Experimental validation of multiphysics model simulations of the thermal response of a cement clinker rotary kiln at laboratory scale

An increasing demand for buildings, transportation systems and civil infrastructure development has driven expansion of cement consumption world-wide, producing a significant increase in related global energy demand. With approximately 7% of the world-wide industrial energy consumption (10.7 exajoules [EJ]), the cement industry is the third most energy intensive industrial processes and a key component for concrete, the most consumed composite material in the global construction industry. In cement manufacturing, the cement kiln accounts for most of the energy consumption in the production process. As the heart of a cement plant, the cement kiln is where the kiln feed primarily containing calcium oxide (CaO), silica (SiO2), alumina (Al2O3), and iron (Fe2O3) are thermally and chemically transformed into clinker minerals. The presented work developed a multiphysics model, designed and built a laboratory-scale rotary cement clinker kiln, and produced cement clinker at laboratory-scale. The model was developed to study the interaction between the various thermal, fluid dynamic and chemical interactions involved in the sintering process used to form Portland cement clinker in an effort to reduce energy use. The analytical model was validated through experimental testing using a unique laboratory-scale rotary cement kiln developed during the investigation. Also demonstrated was the feasibility of producing clinker at laboratory scale. This modeling and lab scale tests were designed to better understand the clinker sintering process so that operational and quality decisions can be made to optimize energy consumption without compromising cement clinker quality. The computational fluid dynamics modeling was developed in COMSOL Multiphysics 6.0. The characteristics of the combustion fluid flow, concentration of species, temperature and heat transfer were studied for a turbulent flow of methane (CH4) gas and oxygen (O2). Theory suggests that heat transfer impacts the cement production process but the multiphysics model more accurately describes the convection, conduction, and radiant heat transfer in the kilning process and thus allows for a better understanding of the energy exchange driving the chemical reactions that produce Portland cement. Clinker minerals were formed because of appropriate burning conditions implemented during experimental model validation. © 2022 American Institute of Chemical Engineers.