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To cite this article: L. Yang & B. Farouk (1997) Modeling of Solid Particle Flow and Heat Transfer
in Rotary Kiln Calciners, Journal of the Air & Waste Management Association, 47:11, 1189-1196,
DOI: 10.1080/10473289.1997.10464069
Volume 47 November 1997 Journal of the Air & Waste Management Association 1189
Yang and Farouk
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Yang and Farouk
equations proposed by Jackson,8 except that the solid Flow Boundary Conditions
viscosities and stresses are computed by simultaneously The no-slip condition is employed for the particles and
solving a “fluctuating energy” equation. The primary as- gas along the calciner wall. A zero gradient gas velocity
sumptions made during development of the flow model boundary condition is applied at the free surface. The
were that the particles in the bed are cohesionless, which boundary condition used for particles at the free sur-
means they possess a relatively high coefficient of restitu- face is, however, not easily defined. As the calciner
tion, and that particles are spherical, rigid, and slightly in- rotates, the particles slide along the free surface,
elastic, which means that properties of granular flows are whereas particles near the calciner wall undergo solid-
isotropic, and the dissipation of energy due to inelastic col- body type rotation. A boundary condition for solid
lisions is permitted. phase is derived at the free surface based on the force
balance on the surface particles and the experimental
Granular Flow Model data:5
The governing equations for granular and interstitial gas
flows are stated as (for relatively high values of the solid ∂u/∂y = 2.76 (ρs. d p) ω [m/s] (5)
volume fraction, εs):8
where u is the velocity component in the direction parallel to
∂(ρ ε ) the free surface, y is the coordinate axis perpendicular to the
k k
+ ∇.(ρ ε V ) = 0 (1) free surface, dp is the particle diameter, ρs is solid density, and w
∂t k k k
is the angular speed of the rotary calciner. The boundary con-
∂
ditions for the granular temperature are:
∂(ρsεsVs)
+ ∇.(ρsεsVsV s) = T˜ = 0 at wall,
∂t
= (ρ s - ρ g)εsg - ∇Ps + β(V s - Vg ) (2) dT˜
=0 at free surface.
dy
(
∂ ρgε gV g ) + ∇. (ρ ε V V )= ρ g − ∇p + β(V
∂t
g g g g g s − Vg ) (3) Quasi Three-Dimensional Model
for Heat Transfer
Both the flow and the heat transfer problems within a
where the subscript k (s or g) indicates either solid or gas calciner are essentially three-dimensional. The axial
phase; V is the bulk velocity; ρ s and ρ g are the solid flow field is related to the mass flow rate through the
and gas phase densities, respectively; and ε s and ε g are calciner and is governed by the inclination and the
the solid and gas volume fractions. P s is the total par- rotation rate of the calciner. The planar flow field (as
ticle phase stress tensor, which consists of both static formulated above) does not vary appreciably in the
and kinetic (streaming and collision) components, and axial direction. The heat transfer process in a calciner,
β is the drag coefficient. The coupling between the however, is profoundly three-dimensional as the ra-
particle phase and the gas phase are provided via β. dial heat transfer (see Figure 1) into the bed is con-
The expression for P s is given by Lun et al. 9 where the vected along the axial direction. Because the large as-
stresses are locally dependent on the “granular tem- pect ratio of most calciners (length to diameter ratios
perature” T˜ , the coefficient of restitution of the par- = 25:1) makes the solution of the resulting equations
ticles, and the volume concentration of the solids. Note computationally demanding, a quasi-three-dimen-
that the granular temperature is not the same as the sional heat transfer model has been used in this study
physical temperature of the particles or the gas phase. (following Boateng5).
Basically, the granular temperature is an estimate of The quasi-three-dimensional model comprises an
the particle fluctuation in granular flow. The granular axial model (one-dimensional) for the bulk gas (free-
temperature is governed by the following equation: 10 board) and the solid phase (bed), and a cross-sectional
∼ model (two-dimensional) for the planar velocity and
3 ∂(ρsεsT + ∇.( ρ ε V T∼
) = P: ∇V s + ∇.q - γ (4) temperature field predictions. The former is used to
2 ∂t s s s PT
independently determine the one-dimensional axial
where the term qPT is the flux of pseudo-thermal energy, temperature profiles for the freeboard gas and the bulk
while γ is the dissipation of pseudo-thermal energy due bed. As part of the procedure for calculating axial tem-
to inelastic collision of particles. The detailed expressions perature profiles, the surface heat flux to the bed is de-
for the above physical quantities can be found in Ding termined and becomes the thermal boundary condition
and Gidaspow.11 employed to drive the cross-sectional model. The bed
Volume 47 November 1997 Journal of the Air & Waste Management Association 1191
Yang and Farouk
temperature gradient computed from the axial model is and the calciner wall) is defined as:
used as a sink term representing rate of energy removal
due to the material flow in the axial direction. hwb = qwb / (Tw -Tb)Awb (12)
Governing Equations for Temperature Fields where qwb is the average heat flux from wall to the bed,
The bulk gas (free board) temperature Tg and bulk particle and Tw and Tb are average wall and particle temperature
temperature, Tb are given by at a given axial plane. Note that hwb was obtained from a
two-dimensional heat transfer model for particles (physi-
dT
g (6) cal temperature).
