This document summarizes a numerical simulation of a rotary kiln. The simulation models turbulent combustion, heat transfer, and granular flow inside the kiln. It seeks to understand formation of rings within the kiln and optimize production. The model considers chemical reactions, turbulence, radiation heat transfer, and NOx formation. It was used to test adjusting the fuel-air ratio to reduce temperature peaks that cause rings. Increasing the ratio from 10 to 12 successfully destroyed an existing ring over 24 hours by lowering the liquid phase temperature below self-sustaining levels. The model will further explore configurations to prevent or counteract ring formation and reduce NOx emissions.
Electrodes for Energy Delivery and StorageDavid Pan
The document summarizes research into developing a new cathode material for energy storage devices by growing carbon fibers directly onto copper wire using nanocatalysts. Key points are: (1) Carbon fibers are grown via chemical vapor deposition onto copper wire to create a highly conductive current collector. (2) Scanning electron microscopy shows the fibers form a dense layer and their diameter increases with higher growth temperatures. (3) Cyclic voltammetry indicates the surface area increases with the fiber growth, improving the electrode performance. The developed current collector will be functionalized with nanoredox centers and tested in batteries and supercapacitors.
This document discusses the thermal performance of concrete masonry. It covers utilizing thermal mass advantages, selecting insulation systems, addressing thermal bridging, and controlling air infiltration. Some key points include how thermal mass can decrease heating and cooling loads, how insulation selection depends on climate and design criteria, how thermal bridging can increase heat loss, and how air infiltration accounts for a large portion of energy use. Proper insulation strategies and air sealing are important to optimize thermal performance.
This document discusses a study on carbon deposition during steam reforming of glycerol using a bimetallic Co-Ni/Al2O3 catalyst. Glycerol is a byproduct of biodiesel production that can be converted to syngas via steam reforming, but carbon deposition must be minimized for process efficiency. The study examines steam reforming of an aqueous glycerol solution over a temperature range of 773-823K using a tubular reactor. Various characterization techniques are used to analyze the catalyst before and after reaction, including thermal gravimetric analysis, total organic carbon content analysis, Fourier transform infrared spectroscopy, and X-ray diffraction.
Knight Frank: The Bishops Avenue, Hapstead, LondonKnight Frank LLP
Set in nearly 2 acres of landscaped gardens on the renowned Bishops Avenue are 14 luxurious apartments, each individually designed with meticulous attention to detail and finished to a world-class specification.
This is a presentation from JSW Steel, one of the finalists at the 5th CII-GBC National
Award for Excellence in Water Management in 2008
The awards are in 2 categories, Within the Fence for work done on minimizing the organisations water footprint, and Beyond the Fence for work done in the community around the industry.
This presentation was in the "Within the Fence" category.
We thank CII and the respective companies for giving us permission to upload these presentations on the India Water Portal website for dissemination to a wider audience.
This document discusses the application of carbon nanotubes in plastics. It describes how carbon nanotubes have extraordinary mechanical and thermal properties like high strength, stiffness, and thermal conductivity. It then explains how Bayer MaterialScience produces multi-walled carbon nanotube agglomerates called Baytubes through a catalytic chemical vapor deposition process at large scale. These Baytubes have very high purity and can enable new applications in conductive polymers, composites, coatings and other materials.
Neoker is the sole producer of single-crystal pure alumina fibers. These fibers show a unique combination of high strength, thermal resistance, and chemical stability. Potential applications include metal matrix composites, ceramic matrix composites, and high-temperature insulation. Neoker was founded as a spin-off from the Institute of Ceramic Materials of Galicia to commercialize this novel fiber production technology.
Nanofibers of aluminum oxide
Nafen is a new material consisting of aluminum oxide nanofibers with gamma and chi crystal phases. It has fiber diameters of 7-10 nm or 30-40 nm, lengths up to 150 mm, and a specific surface area of 155 m2/g. Nafen is produced via a continuous process that yields over 0.5 kg/hour. TEM images show the fine fiber structure and high length-to-diameter ratio. The fibers are co-aligned in blocks up to 50x50x15 cm with a bulk density of 0.1-0.4 g/cm3. Analysis confirms the gamma and chi phases of polycrystalline
Electrodes for Energy Delivery and StorageDavid Pan
The document summarizes research into developing a new cathode material for energy storage devices by growing carbon fibers directly onto copper wire using nanocatalysts. Key points are: (1) Carbon fibers are grown via chemical vapor deposition onto copper wire to create a highly conductive current collector. (2) Scanning electron microscopy shows the fibers form a dense layer and their diameter increases with higher growth temperatures. (3) Cyclic voltammetry indicates the surface area increases with the fiber growth, improving the electrode performance. The developed current collector will be functionalized with nanoredox centers and tested in batteries and supercapacitors.
