A Dynamical Simulation Model of a Cement Clinker Rotary Kiln

TL;DR

This paper develops a 1D dynamical simulation model of a cement clinker rotary kiln based on engineering principles, capturing thermophysical, chemical, and transport phenomena to aid process control development.

Contribution

It introduces a comprehensive first-principles model of a rotary kiln that details phase evolution and combustion, serving as a foundation for process control improvements.

Findings

Model accurately simulates clinker phase development

Demonstrates potential for process control optimization

Provides detailed compound evolution during kiln operation

Abstract

This study provides a systematic description and results of a dynamical simulation model of a rotary kiln for clinker, based on first engineering principles. The model is built upon thermophysical, chemical, and transportation models for both the formation of clinker phases and fuel combustion in the kiln. The model is presented as a 1D model with counter-flow between gas and clinker phases and is demonstrated by a simulation using industrially relevant input. An advantage of the proposed model is that it provides the evolution of the individual compounds for both the fuel and clinker. As such, the model comprises a stepping stone for evaluating the development of process control systems for existing cement plants.