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Research Paper

Multi-physical field coupling simulation study in cement rotary kiln

  • GUAN Jing ,
  • TIAN Yu-Jie ,
  • LIU Yin-Jie ,
  • LI Fei ,
  • YE Jia-Yuan ,
  • XU Cheng-Wen ,
  • LU Chun-Xi ,
  • WANG Wei
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  • 1. State Key Laboratory of Heavy Oil Processing, China University of Petroleum, Beijing 102249, China 2. State Key Laboratory of Mesoscience and Engineering, Institute of Process Engineering, Chinese Academy of Sciences, Beijing 100190, China 3. Anhui Key Laboratory of Green and Low-carbon Technology in Cement Manufacturing, Hefei Cement Research & Design Institute Co., Ltd., Hefei, Anhui 230051, China 4. School of Chemical Engineering, University of Chinese Academy of Sciences, Beijing 100049, China 5. State Key Laboratory of Green Building Materials, China Building Materials Academy Co., Ltd., Beijing 100024, China

Received date: 2024-09-26

  Revised date: 2024-11-19

  Online published: 2025-05-30

Abstract

As a key equipment in the cement production process, the combustion of gas-phase pulverized coal particles and the sintering reaction of solid-phase cement are carried out at the same time, which has a decisive impact on the generation of cement clinker products and the quality of products. However, due to the large difference in reaction rate and flow rate between the two processes, most of the existing simulations are limited to the study of a single solid-phase sintering or gas-phase pulverized coal combustion reaction process, and the interaction between the two processes is rarely discussed. In view of this shortcoming, an innovative gas-solid phase coupling simulation method was proposed, which divided the kiln area into three-dimensional gas-phase pulverized coal combustion zone and one-dimensional solid-phase cement sintering zone, which were simulated independently, and the close coupling between the two processes was realized through iterative calculation. The coupled simulation method effectively overcame the simulation challenges caused by the significant difference in flow velocity between the gas phase and the solid phase, and can more comprehensively reveal the interaction mechanism of fluid flow, heat transfer and chemical reaction in the kiln, providing a multi-scale coupled simulation method for the complex system of rotary kiln. The coupled simulation results showed that compared with the traditional single one-dimensional or three-dimensional simulation, this method can significantly improve the simulation accuracy, and the simulation results were highly consistent with the actual clinker output data of the plant. It can effectively guide the optimal design and operation process of rotary kiln, so as to improve the quality of clinker products, and provide an accurate and efficient simulation method for the simulation of cement rotary kiln.

Cite this article

GUAN Jing , TIAN Yu-Jie , LIU Yin-Jie , LI Fei , YE Jia-Yuan , XU Cheng-Wen , LU Chun-Xi , WANG Wei . Multi-physical field coupling simulation study in cement rotary kiln[J]. The Chinese Journal of Process Engineering, 2025 , 25(5) : 445 -458 . DOI: 10.12034/j.issn.1009-606X.224299

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