(626e) The Estimation Method Using the Advanced Simulation Technology for Cement Manufacturing Process

The cement clinker manufacturing process is one of the key industrial processes in worldwide. Therefore, the investigation of some reactions in this process with respect to both their influence on the final product and the energy balance of the process is very important.

 Japanese Government, METI (Ministry of Economy Trade and Industry) is financially supporting “Innovative Fundamental Technology Development for Cement Manufacturing Project” which was started in2010. Final goal of this project is to accomplish 8% energy reduction in cement manufacturing process. UBE plays a role of “Development of Simulation Technology” in this project, which can evaluate the energy consumption of the cement manufacturing process. To do this, correct treatment of many chemical reaction and heat balances in cement manufacturing process are required.

 In our study, roughly a hundred numbers of pure components, liquid slag and solid solutions has been considered. Furthermore, to estimate the temperature profile in the rotary kiln correctly, “Fluent”, a CFD code, has been used and coupled with “KilnSimu”. The coupled solution yields the enhanced accuracy in estimating the gas volume phenomena compared to one dimensional treatment in “KilnSimu” and detailed analysis of the pulverized coal burner area.

 By using these simulation tools, effect of leakage air, fuel/air ratio, clinker cooler efficiency and rotary kiln dimension are quantitatively examined. Among these factors, improvement of clinker cooler efficiency was most effective for energy reduction in the cement manufacturing process.