This document discusses the thermal performance of concrete masonry. It covers utilizing thermal mass advantages, selecting insulation systems, addressing thermal bridging, and controlling air infiltration. Some key points include how thermal mass can decrease heating and cooling loads, how insulation selection depends on climate and design criteria, how thermal bridging can increase heat loss, and how air infiltration accounts for a large portion of energy use. Proper insulation strategies and air sealing are important to optimize thermal performance.
This document discusses a study on carbon deposition during steam reforming of glycerol using a bimetallic Co-Ni/Al2O3 catalyst. Glycerol is a byproduct of biodiesel production that can be converted to syngas via steam reforming, but carbon deposition must be minimized for process efficiency. The study examines steam reforming of an aqueous glycerol solution over a temperature range of 773-823K using a tubular reactor. Various characterization techniques are used to analyze the catalyst before and after reaction, including thermal gravimetric analysis, total organic carbon content analysis, Fourier transform infrared spectroscopy, and X-ray diffraction.
Knight Frank: The Bishops Avenue, Hapstead, LondonKnight Frank LLP
Set in nearly 2 acres of landscaped gardens on the renowned Bishops Avenue are 14 luxurious apartments, each individually designed with meticulous attention to detail and finished to a world-class specification.
This is a presentation from JSW Steel, one of the finalists at the 5th CII-GBC National
Award for Excellence in Water Management in 2008
The awards are in 2 categories, Within the Fence for work done on minimizing the organisations water footprint, and Beyond the Fence for work done in the community around the industry.
This presentation was in the "Within the Fence" category.
We thank CII and the respective companies for giving us permission to upload these presentations on the India Water Portal website for dissemination to a wider audience.
This document discusses the application of carbon nanotubes in plastics. It describes how carbon nanotubes have extraordinary mechanical and thermal properties like high strength, stiffness, and thermal conductivity. It then explains how Bayer MaterialScience produces multi-walled carbon nanotube agglomerates called Baytubes through a catalytic chemical vapor deposition process at large scale. These Baytubes have very high purity and can enable new applications in conductive polymers, composites, coatings and other materials.
Neoker is the sole producer of single-crystal pure alumina fibers. These fibers show a unique combination of high strength, thermal resistance, and chemical stability. Potential applications include metal matrix composites, ceramic matrix composites, and high-temperature insulation. Neoker was founded as a spin-off from the Institute of Ceramic Materials of Galicia to commercialize this novel fiber production technology.
Nanofibers of aluminum oxide
Nafen is a new material consisting of aluminum oxide nanofibers with gamma and chi crystal phases. It has fiber diameters of 7-10 nm or 30-40 nm, lengths up to 150 mm, and a specific surface area of 155 m2/g. Nafen is produced via a continuous process that yields over 0.5 kg/hour. TEM images show the fine fiber structure and high length-to-diameter ratio. The fibers are co-aligned in blocks up to 50x50x15 cm with a bulk density of 0.1-0.4 g/cm3. Analysis confirms the gamma and chi phases of polycrystalline
Torrefaction is a pretreatment process for biomass that increases its energy density and improves its properties for combustion and gasification. It involves heating biomass to 200-300°C in the absence of oxygen, which makes the biomass more hydrophobic, brittle, and increases its energy content from 18-23 MJ/kg. Several reactor concepts have been tested at the lab scale but no commercial plants yet. The process results in a 70% mass yield but 90% energy yield along with significantly reduced grinding requirements. Further research is still needed but torrefaction shows promise for more efficient biomass utilization.
The document summarizes a workshop on limiting factors in high temperature electrolysis. It discusses environmental and resource concerns motivating hydrogen production from electrolysis. Renewable and nuclear energy could power electrolysis to produce hydrogen for storage or conversion to synthetic fuels. Key challenges include electrolyzer durability, thermodynamics, heat management, and costs. Large-scale electrolysis tests demonstrate feasibility but further advances are needed for commercialization.
This document summarizes a study that models the thermal conductivity of graphite nanosheet (GNS)/epoxy composites. An effective medium model is used to analyze how the thermal conductivity of these composites is affected by the aspect ratio and orientation of the GNS, as well as the interfacial thermal resistance between the GNS and polymer matrix. The model predicts that the interfacial thermal resistance between GNS and polymers is about one order of magnitude lower than between carbon nanotubes and polymers, potentially explaining the high thermal conductivity observed experimentally for GNS/epoxy composites.
The Athletes Village project achieved significant reductions in carbon emissions through improved building design and construction techniques. Specifically:
1) Building designs focused on energy efficiency, using improved insulation, airtight construction, and heat recovery systems to reduce energy consumption by over 60% on average.
2) Construction methods like on-site soil reuse and rail transport of aggregates reduced embodied carbon in materials.
3) Operational carbon is predicted to be reduced by 83% per apartment compared to typical buildings, avoiding over 13,000 tonnes of CO2 emissions annually through efficient lighting, appliances, and connection to low-carbon power.
