Rotary cement kiln coating estimator: Integrated modelling of kiln with shell temperature measurement

Coating thickness protection in the burning zone of a rotary cement kiln during operation is important from the viewpoint of the kiln productivity. In this paper, an integrated model is presented to estimate the coating thickness in the burning zone of a rotary cement kiln by using measured process variables and scanned shell temperature. The model can simulate the variations of the system, thus the impact of different process variables and environmental conditions on the coating thickness can be analysed. The presented steady‐state model derived from heat and mass balance equations uses a plug flame model for simulation of gas and/or fuel oil burning. Moreover, the heat transfer value from shell to the outside is improved by a quasi‐dynamic method. Therefore, at first, the model predicts the inside temperature profile along the kiln, then by considering two resistant nodes between temperatures of the inside and outside, the latter measured by shell scanner, it estimates the formed coating thickness in the burning zone. The estimation of the model was studied for three measured data sets taken from a modern commercial cement kiln. The results confirm that the average absolute error for estimating the coating thickness for the cases 1, 2, and 3 are 3.26, 2.82, and 2.21 cm, respectively.     

Energy Saving in Industrial Wood Drying Addressed by a Multiscale Computational Model: Board, Stack, and Kiln

This article proposes a multiscale computational model able to calculate energy consumption in a batch lumber kiln. A dual-scale computational model of wood drying deals with the boards/stack interaction and serves as a basis for the present work. A new module was added here that calculates heat losses through kiln walls (convection, condensation) and the energy used by each kiln component (fans, heating elements, humidifier, vacuum pump, etc.). The corresponding mathematical formulation is presented and then theoretical results are compared to those collected in an industrial vacuum kiln. As application example, the effect of air reversal, air velocity, and kiln insulation are exhibited, which depicts the great potential and prospects of this new tool for energy savings in relation to the product quality.     

Energy Saving in Industrial Wood Drying Addressed by a Multiscale Computational Model: Board,Stack, and Kiln

This article proposes a multiscale computational model able to calculate energy consumption in a batch lumber kiln. A dual-scale computational model of wood drying deals with the boards/stack interaction and serves as a basis for the present work. A new module was added here that calculates heat losses through kiln walls (convection, condensation) and the energy used by each kiln component (fans, heating elements, humidifier, vacuum pump, etc.). The corresponding mathematical formulation is presented and then theoretical results are compared to those collected in an industrial vacuum kiln. As application example, the effect of air reversal, air velocity, and kiln insulation are exhibited, which depicts the great potential and prospects of this new tool for energy savings in relation to the product quality.     

华润水泥（龙岩曹溪）#1熟料生产线技术改造介绍

华润水泥(龙岩曹溪)公司~#1线是由德国洪堡公司提供主要装备的水泥生产线,是我国第一条采用无烟煤煅烧水泥熟料的生产线,也是我国首先采用辊压机终粉磨系统进行生料制备的生产线。经过长期连续运行,有些设备和设施已不能满足现有要求。中材国际工程股份有限公司(南京)运用现代水泥技术,于2012年对该线的熟料生产系统和相关车间进行了综合技术改造。3年的生产实践证明,本次技术改造实现了原定的各项技改目标,取得了优异的节能降耗效果。     

High intakes of Cr, Ni, and Zn in clinker: Part II. Influence on the hydration properties

This work presents the results of the hydration of cements with high intakes of Cr, Ni, and Zn. The cements were produced from clinkers that were doped with 200 to 25,000 ppm of heavy metal. Investigations on the clinkers were presented in Part I. In this paper the rate of heat generation of the cements in the first 2 days was analysed by differential scanning calorimetry. The hydration products were investigated by scanning electron microscopy combined with energy-dispersive X-ray spectrometer and also by X-ray powder diffraction. The initial setting of some samples was tested, as well as the strength. The results show that heavy metals only have an influence on the hydration properties of the cements if the dosage is much higher than in ordinary Portland cement.     

