Heat Balance Analysis in Cement Rotary Kiln

Shihab Ali Khalifa; Doha Yahia Alsadig

doi:doi:10.11648/j.aas.20190402.11

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Heat Balance Analysis in Cement Rotary Kiln

Shihab Ali Khalifa, Doha Yahia Alsadig

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.

DOI	10.11648/j.aas.20190402.11
Published in	Advances in Applied Sciences (Volume 4, Issue 2, April 2019)
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), 2024. 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

Shihab Ali Khalifa

Nile Cement Company Ltd, Rabak, Sudan
Doha Yahia Alsadig

Nile Cement Company Ltd, Rabak, Sudan

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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

Copy | Download

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

Copy | Download

@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}
}

Copy | Download

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  -

Copy | Download