AERODYNAMIC & COMBUSTION MODELLING STUDY

This activity involves combustion and heat transfer modelling of the kiln system under the existing and optimised conditions. This includes the design, manufacture and test at our works, of a physical model of the kiln and the preparation of a technical report, including photographs. The design of the model will be based on plant drawings and data supplied by the site personnel and obtained during the site survey.

The model investigations will use acid/alkali modelling to study fuel/air mixing and the combustion characteristics of the existing systems, combined with water/bead modelling to investigate flow patterns.  The physical modelling will be used to investigate the present operating conditions and to determine the optimum conditions which can be achieved.

Mathematical modelling of the combustion and heat transfer in the kiln will also be undertaken. This is based on the above air/fuel mixing regimes to determine the heat flux and heat transfer to the product in the kiln. The mathematical modelling will take into account the effect of the fuel burnout and heat transfer characteristics of the specified fuels.

The results of the model study together with recommendations are presented in a report.

Activities typically include:

  • design and manufacture of a scale physical model of cooler, hood and kiln rotary section
  • verify current combustion system operating conditions
  • optimisation of combustion system operating conditions, which can include:
    • burner insertion distance and alignment
    • dam ring geometry and location
    • hood geometry and in-leakage
    • burner process parameters and mechanical configuration
  • optimisation of combustion system operating conditions, which will include:
    • aerodynamic modelling of kiln cooler and hood
    • combustion modelling of kiln cooler, hood and firing system

Deliverables typically include:

  • basic combustion system optimised parameters
  • establishing fuel/air mixing regime
  • derive heat flux profile
  • identify requirements for modification
  • report of conclusions and recommendations (paper and electronic version), with option for video

The Method