This document summarizes a project to optimize combustion at the Crystal River Unit 4 power plant through continuous combustion management. Equipment was added to measure and control coal and air flows to burners. Coal flow was balanced across pulverizers and burners. Secondary air flows were measured and automatically adjusted at each burner. O2 and CO probes were relocated or augmented. These changes improved boiler efficiency by 0.5%, reduced NOx emissions by 7-15%, and lowered operating costs through reduced reagent and fuel usage and extended equipment life.
Reducing Embodied Carbon in the built environment will play an increasingly important role in reducing overall carbon emissions over the next 20 years. For buildings, the focus has mostly been on reducing emissions by reducing the use of fossil fuels for operating energy. But we also need to reduce the carbon emissions embodied in the materials and resulting from the construction phase. As buildings become more efficient to operate, the embodied energy and emissions from materials and construction becomes an increasingly significant portion of total GHG emissions.
The document discusses ways to reduce nitrogen oxide (NOx) emissions from cement plants. It outlines various primary measures cement plants can take including optimizing processes like air levels and burner operations, using low-nitrogen fuels, and installing equipment like low-NOx burners and calciners. Secondary measures like selective non-catalytic reaction and selective catalytic reaction are also mentioned. Charts show the effectiveness of different measures and NOx emission levels from specific plants over time periods. The goal is to control NOx emissions to meet regulatory limits.
The document provides information on Satna Cement Works, a cement plant owned by Birla Corp. Ltd. in Satna, Madhya Pradesh, India. It details the plant's current installed capacity of 2.36 million tons and planned expansion to 2.84 million tons. It then outlines the 17 major processes involved in cement production, from limestone quarrying and crushing to clinker production, cement milling, storage, and dispatch. Finally, it includes a Gantt chart scheduling the author's six-week training program at the plant.
CON 123 - Session 2 - Raw Materials and Grindingalpenaccedu
The document discusses the raw materials and manufacturing process for Portland cement. Key raw materials include limestone, silica, alumina, and iron which are ground and blended. The blended raw mix is then burned at high temperatures in a kiln to form cement clinker in a chemical reaction. The clinker is then ground with gypsum to produce Portland cement, which is stored and delivered. Modern dry processing uses a preheater and precalciner to burn the raw mix more efficiently in a shorter kiln.
The document summarizes literature on the relationship between clinker microstructure and grindability. The key findings are:
1) The primary factors influencing grindability are alite and belite crystal size and content, with smaller crystals and more alite (less belite) resulting in easier grinding.
2) Secondary factors like belite clustering, porosity, and trace element content can also affect grindability.
3) Several equations exist to estimate grindability based on alite/belite content and size, though results may vary slightly between equations. All show easier grinding with high alite and low belite content and smaller crystal sizes.
- Portland cement is produced by heating limestone, clay, and other materials to form clinker, which is then ground with gypsum.
- The main compounds in clinker are tricalcium silicate, dicalcium silicate, tricalcium aluminate, and tetracalcium aluminoferrite.
- The proportions of calcium oxide, silicon dioxide, aluminum oxide, and iron oxide in the raw materials determine the compound composition through Bogue equations.
The document discusses NOx assessment and reduction techniques. It provides information on:
1) NOx emissions from cement kilns can range from <500 to >1500 mg/Nm3 without additional controls, depending on factors like fuel used, kiln operation, and calciner design. Getting below 500 mg/Nm3 typically requires optimized reburn design or retrofits.
2) Hot reburn designs by CINAR involve maintaining temperatures of 1200C or 1300C for short residence times (0.15-1 seconds) before additional air/meal introduction to allow NOx reduction reactions while avoiding re-oxidation.
3) Optimizing SNCR for maximum NOx reduction requires understanding the impact of CO
CON 123 Session 3 - Typical Raw Mix Designalpenaccedu
The document discusses the raw materials and chemical processes involved in manufacturing Portland cement. It describes the key oxides (calcium, silica, alumina, iron) needed in the raw mix and how the Bogue equations are used to calculate the compounds (C3S, C2S, C3A, C4AF) formed during burning. An example raw mix design is provided along with the calculations to determine the compounds using the Bogue equations on the loss-free chemical analysis. The moduli calculations for lime saturation, silica ratio, and alumina ratio are also outlined. Finally, it briefly describes the wet and dry production processes and shows images of Portland cement clinker.
The cement manufacturing process involves quarrying raw materials such as limestone and clay, crushing and transporting them to the cement plant. At the plant, the raw materials are homogenized and finely ground into a raw mix, which is preheated and burnt in a kiln at 1500°C to produce clinker. The clinker is cooled, ground with gypsum and other additives to produce cement powder, which is stored in silos before being packed and dispatched.
This document discusses cement kiln operations, including:
1. The basic components of a cement kiln system including a preheater, rotary kiln, and clinker cooler.
2. Key parameters for monitoring kiln performance like production rate, fuel consumption, and temperatures.
3. Developments in preheater and precalciner technologies that have improved efficiency.
4. Factors that affect kiln operation and ways to optimize performance, such as maintaining proper free lime levels and maximizing secondary air temperature.
