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Engin and Ari investigated energy audit in a dry type cement rotary kiln using empirical data. They analyzed all three parts (rotary kiln, preheater and cooler) [24]. Mujumdar et al. presented the integrated model for cement rotary kiln, calciner, cooler and preheater, and developed a simulation software titled RoCKS [25].
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An appreciable portion of the energy is being lost in the rotary kiln which has been shown through material and energy balance reported in Table 10, Table 11. The computation points out that 4.2%, 1.12%, 43.5% and 3.6% energy is lost through streams of sponge iron, char, waste gas and volatile matter, respectively.
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The rotary kiln is used in many solid processes, including drying, incineration, heating, cooling, humidification, calcination and reduction. This widespread …
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cement/concrete industry. The cover diagram shows a thermal image of an operating kiln. The high temperature of the kiln surface (300°F to 400°F) accounts for about a 5% energy efficiency loss. The diagram on the cover depicts a kiln that has lost insulating refractory material and shows hot spots and a hot ring that will require future repair.
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The raw material passes through the rotary kiln towards the flame. In the calcination zone, calcination process, combination of alumina, silica and ferric oxide with …
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main units in a cement plant that consumes the most energy is the rotary kiln. Rotary kiln is used for calcination process of cement raw material into clinker. It …
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Analysis of Heat balance was used to determine the sources of heat loss from the kiln system. Based on the collected data, an energy balance is applied to the …
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Influence construction of suspension preheater on energy consumption process during burning in rotary kiln 5 In the suspension preheater, apart from heating and the drying of material has place
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Reaching the outlet of the rotary kiln, the material is discharged into the cooler where lime is cooled and the secondary air is preheated. 3. ... Using the model, the energy balance in the lime production process was also evaluated and related results are depicted in Fig. 6. As shown in this figure, near 70% of fuel burning energy is consumed ...
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DOI: 10.1016/J.APPLTHERMALENG.2016.08.095 Corpus ID: 114547410; Material and energy flows in rotary kiln-electric furnace smelting of ferronickel alloy with energy saving @article{Liu2016MaterialAE, title={Material and energy flows in rotary kiln-electric furnace smelting of ferronickel alloy with energy saving}, author={Peng Fei Liu and Baokuan Li …
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The fuel consumption is calculated analytically by establishing an energy balance over the kiln where the energy for calcination, drying as well as the heat energy of the in- and outgoing streams is accounted for. To calculate the heat energy of the different streams, polynomials were used to describe the temperature ...
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The main function of the rotary kiln in the minerals and materials industry is to convert raw materials (ore) into useful product materials. ... 9 - Mass and Energy Balance. Pages. 203-229. View chapter. Abstract. Heat balance calculations are usually carried out when developing new rotary kiln chemical processes or when improving old ones. No ...
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2.4 Material Balance 12 2.5 Energy Balance 15 2.6 Energy Performance Assessment of Key Equipment 15 3.0 Energy-efficient Technologies in Direct Reduction of Iron Process 17 3.1 Waste Heat Recovery for Power Generation 18 3.2 Iron Ore Preheating Rotary Kiln Using Waste Heat Recovery System 20 3.3 Coal Gasification for Partial Substitution in ...
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Flue gases and shell losses represent around 25% and 8% of the energy input, respectively, while the vaporization of free moisture consumes nearly 15% of the energy input. The rotary kiln furnace ...
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Analysis of Heat balance was used to determine the sources of heat loss from the kiln system. Based on the collected data, an energy balance is applied to the kiln system. The physical properties and equations can be found in Perry's handbook. The reference enthalpy is considered to be zero at 0°C for the calculations.
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Analysis of Heat balance was used to determine the sources of heat loss from the kiln system. Based on the collected data, an energy balance is applied to the kiln system. The physical properties and equations can be found in Perry's handbook. The reference enthalpy is considered to be zero at 0°C for the calculations.
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Q is the rate of heat transfer, W is the rate of work (power), m is the mass flow rate and h is the enthalpy. General energy balance for the rotary kiln and cooler unit can be defined as ...
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In the analysis, they utilized two different heat sources. Karamarkovic et al. [9] used the energy balance of a rotary kiln for calcination of dolomite in a magnesium production company identified the kiln shell (26.35% of the input energy) and exhaust gases (18.95%) as the major sources of heat losses. A heat exchanger is designed to …
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It is clear that the total 39 Shihab Ali Khalifa and Doha Yahia Alsadig: Heat Balance Analysis in Cement Rotary Kiln energy used in the process is …
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The clinker production stages in the rotary cement kiln were evaluated. • Energy and exergy analysis-based laws of thermodynamics were made for a rotary kiln. • The energy analysis demonstrated the first law efficiency of the rotary kiln is 49 %. • The exergy analysis indicated the second law efficiency of the rotary kiln is 37 %. •
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The calculation results of material and energy flows balance of each subsystem are shown in Table 6, Table 7. ... while the vaporization of free moisture consumes nearly 15% of the energy input. The rotary kiln furnace shows energy and exergy efficiencies of 66.4% and 32.3%, respectively, leaving room for waste heat …
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Rasul et al. [1] evaluated the thermal performance of a cement plant in Indonesia with the models of material balance, heat balance, and exergy balance. The analysis showed that the first law of thermodynamics and combustion efficiency of the rotary kiln were 57.07% and 52.07%, respectively, and the heat recovery efficiency of …
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1. Introduction. Over the last century, Portland cement-based concrete has become the highest manufactured product on Earth in terms of volume. Concrete is used worldwide as a building material and is the most consumed substance on Earth after water (Sakai, 2009).The volume of concrete produced globally is approximately 5.30 billion m …
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Heat transfer plays a critical role in the preparation of clinker for a rotary kiln. Often supplied with energy by means of a burner placed at its end, the rotary kiln is the site of numerous heat transfers between walls, and loads circulating and the gas circulating above the free surface of the bed. ... Discharging granular material from a ...
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In order to analyze the conduction in a cement rotary kiln, its cross section has two parts, depending on the presence of product, as shown in Figure 1, and the heat flows also through the product ...
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The results show that after the application of biomass energy in rotary kiln and the improvement of its technology, as well as the production cost and land rent, the enterprise can achieve the maximum economic scale when the production quantity of aluminate cement ranges from 50,000 to 90,000 tons, and may enter the decreasing stage for ...
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4 – Rotary Kiln – Material Bed: This part of the study deals with the mass and energy balance and chemical reactions that the material undergoes throughout the kiln. The main result of this stage of the study is the thermal profile of the gases and the temperature profile of the material bed.
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The exergy balance of the rotary kiln is calculated with the same equations as the calculation for the rotary dryer, and the results are shown in Table 2. One of the main exergy input for the rotary kiln comes from the bituminous coal (i.e. 54.33%) which is more than half of the total exergy input, similar to the energy proportion.
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Download Table | Heat Balance of Kiln from publication: Energy audit of thermal utilities in a cement plant | Energy Audit and Thermal | ResearchGate, the professional network for scientists.
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