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Dynamical Simulation Model of the Pyro-Process in Cement Clinker Production

Jan Lorenz Svensen, Wilson Ricardo Leal da Silva, Zhanhao Zhang, Steen Hørsholt, John Bagterp Jørgensen

TL;DR

The paper addresses reducing CO$_2$ emissions in cement clinker production by developing a dynamic, physics-based simulator of the full pyro-process. It constructs an index-$1$ DAE system using a modular finite-volume framework that couples mass and energy balances with thermo-physical properties, transport phenomena, stoichiometry/kinetics, geometry, and module interconnections. A key contribution is the unified, controllable model that integrates cyclones, calciner, kiln, and cooler with boundary conditions and false-air effects, calibrated to a steady-state scenario and validated by dynamic responses to a step-feed input. The results demonstrate the model’s potential for model-based control and optimization to improve clinker quality, energy efficiency, and emissions in cement plants, providing a foundation for digital twins and control strategies in practice.

Abstract

This study presents a dynamic simulation model for the pyro-process of clinker production in cement plants. The study aims to construct a simulation model capable of replicating the real-world dynamics of the pyro-process to facilitate research into the improvements of operation, i.e., the development of alternative strategies for reducing CO2 emissions and ensuring clinker quality, production, and lowering fuel consumption. The presented model is an index-1 differential-algebraic equation (DAE) model based on first engineering principles and modular approaches. Using a systematic approach, the model is described on a detailed level that integrates geometric aspects, thermo-physical properties, transport phenomena, stoichiometry and kinetics, mass and energy balances, and algebraic volume and energy conservations. By manually calibrating the model to a steady-state reference, we provide dynamic simulation results that match the expected reference performance and the expected dynamic behavior from the industrial practices.

Dynamical Simulation Model of the Pyro-Process in Cement Clinker Production

TL;DR

The paper addresses reducing CO emissions in cement clinker production by developing a dynamic, physics-based simulator of the full pyro-process. It constructs an index- DAE system using a modular finite-volume framework that couples mass and energy balances with thermo-physical properties, transport phenomena, stoichiometry/kinetics, geometry, and module interconnections. A key contribution is the unified, controllable model that integrates cyclones, calciner, kiln, and cooler with boundary conditions and false-air effects, calibrated to a steady-state scenario and validated by dynamic responses to a step-feed input. The results demonstrate the model’s potential for model-based control and optimization to improve clinker quality, energy efficiency, and emissions in cement plants, providing a foundation for digital twins and control strategies in practice.

Abstract

This study presents a dynamic simulation model for the pyro-process of clinker production in cement plants. The study aims to construct a simulation model capable of replicating the real-world dynamics of the pyro-process to facilitate research into the improvements of operation, i.e., the development of alternative strategies for reducing CO2 emissions and ensuring clinker quality, production, and lowering fuel consumption. The presented model is an index-1 differential-algebraic equation (DAE) model based on first engineering principles and modular approaches. Using a systematic approach, the model is described on a detailed level that integrates geometric aspects, thermo-physical properties, transport phenomena, stoichiometry and kinetics, mass and energy balances, and algebraic volume and energy conservations. By manually calibrating the model to a steady-state reference, we provide dynamic simulation results that match the expected reference performance and the expected dynamic behavior from the industrial practices.

Paper Structure

This paper contains 43 sections, 91 equations, 10 figures, 13 tables.

Table of Contents

  1. Introduction
  2. Paper outline
  3. The pyro-process
  4. Dynamic simulation model
  5. Model approach and notation
  6. Mass and energy balances
  7. Cyclones
  8. Calciner and risers
  9. Kiln
  10. Cooler
  11. Algebraic equations for volume and internal energy
  12. Thermo-physical models
  13. Enthalpy
  14. Volume
  15. Heat capacity
  16. ...and 28 more sections

Figures (10)

  • Figure 1: A conceptual layout of the pyro-process of clinker production. The flow patterns of feed material, gas content, and their mixture are indicated by directional arrows.
  • Figure 2: Geometric profiles of the cyclone: (a) the horizontal cross section at entrance level, (b) the vertical axial profile.
  • Figure 3: Diagrams of the calciner profiles. The diagrams illustrate the dimensions and flow direction.
  • Figure 4: Diagram of the cooler axial profile. The arrows show the cross-current flows of clinker and air.
  • Figure 5: Diagram of kiln profiles. The arrows show the flow directions.
  • ...and 5 more figures