This document provides information about cement, including its chemistry, composition, types, manufacturing process, and key equipment used. Cement is made by heating limestone and other materials to form clinker, which is then ground with gypsum. The main steps are mining raw materials, crushing, grinding to a raw meal, pyroprocessing to form clinker, and final grinding of clinker to cement. Key equipment includes raw mills, kilns, preheaters, and ball mills.
This document is the second edition of the Cement Plant Operations Handbook. It provides concise guidance on cement manufacture using dry process cyclone preheater kiln technology, which accounts for over 80% of global cement production. The handbook covers various aspects of cement plant operations including raw materials, grinding, burning, cooling, finishing, quality control, maintenance, accounting and reporting. It also includes process data, calculations and conversion tables to support plant operations. The handbook is intended to serve as a useful reference for cement plant personnel.
The document provides an overview of the cement production process and factors that influence quality. It discusses:
1. Raw materials used like limestone, clay, and their quality parameters which determine the raw mix design and chemical composition.
2. The cement manufacturing stages of raw grinding, kiln burning and clinker cooling. Key factors like raw mix characteristics, burning process, and clinker/fuel quality influence the final cement quality.
3. Different cement types produced for various applications and how additives like gypsum and fly ash affect the physical properties.
A Rotary kiln is a pyroprocessing device used to raise materials to a high temperature (calcination) in a continuous process. Materials produced using rotary kilns include: Cement. Lime.
1. The residence time in a rotary kiln is calculated using a formula that considers the angle of repose of the limestone, length of the kiln, kiln inclination, effective diameter, and rotation speed.
2. A rotary kiln's capacity is determined by considering factors like the capacity of the ID fan, preheater cyclone design, proclaimed design and volume, kiln inclination and volume, kiln filling percentage, specific volume and thermal loading, and kiln drive capacity.
3. Important kiln parameters include the specific volume loading, specific thermal loading, cooler specific loading, and kiln percentage filling, which should be between 4-16%.
Torrefaction is a pretreatment process for biomass that increases its energy density and improves its properties for combustion and gasification. It involves heating biomass to 200-300°C in the absence of oxygen, which makes the biomass more hydrophobic, brittle, and increases its energy content from 18-23 MJ/kg. Several reactor concepts have been tested at the lab scale but no commercial plants yet. The process results in a 70% mass yield but 90% energy yield along with significantly reduced grinding requirements. Further research is still needed but torrefaction shows promise for more efficient biomass utilization.
The document summarizes a workshop on limiting factors in high temperature electrolysis. It discusses environmental and resource concerns motivating hydrogen production from electrolysis. Renewable and nuclear energy could power electrolysis to produce hydrogen for storage or conversion to synthetic fuels. Key challenges include electrolyzer durability, thermodynamics, heat management, and costs. Large-scale electrolysis tests demonstrate feasibility but further advances are needed for commercialization.
This document summarizes a study that models the thermal conductivity of graphite nanosheet (GNS)/epoxy composites. An effective medium model is used to analyze how the thermal conductivity of these composites is affected by the aspect ratio and orientation of the GNS, as well as the interfacial thermal resistance between the GNS and polymer matrix. The model predicts that the interfacial thermal resistance between GNS and polymers is about one order of magnitude lower than between carbon nanotubes and polymers, potentially explaining the high thermal conductivity observed experimentally for GNS/epoxy composites.
The Athletes Village project achieved significant reductions in carbon emissions through improved building design and construction techniques. Specifically:
1) Building designs focused on energy efficiency, using improved insulation, airtight construction, and heat recovery systems to reduce energy consumption by over 60% on average.
2) Construction methods like on-site soil reuse and rail transport of aggregates reduced embodied carbon in materials.
3) Operational carbon is predicted to be reduced by 83% per apartment compared to typical buildings, avoiding over 13,000 tonnes of CO2 emissions annually through efficient lighting, appliances, and connection to low-carbon power.
This document summarizes a project to optimize combustion at the Crystal River Unit 4 power plant through continuous combustion management. Equipment was added to measure and control coal and air flows to burners. Coal flow was balanced across pulverizers and burners. Secondary air flows were measured and automatically adjusted at each burner. O2 and CO probes were relocated or augmented. These changes improved boiler efficiency by 0.5%, reduced NOx emissions by 7-15%, and lowered operating costs through reduced reagent and fuel usage and extended equipment life.
Reducing Embodied Carbon in the built environment will play an increasingly important role in reducing overall carbon emissions over the next 20 years. For buildings, the focus has mostly been on reducing emissions by reducing the use of fossil fuels for operating energy. But we also need to reduce the carbon emissions embodied in the materials and resulting from the construction phase. As buildings become more efficient to operate, the embodied energy and emissions from materials and construction becomes an increasingly significant portion of total GHG emissions.
