The Effect of Alternative Fuel Combustion in the Cement Kiln Main Burner on Production Capacity and Improvement with Oxygen Enrichment

Authors: W. K. Hiromi Ariyaratne, Morten C. Melaaen, Lars-André Tokheim

Abstract:

A mathematical model based on a mass and energy balance for the combustion in a cement rotary kiln was developed. The model was used to investigate the impact of replacing about 45 % of the primary coal energy by different alternative fuels. Refuse derived fuel, waste wood, solid hazardous waste and liquid hazardous waste were used in the modeling. The results showed that in order to keep the kiln temperature unchanged, and thereby maintain the required clinker quality, the production capacity had to be reduced by 1-15 %, depending on the fuel type. The reason for the reduction is increased exhaust gas flow rates caused by the fuel characteristics. The model, which has been successfully validated in a full-scale experiment, was also used to show that the negative impact on the production capacity can be avoided if a relatively small part of the combustion air is replaced by pure oxygen.

Keywords: Alternative fuels, Cement kiln main burner, Oxygen enrichment, Production capacity.

Digital Object Identifier (DOI): doi.org/10.5281/zenodo.1080684

References:

[1] P. Lemieux, E. Stewart, M. Realff and J.A. Mulholland, "Emissions study of co-firing waste carpet in a rotary kiln," Journal of Environmental Management, Vol. 70, no. 1, pp. 27-33, Jan. 2004.
[2] G. Genon and E. Brizio, "Perspectives and limits for cement kilns as a destination for RDF," Waste Management, Vol. 28, no. 11, pp. 2375- 2385, Nov. 2008.
[3] K. H. Karstensen, "Formation, release and control of dioxins in cement kilns," Chemosphere, Vol. 70, no. 4, pp. 543-560, Jan. 2008.
[4] S. Zemba et al., "Emissions of metals and polychlorinated dibenzo(p)dioxins and furans (PCDD/Fs) from Portland cement manufacturing plants: Inter-kiln variability and dependence on fueltypes," Science of the Total Environment, Vol. 409, no. 20, pp. 4198- 4205, Sep. 2011.
[5] Q. Guo and J. O. Eckert, "Heavy metal outputs from a cement kiln cofired with hazardous waste fuels," Journal of Hazardous Materials, Vol. 51, no. 1-3, pp. 47-65, Nov. 1996.
[6] J. O. Eckert and Q. Guo, "Heavy metals in cement and cement kiln dust from kilns co-fired with hazardous waste-derived fuel: Application of EPA leaching and acid-digestion procedures,"Journal of Hazardous Materials, Vol. 59, no. 1, pp. 55-93, Mar. 1998.
[7] W. v. Loo, "Dioxin/furan formation and release in the cement industry," Environmental Toxicology and Pharmacology, Vol. 25, no. 2, pp. 128- 130, Mar. 2008.
[8] U. Kaantee, R. Zevenhoven, R. Backman and M. Hupa, "Cement manufacturing using alternative fuels and the advantages of process modelling," Fuel Processing Technology, Vol. 85, no. 4, pp. 293-301, Mar. 2004.
[9] U. Kääntee, R. Zevenhoven, R. Backman and M. Hupa, "Modelling a cement manufacturing process to study possible impacts of alternative fuels," in TMS fall 2002 Extraction and processing division meeting on recycling and waste treatment in mineral and metal processing: technical and economic aspects, Sweden, June 2002.
[10] M. Kara, "Environmental and economic advantages associated with the use of RDF in cement kilns," Resources, Conservation and Recycling, Vol. 68, pp. 21-28, Nov. 2012.
[11] I. K. Kookos, Y. Pontikes, G.N. Angelopoulos and G. Lyberatos, "Classical and alternative fuel mix optimization in cement production using mathematical programming," Fuel, Vol. 90, no. 3, pp. 1277-1284, Mar. 2011.
[12] C.A. Tsiliyannis, "Alternative fuels in cement manufacturing: Modeling for process optimization under direct and compound operation," Fuel, Vol. 99, pp. 20-39, Sep. 2012.
[13] W. K. H. Ariyaratne, E. V. P. J. M. Edirisinghe, M. C. Melaaen and L.A. Tokheim, "Kiln process impact of alternative solid fuel combustion in the cement kiln main burner - Mathematical modelling and full-scale experiment,", in International Conference on Frontiers of Mechanical Engineering, Materials and Energy, Beijing, 2012, to be published.
[14] O. Marin, O. Charon, J. Dugue, S. Dukhan and W. Zhou, "Simulating the impact of oxygen enrichment in a cement rotary kiln using advanced computational methods," Combustion Science and Technology, Vol. 164, no. 1, pp. 193-207, 2001.
[15] K. S. Mujumdar and V. V. Ranade, "CFD modelling of rotary cement kilns," Asia-Pacific journal of Chemical Engineering, Vol. 3, no. 2, pp. 106-118, Mar./Apr. 2008.
[16] F. Zeman, "Oxygen combustion in cement production," Energy Procedia, Vol. 1, no. 1, pp. 187-194, Feb. 2009.
[17] B. Manickam, F. Dinkelacker, T. Lobe and M. Tertychnyy, "Enriched oxygen combustion simulation for rotary kiln application," in Proceedings of the European Combustion Meeting, 2009.
[18] G. Jankes, M. StanojevicÔÇ▓, M. Karan, M. KuburovicÔÇ▓ and M. AdzicÔÇ▓, "The use of technical oxygen for combustion processes in industrial furnaces," FME Transactions, Vol. 31, pp. 31-37, Apr. 2003.
[19] W. K. H. Ariyaratne, M. C. Melaaen, K. Eine and L. A. Tokheim, "Meat and bone meal as a renewable energy source in cement kilns: Investigation of optimum feeding rate," in International Conference on Renewable Energies and Power Quality, Spain, Apr. 2010.
[20] L. A. Tokheim, "Kiln system modification for increased utilization of alternative fuels at Norcem Brevik," Cement International, Vol.4, no. 4, pp. 52-59, 2006.
[21] W. K. H. Ariyaratne, ├ÿ. Asgautsen, M. C. Melaaen, K. Eine and L.A.Tokheim, "Determination of fossil fraction of refuse derived fuel by the selective dissolution method in calorific value basis: Development of simplified method," Fuel, Vol. 98, pp. 41-47, Aug. 2012.
[22] Specification Vt10, "Execution and Evaluation of kiln performance tests," in Report, German Association of Cement Works (VDZ), May 1992.
[23] L. A. Tokheim, "The impact of staged combustion on the operation of a precalciner cement kiln," in Ph.D. thesis, Telemark University College / Norwegian University of Technology and Science, Norway, 1999.