m˙ gCg = hgb Agb (Tb − T g ) + hwg Awg (T w − T g )
dz Once the axial gradient of the bulk particle tempera-
and ture is known, a planar (two-dimensional) heat transfer
dT b model for the particles can be formulated as:
m˙ b Cb = hgb Agb (Tg − Tb ) + hwb Awb (Tw − T b )
dz
+ hr Awb (Tw − Tb ) (7) ∂T ∂Ts ∂ 2T ∂ 2 Ts dTb
ρ Cb u +v −k
2 +
− m& C = 0 (13)
s s
eff b b
∂x ∂y ∂x ∂y 2 dz
where mg is the mass flow rate of freeboard gas, mb is
the calciner feed rate, and hwb, h gb, and hwg are the con- where Ts(x,y) is the particle temperature distribution at a
vection coefficients between wall and bed, freeboard given axial location. The effective thermal conductivity
gas and bed, and wall to free board gas, respectively. keff is defined as follows:
The following expressions are used for the heat trans- 1 − εs
k eff = 3 + 4ε s σεd p T
3
fer coefficients (Boateng, 1993). For the convective heat 1 / ks + 1/ 4σεd p T (14)
transfer between the calciner wall and free board gas,
For given wall and bulk bed temperature values, eq 13
hwg = 0.036 kg/Dk Re0.8 Pr0.33 (D/L)0.055 (8) can be solved to calculate hwb.
where D and L are calciner diameter and length, respec- SOLUTION PROCEDURE
tively. The Cartesian coordinate system was employed to describe
For the convective heat transfer between the free the granular flow field considered. The computational
board gas and the exposed bed surface domain is shown in Figure 2. The x-axis is considered
to be parallel to the bed free surface while the y-axis is
hgb = 0.4 Gg0.62 (9) perpendicular to the bed surface. An interpolation tech-
where nique was used to handle the circular boundary of the
.
3600mg calciner surface. The governing equations describing the
Gg = [kg/m2 hr] (10) flow and heat transfer in this problem were solved nu-
Ag merically using a finite difference discretization proce-
The radiative heat transfer coefficient between the exposed dure. The SIMPLE scheme of Patankar11 is used to solve
bed surface and the calciner wall is given by the finite difference equations (1-4 and 13). The present
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Yang and Farouk
Figure 4. Predicted and measured velocity as functions of depth at Figure 6. Predicted and measured velocity as function of depth at
mid-chord, 15% fill; rotation rate = 3 rpm. mid-chord, 29% fill; rotation rate = 3 rpm.
computations employed a uniform mesh system with for gas/particle medium, only particle (solid) phase results
750 grid points. For the parameters considered, the grid are presented here. The gas phase flow fields will be im-
was found to be adequate. Sample calculations were portant when the desorption of the volatiles in the par-
performed with denser grids, which did not produce ticles are considered in the future.