The document discusses ways to reduce nitrogen oxide (NOx) emissions from cement plants. It outlines various primary measures cement plants can take including optimizing processes like air levels and burner operations, using low-nitrogen fuels, and installing equipment like low-NOx burners and calciners. Secondary measures like selective non-catalytic reaction and selective catalytic reaction are also mentioned. Charts show the effectiveness of different measures and NOx emission levels from specific plants over time periods. The goal is to control NOx emissions to meet regulatory limits.
The document provides information on Satna Cement Works, a cement plant owned by Birla Corp. Ltd. in Satna, Madhya Pradesh, India. It details the plant's current installed capacity of 2.36 million tons and planned expansion to 2.84 million tons. It then outlines the 17 major processes involved in cement production, from limestone quarrying and crushing to clinker production, cement milling, storage, and dispatch. Finally, it includes a Gantt chart scheduling the author's six-week training program at the plant.
CON 123 - Session 2 - Raw Materials and Grindingalpenaccedu
The document discusses the raw materials and manufacturing process for Portland cement. Key raw materials include limestone, silica, alumina, and iron which are ground and blended. The blended raw mix is then burned at high temperatures in a kiln to form cement clinker in a chemical reaction. The clinker is then ground with gypsum to produce Portland cement, which is stored and delivered. Modern dry processing uses a preheater and precalciner to burn the raw mix more efficiently in a shorter kiln.
The document summarizes literature on the relationship between clinker microstructure and grindability. The key findings are:
1) The primary factors influencing grindability are alite and belite crystal size and content, with smaller crystals and more alite (less belite) resulting in easier grinding.
2) Secondary factors like belite clustering, porosity, and trace element content can also affect grindability.
3) Several equations exist to estimate grindability based on alite/belite content and size, though results may vary slightly between equations. All show easier grinding with high alite and low belite content and smaller crystal sizes.
- Portland cement is produced by heating limestone, clay, and other materials to form clinker, which is then ground with gypsum.
- The main compounds in clinker are tricalcium silicate, dicalcium silicate, tricalcium aluminate, and tetracalcium aluminoferrite.
- The proportions of calcium oxide, silicon dioxide, aluminum oxide, and iron oxide in the raw materials determine the compound composition through Bogue equations.
The document discusses NOx assessment and reduction techniques. It provides information on:
1) NOx emissions from cement kilns can range from <500 to >1500 mg/Nm3 without additional controls, depending on factors like fuel used, kiln operation, and calciner design. Getting below 500 mg/Nm3 typically requires optimized reburn design or retrofits.
2) Hot reburn designs by CINAR involve maintaining temperatures of 1200C or 1300C for short residence times (0.15-1 seconds) before additional air/meal introduction to allow NOx reduction reactions while avoiding re-oxidation.
3) Optimizing SNCR for maximum NOx reduction requires understanding the impact of CO
CON 123 Session 3 - Typical Raw Mix Designalpenaccedu
The document discusses the raw materials and chemical processes involved in manufacturing Portland cement. It describes the key oxides (calcium, silica, alumina, iron) needed in the raw mix and how the Bogue equations are used to calculate the compounds (C3S, C2S, C3A, C4AF) formed during burning. An example raw mix design is provided along with the calculations to determine the compounds using the Bogue equations on the loss-free chemical analysis. The moduli calculations for lime saturation, silica ratio, and alumina ratio are also outlined. Finally, it briefly describes the wet and dry production processes and shows images of Portland cement clinker.
The cement manufacturing process involves quarrying raw materials such as limestone and clay, crushing and transporting them to the cement plant. At the plant, the raw materials are homogenized and finely ground into a raw mix, which is preheated and burnt in a kiln at 1500°C to produce clinker. The clinker is cooled, ground with gypsum and other additives to produce cement powder, which is stored in silos before being packed and dispatched.
This document discusses cement kiln operations, including:
1. The basic components of a cement kiln system including a preheater, rotary kiln, and clinker cooler.
2. Key parameters for monitoring kiln performance like production rate, fuel consumption, and temperatures.
3. Developments in preheater and precalciner technologies that have improved efficiency.
4. Factors that affect kiln operation and ways to optimize performance, such as maintaining proper free lime levels and maximizing secondary air temperature.
This document provides information about cement, including its chemistry, composition, types, manufacturing process, and key equipment used. Cement is made by heating limestone and other materials to form clinker, which is then ground with gypsum. The main steps are mining raw materials, crushing, grinding to a raw meal, pyroprocessing to form clinker, and final grinding of clinker to cement. Key equipment includes raw mills, kilns, preheaters, and ball mills.
