it is divided in N parts, not necessarily equal, solving each of them
independently.
The solution of each division is made starting from a detailed finite element model, reflecting the kiln
geometry as well as the different materials and their position. After establishing the adequate contour
conditions to solve of the elements, this is done using the ANSYS calculation package by finite elements of
general purpose.
The choice of the number of divisions is based on two criteria: calculation accuracy and computing time.
The greater the number of divisions is, the shorter is the length of the element to solve, and therefore, the
calculation accuracy is greater. It must be considered that in each element heat transfer phenomena, all
parameters depending on the temperature, are solved. Initially, its variation along the element must be
estimated or decided, so with smaller element less iterations are needed to obtain a valid solution.

On the other hand, greater the number of divisions means, longer the calculation time, exponentially with
the size of the problem. A decision must be taken considering both aspects.
Given that the kiln is divided in N parts, it is possible to define a different geometry for each of them;
obviously this must be consistent with reality, that is to say there cannot be brusque changes in diameter,
thickness, etc.
This possibility of establishing different values for the generic parameters (model parameterization) of each
element is imposed by the product circulation, since it has different speeds depending on each process, as
already stated. That applies to the loading angle, product stay angle, as well as the diameters, and even the
mesh each element.

Figure 9. Finite element model of a kiln element

Transition algorithm
As previously described, the resolution procedure of a kiln is sequential. The continuity between elements
is ensured with a transition algorithm which stores the output parameters of one element, and writes them
as starting values of the following element to be calculated.
The reason for this is that to solve an element it is necessary to know initial inlet data, which generally are,
as said, the final data obtained solving the preceding element.

Gas initial temperature.

Local temperature in the border parts of the element feed side.

Gas mass flow.

Product mass flow.

Temperature gradient in the longitudinal direction.

Concentration of the several substances (gas and product).

Figure 10. Transition algorithm

This procedure obtains these outlet data of the element "i" and takes them as initial calculation data for the
element "i+1", by means of the automatic construction of a file in which are included all the necessary data
for the solution of the i+1 element.

Post process
The data obtained in the solution of each element gives a description of the complete kiln. The parameters
obtained directly and indirectly from the solution of the finite element model are here listed:

Evolution of the gas average2 temperature in the whole kiln length.

Map of local temperature in any point of the product.

Map of local temperature in any point of the refractory.

Map of local temperature in any point of the ring.

Evolution of the mass flow of gas mixture, as well as the concentrations of its different chemical
species.

Evolution of the product mass flow, as well as the concentrations of its different chemical species.

Estimated value of physical properties of fluids and solids in any point of the kiln.

Averaged in each cross section

Energy transferred by any of the transfer modes in any point of the kiln. Enthalpy differences in
the gas mixture between any chosen two points of the kiln. Heat flow by longitudinal convection
in any cross section direction of the kiln. Heat implied in the evolution of every chemical reaction.

Because of the architecture of the calculation program ANSYS, the temperature results derived
from the complete solution of the kiln can be directly used as solicitation conditions on a finite
element model of the kiln for mechanical analysis.

Figure 11. Energy transferred from the outside to each element

Figure 12. Mass fraction distribution of CIO

Figure 13. Temperature distribution in product and gas

Figure 14. Temperature distribution in the 50 first meters of the kiln

Figure 15. Detailed temperature contour plot of three elements with a refractory failure

Conclusions
A methodology is proposed to undertake the simulation of the thermal and mass transfer behavior of a
rotary cement kiln. The combination of a programming environment with a tool for analysis by the of finite
elements method allows offering very detailed results together with its extension to the whole geometry of
the kiln. The thermal analysis involves the development of chemical models.
Although there is still a lot of work to be done to improve the accuracy of the results, and substituting the
simplified assumption by approaches more closed to actual processes, it can be stated that a fairly complete
model has been built. Properly developed, it will be an efficient tool to help designing and running rotary
cement kilns.

References
[1] ANSYS SAS IP, Inc. (2003), APDL Programmer Guide, Revision 7.0, Canonsburg
[2] TCL-TK Manual Page, http://www.tcl.tk
[3] ANSYS SAS IP, Inc. (2001), UIDL Programmer Guide, Revision 5.5, Canonsburg
[4] Incropera, F.P. y Witt, D.P. de (1990) Fundamentals of Heat and Mass Transfer, John Wiley & Sons,
New York