appreciable differences in the flow structure or heat Figure 3 shows a typical predicted flow field in a
transfer characteristics. Equations 6 and 7 are also nu- cross-sectional plane of the calciner. The flow and geo-
merically solved by a finite difference method. If the metric parameters are chosen so that direct comparison
free board gas flow mode is countercurrent to the bed of the predictions can be made with the experimental
material flow, a false transient formulation can be used results of Boateng.5 For the result shown in Figure 3, the
to obtain the solutions. The computations were per- diameter of calciner is chosen as 1.0 m. The rotational
formed on an IBM RISC-6000 workstation. The typical speed is 3 rpm. The polyethylene particle diameters
CPU time used for the steady state solution is about are 3.6 mm and the bulk density is 960 kg/m3. The
600 seconds. coefficient of restitution is 0.85. The angle of repose is
28°, which gives a 15% filling percentage. The solid
volume fraction εs is 0.8. The values of emissivities used
RESULTS AND DISCUSSIONS for the calciner surface and the sad are 0.3 and 0.8,
Flow Field Modeling respectively. Figure 4 shows the predicted and mea-
Results are first presented for the planar (two-dimensional) sured granular velocity profiles at the mid-chord of the
flow fields of the particles. While the formulation is given bed. Satisfactory agreement between theoretical and
experimental results is found near the top and bottom
regions. The deviation near velocity inversion point
could be due to two reasons: the granular flow model
is not accurate when the particle velocity is small, and
Figure 5. Predicted granular flow field with polyethylene in the 1 m Figure 7. Predicted and measured velocity as function of depth at
I.D. rotary drum filled at 29%; rotation rate = 3 rpm. mid-chord, 15% fill; rotation rate = 5 rpm.
Volume 47 November 1997 Journal of the Air & Waste Management Association 1193
Yang and Farouk
Figure 9. The effect of the particle size on the granular velocity profile Figure 11. Temperature contours at the entrance of the calciner
at mid-chord. predicted by the quasi-three-dimensional model (Tw = 323K, ∆T = 6K).
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Yang and Farouk
Figure 12. Temperature contours at the middle plane of the calciner Figure 13. Temperature contours at the exit of the calciner predicted
predicted by the quasi-three-dimensional model (Tw = 340K, ∆T = 6K). by the quasi-three-dimensional model (Tw = 366K, ∆T = 6K).
Ottawa sand was heated by passing it countercurrent to a necessary to develop an advanced mathematical
flow of preheated air in a 2.5 m long, 0.19 m I.D. rotary model to predict the flow and temperature distribu-
calciner. The preheated air temperature was 450 K and tion of granular materials. A two-dimensional nu-
the temperature of sand at the entrance is 325 K. The sand merical model has been developed to predict the
feed rate was 175 kg/m2.h, and air flow rate was 3300 kg/ fl o w a nd t em p era t u re di st ri b u t i o n i n a ro t a r y
m2.h. The rotational speed of the kiln was 1.5 rpm. The calciner. Based on the predicted flow field, a quasi
percent fill was 17%. The present model is tested based three-dimensional model for heat transfer has been
on the same conditions as the above experimental work. developed to predict the axial bulk temperature
The comparisons of the predicted axial temperature varia- variations. The temperature distributions at specified
tion with the experimental data are shown in Figure 10. axial locations in the bed are predicted using the bulk
The good agreement between them shows that the quasi temperature gradients. The predicted flow and heat
three-dimensional assumption and the mathematical transfer results showed satisfactory agreement with the
model is satisfactory. experimental results, which provides confidence to
Figures 11-13 show the temperature contours at three further the present study. Combined with the flow and
axial locations: the calciner entrance, the mid-section of thermal conditions obtained from the present mod-
the calciner, and the exit of the calciner. The temperature els, a devolatilization model will be developed and
distributions within the bed largely depend on the tem- employed to predict the overall desorption process.
perature difference between the surrounding gas and the The devolatilization model (kinetics of calcination) will
bulk bed temperature. For the air heating situation consid- provide quantitative evaluation of a calciner as a func-
ered here, convective heat transfer is the primary mode for tion of the operating parameters. Such models can even-
bed heating. This is, however, not the case for most indus- tually be used for optimized design of the calciners.
trial processes. Due to the countercurrent flow of the pre-
heated air, the heat transfer is effective along the entire NOMENCLATURE
length of the calciner. It is interesting to note that due to A area [m2]
the counter-clockwise rotation of the bed materials, the C specific heat [kJ/kg.°C]
higher temperature region in the bed is at the top left cor- D diameter [m]
ner. Figures 11-13 show the same feature. These results also d diameter [m]
demonstrate the non-isothermal temperature distributions h heat transfer coefficient [W/m2.°C]
that can be obtained within calciners. The temperature non- k thermal conductivity [W/m.°C]
uniformities can be mitigated by enhancing mixing within L length [m]
the bed material. Frequently, this is achieved in calciners P total stress tensor [Pa]
by placing protrusions and “lifters” on the calciner wall. Pr Prandtl number (=µCp/k)
q heat flux [W/m2]
SUMMARY Re Reynolds number (=VD/n)
To achieve a better understanding of the mixing, heat T thermal temperature [°C]
transfer and desorption processes in calciners, it is t time [s]
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Yang and Farouk
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