This document is the second edition of the Cement Plant Operations Handbook. It provides concise guidance on cement manufacture using dry process cyclone preheater kiln technology, which accounts for over 80% of global cement production. The handbook covers various aspects of cement plant operations including raw materials, grinding, burning, cooling, finishing, quality control, maintenance, accounting and reporting. It also includes process data, calculations and conversion tables to support plant operations. The handbook is intended to serve as a useful reference for cement plant personnel.
The document provides an overview of the cement production process and factors that influence quality. It discusses:
1. Raw materials used like limestone, clay, and their quality parameters which determine the raw mix design and chemical composition.
2. The cement manufacturing stages of raw grinding, kiln burning and clinker cooling. Key factors like raw mix characteristics, burning process, and clinker/fuel quality influence the final cement quality.
3. Different cement types produced for various applications and how additives like gypsum and fly ash affect the physical properties.
A Rotary kiln is a pyroprocessing device used to raise materials to a high temperature (calcination) in a continuous process. Materials produced using rotary kilns include: Cement. Lime.
1. The residence time in a rotary kiln is calculated using a formula that considers the angle of repose of the limestone, length of the kiln, kiln inclination, effective diameter, and rotation speed.
2. A rotary kiln's capacity is determined by considering factors like the capacity of the ID fan, preheater cyclone design, proclaimed design and volume, kiln inclination and volume, kiln filling percentage, specific volume and thermal loading, and kiln drive capacity.
3. Important kiln parameters include the specific volume loading, specific thermal loading, cooler specific loading, and kiln percentage filling, which should be between 4-16%.
This document discusses Portland cement and the cement manufacturing process. It begins with an overview of what cement is and how it is used to make concrete. It then describes the industrial process for manufacturing cement, involving grinding raw materials like limestone and clay at high temperatures in a kiln to form clinker, which is then pulverized with gypsum to become Portland cement powder. The document also provides a brief history of cement development and explains how cement kilns can beneficially reuse solid and hazardous wastes as a source of energy and raw material replacement due to the kilns' high temperatures and long retention times.
Ring and snowball formation can occur in the kiln due to various process, operational, and maintenance factors. Key factors include raw material chemistry variations, unstable kiln and calciner operations, refractory selection, and flame characteristics. The formation of rings is a dynamic process where deposit-forming forces outweigh destructive forces, such as melting/freezing due to heat changes and interlocking of particles. Common ring types include spurrite and sulfo-spurrite rings formed by clinker freezing in the calcining zone. Addressing issues like feed continuity, material segregation, and combustion can help reduce ring formation.
System combines the advantages of 100% scrap preheating and continuous scrap feeding through its chambers, without the need of EAF roof opening. EPC prevents totaly, any dust emission and heat loss during furnace charging stage, as it is the case normally for other operations. The EPC-EAF is a new generation, economical and environmentaly friendly Electric Arc Furnace. Considerable reduction in electric energy consumption, increased productivity, meeting strict environmental regulations, less dust load within the melt shop, flicker reduction& harmonic disturbance reduction are some of the important features of the new and superior EPC system.
Ring-Formation-in-Rotary-Kilns of cement plantSaurabhVyAs34
- Rings forming in rotary kilns used for cement production can cause shutdowns costing over 150,000 euros. Numerical modeling revealed rings form where radiative heat transfer is highest, overheating the material and causing it to stick to walls.
- Increasing secondary air injection was proposed to cool oven surfaces and counteract ring formation. Experimental validation showed this solution effectively prevented unscheduled shutdowns, saving five figures monthly.
- A computational fluid dynamics model of an empty kiln was developed to analyze temperature profiles and understand ring formation mechanisms without modeling the complex moving bed. Increasing air-fuel ratio reduced hotspot temperatures predicted to cause ring formation.
The document provides an overview of AEP's Mountaineer Commercial Scale Carbon Capture & Storage (CCS II) Project Phase I and lessons learned. Key points include: (1) The project aimed to demonstrate Alstom's Chilled Ammonia Process CO2 capture technology and deep saline CO2 storage at commercial scale. (2) Technical challenges included integrating the capture system with the existing power plant and variable coal supply, and managing water from the capture process. (3) Lessons involved selection of anhydrous ammonia as the reagent, exhaust stack options, water management approaches, steam sourcing for the capture system, and using variable speed pumping for CO2 compression and injection.
The convergence of high energy prices,
global warming potential, general environmental
pollution, home-grown energy imperatives,
and green energy possibilities has
created opportunities that far-sighted companies
can capture and the public expects.
The energy-saving audit project in Malaysia aimed to implement advanced energy-saving technologies from Japanese companies at selected model companies in Malaysia to help reduce energy costs and carbon emissions, with the project selecting 2-3 large processed food or beverage companies to conduct free audits and provide recommendations, and requesting MGTC's help in recommending model companies and linking the project to Malaysia's Green Technology Financing Scheme.
