The Effect of Alternative Fuel Combustion in the Cement Kiln Main Burner on Production Capacity and Improvement with Oxygen Enrichment
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.
[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.
[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.
@article{"International Journal of Chemical, Materials and Biomolecular Sciences:62226", author = "W. K. Hiromi Ariyaratne and Morten C. Melaaen and Lars-André Tokheim", title = "The Effect of Alternative Fuel Combustion in the Cement Kiln Main Burner on Production Capacity and Improvement with Oxygen Enrichment", 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.", volume = "7", number = "4", pages = "205-7", }
