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A Dynamic Cooler Model for Cement Clinker Production

Jan Lorenz Svensen, Wilson Ricardo Leal da Silva, Javier Pigazo Merino, Dinesh Sampath, John Bagterp Jørgensen

Abstract

We present a 2D model for a grate belt cooler in the pyro-section of a cement plant. The model is formulated as an index-1 differential-algebraic equation (DAE) model based on first engineering principles. The model systematically integrates thermo-physical aspects, transport phenomena, reaction kinetics, mass and energy balances, and algebraic volume and energy relations. The model is used for dynamic simulation of the cooler and the paper provides dynamic and steady-state simulation results matching the expected behavior. The cooler model is one part of a full pyro-section model for dynamical simulations. The model can serve as a basis for the design of optimization and control systems towards improving energy efficiency and CO2 emission.

A Dynamic Cooler Model for Cement Clinker Production

Abstract

We present a 2D model for a grate belt cooler in the pyro-section of a cement plant. The model is formulated as an index-1 differential-algebraic equation (DAE) model based on first engineering principles. The model systematically integrates thermo-physical aspects, transport phenomena, reaction kinetics, mass and energy balances, and algebraic volume and energy relations. The model is used for dynamic simulation of the cooler and the paper provides dynamic and steady-state simulation results matching the expected behavior. The cooler model is one part of a full pyro-section model for dynamical simulations. The model can serve as a basis for the design of optimization and control systems towards improving energy efficiency and CO2 emission.
Paper Structure (20 sections, 30 equations, 7 figures, 4 tables)

This paper contains 20 sections, 30 equations, 7 figures, 4 tables.

Table of Contents

  1. Introduction
  2. The Cooler
  3. A mathematical cooler model
  4. Algebraic relations
  5. Mass and Energy balances
  6. Thermodynamic
  7. Stoichiometry and kinetics
  8. Transport
  9. Material flux
  10. Enthalpy and heat transport
  11. Velocities
  12. Heat transfer between phases
  13. Viscosity and conductivity
  14. boundary conditions
  15. Simulation Results
  16. ...and 5 more sections

Figures (7)

  • Figure 1: The pyro-section for clinker production in a cement plant consists of preheating tower of cyclones (Cy), a calciner (Ca), a rotary kiln (K), and a cooler (Co).
  • Figure 2: Cooler axial profile.
  • Figure 3: Segment layout of the cooler with a selection of flows; solid flows (dark blue) and gas flows (light blue).
  • Figure 4: Dynamic simulation of cooler concentration and temperature. The cooler is divided into 10 segments of finite volumes.
  • Figure 5: The steady-state mass flows of solids along the length of the cooler. All of the decomposition of Alite (C3S) to Belite (C2S) is quickly halted by the cooling.
  • ...and 2 more figures