This document describes a computational fluid dynamics (CFD) model developed to analyze and counteract ring formation in rotary kilns used in cement production. The model revealed that rings typically form in zones of maximum radiative heat transfer, causing local overheating and overproduction of liquid material that sticks to the kiln wall. To counteract this, the model proposes increasing secondary air injection to cool the kiln and eliminate temperature peaks that cause ring formation. Experimental validation at the plant confirmed that increasing secondary air was effective at preventing unscheduled shutdowns from ring formation.
This document describes a computational fluid dynamics (CFD) model developed to address ring formation in rotary kilns used for cement production. The model revealed that rings typically form in zones of maximum radiative heat transfer, causing local overheating and increased liquid phase production of material. To counteract ring formation, the model proposes increasing secondary air injection to cool the kiln and eliminate temperature peaks. Experimental validation at the plant confirmed this solution effectively prevented unscheduled shutdowns from ring formation.
1. The document describes research into coating carbon fibers with various ceramic materials to improve their oxidation resistance at high temperatures.
2. Sic coatings were applied using chemical vapor deposition (CVD) and by pyrolyzing a polycarbosilane (PCS) solution. SiO2 and Al2O3 coatings were also investigated using a sol-gel method.
3. Coatings improved the oxidation resistance of carbon fibers, with CVD Sic providing the best protection. A composite or gradient coating combining different materials was found to further enhance oxidation resistance.
Improving the properties of Ni-Based Alloys by Co AdditionIRJET Journal
1) The document discusses improving the properties of nickel-based alloys through the addition of cobalt.
2) Cobalt addition leads to grain refinement in the alloys, which influences both microstructure and corrosion resistance. Finer grain size improves hardness.
3) Samples of Ni-5Cr-5Al-xCo (where x is the cobalt content from 0-30%) were produced by vacuum arc melting and characterized through XRD, optical microscopy, and Vickers hardness testing.
4) Results showed that increasing the cobalt content refined grain size and improved hardness, while also enhancing corrosion resistance properties over the substrate material alone.
IJERA (International journal of Engineering Research and Applications) is International online, ... peer reviewed journal. For more detail or submit your article, please visit www.ijera.com
Double layer energy storage in graphene a studysudesh789
This document summarizes research on using graphene for energy storage in electrochemical double layer capacitors (EDLCs). Graphene has potential as an electrode material due to its high surface area and conductivity. Studies have measured specific capacitances as high as 205 F/g for graphene electrodes, though capacitance depends on accessible surface area. Graphene electrodes can allow for high power applications with fast charge/discharge rates over 10 kW/kg. Ongoing research aims to prevent restacking of graphene sheets and improve ion accessibility to maximize surface area utilization and energy storage performance.
MET 401 Chapter 2 -_updated_simple_ideal_rankine_cycleIbrahim AboKhalil
The document discusses the Rankine cycle, which is the ideal cycle for vapor power plants. It improves upon the Carnot cycle by superheating steam in the boiler and completely condensing it in the condenser. The Rankine cycle does not involve any internal irreversibilities. Examples are provided to illustrate calculating efficiency and other parameters for Rankine cycle power plants. The actual vapor power cycle differs from the ideal Rankine cycle due to component irreversibilities. The Carnot cycle is impractical for power plants due to limitations on heat transfer processes and handling two-phase fluids.
The Effects of Heating and Cooling Energy Piles Under Working load at Lambeth...Tonyamis
The document summarizes a study on the effects of heating and cooling energy piles under working loads. Instrumented load tests were conducted on test piles at Lambeth College in the UK. Temperature cycles were applied to the piles using a ground source heat pump system. Results from strain gauges and fiber optic sensors confirmed that pile load-settlement response was not adversely affected by temperature cycles. Monitoring also showed temperature variations within the pile from the heating and cooling, with the pile reaching equilibrium after two weeks of cooling. Installation method of fiber optic sensors did not significantly impact results.
The document discusses solutions for reducing costs and emissions in the aluminum industry. It proposes that Sammo Energy would implement full solutions to capture waste heat from aluminum production processes using technologies like organic Rankine cycle turbines. Sammo Energy would invest its own resources and share benefits with industry partners through long-term agreements. This would allow industries to reduce energy costs and emissions without investments of their own.
1) The document discusses closing the carbon cycle through capturing carbon dioxide from the air or flue gases to produce energy and other products.
2) It proposes using air capture technology, like Global Thermostat's, to facilitate transitioning to renewable energy by connecting sources of air and concentrated carbon dioxide.
3) Global Thermostat seeks partners to broadly disseminate its licensing model for air capture technology in order to make money by reducing carbon emissions.
This study examined the effects of different temperatures and temperature cycling on the breakdown voltages of tantalum capacitors. High and low temperature tests as well as temperature cycling tests were conducted inside the operating temperature limits of the capacitors. The results showed that high or low temperature testing did not affect breakdown voltage. However, temperature cycling was found to lower the breakdown voltages of the tantalum capacitors. Failure analysis of the capacitors that broke down during temperature cycling testing revealed cracks and defects in the dielectric material.
