Kilns heat transfer

Heat Transfer in Rotary Kilns. Heat transfer in rotary kilns occurs by conduction, convection, and radiation. In a highly simplified model, the treatment of radiation can be explained by applying a one-dimensional furnace approximation (19). The gas is assumed to be in plug flow the absorptivity, a, and emissivity, S, of the gas are assumed equal (a = e ) and the presence of water in the soHds is taken into account. Energy balances are performed on both the gas and soHd streams. Parallel or countercurrent kilns can be specified. 

The sohds are also assumed to be in plug flow. As part of the plug flow approximation, the gas and soHds are assumed isothermal in the radial direction at a given axial location. Detailed models for kiln heat transfer are available (20,21). 

The time constants characterizing heat transfer in convection or radiation dominated rotary kilns are readily developed using less general heat-transfer models than that presented herein. These time constants define simple scaling laws which can be used to estimate the effects of fill fraction, kiln diameter, moisture, and rotation rate on the temperatures of the soHds. Criteria can also be estabHshed for estimating the relative importance of radiation and convection. In the following analysis, the kiln wall temperature, and the kiln gas temperature, T, are considered constant. Separate analyses are conducted for dry and wet conditions. 

Comparisons of the complete heat-transfer model with pilot-scale rotary kiln data are shown iu Figure 5 (21) for moisture levels ranging from 0 to 20 wt %. The tremendous thermal impact of moisture is clearly visible iu the leveling of temperature profiles at 100°C. 

Operabihty (ie, pellet formation and avoidance of agglomeration and adhesion) during kiln pyrolysis of urea can be improved by low heat rates and peripheral speeds (105), sufficiently high wall temperatures (105,106), radiant heating (107), multiple urea injection ports (106), use of heat transfer fluids (106), recycling 60—90% of the cmde CA to the urea feed to the kilns (105), and prior formation of urea cyanurate (108). 

Equation (12-57) does not account for gas radiation at high temperature when the kiln charge can see the burner flame hence, the method will yield a conservative design. When a kiln is fired internally, the major source of heat transfer is radiation from the flame and hot gases. This occurs directly to both the sohds surface and the wall, and from the latter to the product by reradiation (with some conduction). 

Rotary kilns operate at various temperatures throughout their length. A graph of approximate gas and charge temperatures for wet-process cement is shown in Fig. 12-67. The maximum charge temperature is 1700 to 1800 K for the gases, 1800 to 1925 K. Overall heat-transfer rates have been estimated to be in the range of 25 to 60 KJ/(s-m ) on the basis of total kiln volume. 

Multi-stage preheating, pre-calciners, kiln combustion system improvements, enhancement of internal heat transfer in kiln, kiln shell loss reduction, optimize heat transfer in clinker cooler, use of waste fuels Blended cements, cogeneration... 

An important application of heat transfer to a sphere is that of conduction through a stationary fluid surrounding a spherical particle or droplet of radius r as encountered for example in fluidised beds, rotary kilns, spray dryers and plasma devices. If the temperature difference T[ T2 is spread over a very large distance so that r2 = oo and 7 t is the temperature of the surface of the drop, then ... 

Dry process cement production facilities often have several other types of manufacturing equipment designed to increase fuel efficiency. First, many dry process kilns add a preheater to the feed end of the kiln to begin heating of the feed prior to its entrance to the kiln. Two main types of preheaters exist, the suspension preheater and the traveling grate preheater both use hot, exiting kiln air to facilitate a more efficient heat transfer to the feed than could occur in the feed end of the kiln itself.1 This... 

Haloclean A pyrolytic process for destroying scrap plastics, especially those derived from scrap electronic equipment. The material is passed through a horizontal rotary kiln containing metal spheres that aid the heat transfer. Developed in Karlsruhe, Germany, and piloted from 2006. 

Weber, P. Heat Transfer in Rotary Kilns, 98 pp., Bauverlag, Wiesbaden and Berlin (1963). 

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