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Sammo Energy proposes a full solution to help the aluminum industry reduce costs and emissions. They will invest their own resources to implement power generation and batch preheating systems at aluminum facilities. This will lower energy costs for the industry from day one without requiring any investment. Sammo Energy will also manage programs to share benefits like carbon credits. Their approach involves surveying all waste heat sources, evaluating coordinated use of these sources, and selecting optimal technologies like organic Rankine cycle turbines to recover waste heat for power generation.
This document summarizes an energy audit of a reheating furnace used in a rolling mill. Key findings include:
1) The furnace's current efficiency is 34.1%, lower than claims of 42-45% by equipment manufacturers. Improving combustion efficiency to 82% by reducing excess oxygen to 5-7% and lowering flue gas temperature could save 157 kiloliters of fuel per year.
2) Surface temperatures of the uninsulated furnace indicate heat losses. Insulating the furnace could save 14 kiloliters of fuel annually with a 13 month payback period.
3) Openings for material loading contribute to heat losses. Further blocking openings could save 9.3 kil
Innovative engineering design in circulating fluid bed technologyIgor Sidorenko
Sneyd, S., Sidorenko, I., Orth, A., & Laumann, M.-D. (2007) Innovative engineering design in circulating fluid bed technology. Paper presented at CHEMECA conference, Melbourne.
Innovative engineering design in circulating fluid bed technology
Poster Pisaroni
1. Numerical Simulation of a Rotary Kiln
M. Pisaroni and D. J. P. Lahaye, Scientific Computing Group, Delft Institute of Applied Mathematics, Faculty of Electrical Engineering,
Mathematics and Computer Science, Delft University of Technology, The Netherlands
Objectives The Model Practical Applications
A rotary kiln is a long cylindrical equipment slightly inclined Turbulent combustion results from the two-way interaction of chemistry and turbulence. When a fame interacts Counteracting ring formation: different configurations of the kiln was tested to
tilted on its axis. The objective of this rotary kiln is to drive the with a turbulent flow, turbulence is modified by combustion because of the strong flow accelerations through the find the best one to reduce such negative effect.
specific bed reactions, which, for either kinetic and thermodynamic reasons, flame front induced by heat release, and because of the large changes in kinematic viscosity associated with In severe cases, ring grows rapidly and can cause unscheduled shutdown of the
require high bed temperature. temperature changes. kiln in less than a month. Depending on the severity of the problem,
The energy originates with the combustion of hydrocarbon fuels via a main Instantaneous balance equations Exact equations for mean properties maintenance labour, make-up lime purchease, and lime mud disposal can bring
burner at the hot end. the cost of a ring outage very high due to several days production loss.
1 Here an example of a severe ring formation
that was observed in our kiln.
Chemical source 3 2
The standard production configuration (A/G=10)
Heat flux of the kiln shows a limited region in the
interface between the gas and the solid lining
Heat source where we identified a peak in temperature and
Realizable k-epsilon model radiative absorption.
Std_Configuration (A/G ratio 10)
In 1979 the Almatis cement plant (Rotterdam) was built. The kiln was designed
to produce Calcium Aluminate Cement (CAC), a very white, high purity 1 Reynolds stress tensor
hydraulic bonding agents providing controlled setting times and strength
development for today’s high performance refractory products. The design of
the kiln was based only on a downscaling of typical Portland cement plants.
H_Air (A/G ratio 12)
Increasing market demand for high purity cement 2 Turbulent scalar flux Eddy diffusivity model
Unscheduled shutdown due to ring formation
Restrictive emission regulations (i.e NOx)
Future project to expand the plant by building a new kiln
have triggered Almatis' management to increase it's knowledge base on kiln 3 Mean source term
processes. Eddy Break-Up Model (EBU)
The model is used to understand in more details what happen inside such a
‘black-box’ and help to control the standard production procedure but in As presented it is evident that we reduced the peak temperature and the
particular underline critical aspects. In the next stage the model will be used to + Radiation: Participating Media Radiation Model (DOF) incident radiation only by increasing the A/G ratio.
optimize the kiln production and to test solutions for a new equipment. + NOx: Zeldovich Model
This setup was tested during a severe ring formation and as the images below
The grid was done using polyhedral elements: 2.8 Millions of elements shows, after a few hours we destroyed the ring. With a lower temperature the
Physical Phenomena liquid phase is too low that the vibrations due to the rotations are able to break
lumps from the ring and clean the kiln.
ggg
Conclusions
Turbulent non-premixed
combustion
Heat transfer in the gas Some results: Ring After 4h After 24h After 40h
We are using now this model to find out other configurations that can prevent
Heat transfer in the or counteract ring formations in the kiln but also that can reduce NOx
lining production.
Granular flux
References
Counteracting Ring Formation in Rotary Kilns by Fuel-Air Composition,
M. Pisaroni, D. J. P. Lahaye and R. Sadi.