Application of the reaction engineering approach (REA) for modeling intermittent drying under time-varying humidity and temperature

A ‘good’ drying model is important for the design of dryer, evaluation of dryer performance and prediction of product quality. Among the available models, the reaction engineering approach (REA) is a lumped model, proven to be simple, robust and accurate to model drying of several materials. In this paper, the REA is implemented to model intermittent drying, which is usually practiced for saving energy consumption and maintaining product quality during drying, under time-varying drying air temperature and humidity, which is a challenging drying case to model. For this purpose, the equilibrium activation energy (ΔE_v,b) is defined according to the drying settings in each time period and combined with the relative activation energy (ΔE_v/ΔE_v,b) generated from the convective drying experimental data obtained under constant drying conditions. The mass and heat balances also implement the corresponding drying settings in each time period during the intermittent drying. The results indicate that the REA can describe both the moisture content and temperature profiles of the intermittent drying under time-varying drying air temperature and humidity well. The accuracy, simplicity and robustness of the REA for the intermittent drying under time-varying drying air temperature and humidity are proven here. This has provided a major and significant extension of the REA on modeling challenging drying cases.     

Influence of chemical and physical characteristics of cement kiln dusts (CKDs) on their hydration behavior and potential suitability for soil stabilization

The interaction of CKDs with a given soil depends on the chemical and physical characteristics of the CKDs. Hence, the characterization of CKDs and their hydration products may lead to better understanding of their suitability as soil stabilizers. In the present article, four different CKD powders are characterized and their hydration products are evaluated. A detailed chemical (X-ray diffraction), thermogravimetric and morphological (scanning electron microscope) analyses of both the CKD powders and the hydrated CKD pastes are presented. In general, high free-lime content (~ 14–29%) CKDs, when reacted with water produced significant amounts of calcium hydroxide, ettringite and syngenite. These CKDs also developed higher unconfined compressive strength and higher temperature of hydration compared to CKDs with lower amounts of free-lime. An attempt was made to qualitatively correlate the performance of CKD pastes with the chemical and physical characteristics of the original CKD powders and to determine their potential suitability as soil stabilizers. To that effect a limited unconfined compressive strength testing of CKD-treated kaolinite clays was performed. The results of this study suggest that both the compressive strength and the temperature of hydration of the CKD paste can give early indications of the suitability of particular CKD for soil stabilization.     

可靠性、可用性与可维修性分析在LNG接收站产能预测中的应用

LNG设施通常包括天然气液化、LNG储运及运输等。在中国天然气供应链对经济民生影响重大。天然气供应链或供应系统中关键设备的非计划及计划性维修导致的天然气供应中断,都可能造成巨大的经济损失。本项目应用可靠性、可用性及可维修性(RAM)分析方法对于液化天然气储备库及附属设施的可靠性指标进行评估,定量分析LNG供应链中关键设备的失效及维修时间对于整个供应链可靠性指标的影响。RAM分析可以用来预测在指定的运行周期内整个LNG供应链的运行绩效。RAM分析辨识关键设备的失效模式,确定失效数据,并采取Monte Carlo的模拟计算,获得LNG供应链或系统中,关键设备失效对于可靠性指标影响。本文通过国内某LNG储备库项目的RAM分析,应用以Monte Carlo模拟为基础的系统可靠性分析软件ReliaSuite^®,评估LNG储备库系统设计能否满足可靠性指标。并且对LNG储运设施的卸料臂进行了失效模式及关键性影响分析(FMECA)。通过对LNG储备库各子系统对于项目整体可靠性的贡献进行敏感性分析,找到影响项目整体可靠性的瓶颈及解决方案。     

Optimization of Kiln Drying for Softwood through Simulation of Wood Stack Drying, Energy Use, and Wood Color Change

An integrated modeling system was developed to simulate the drying processing, energy use, and wood color change in kiln drying of softwood timber. The model has been applied for a temperature range from 50 to 70°C and an airspeed from 3 to 9 m/s. The model is based on theoretical analysis and contains components such as kiln configuration and practical operations. From the model simulation, optimized drying schedules for minimizing color change and energy use are recommended with dry bulb temperature of 60 to 70°C and wet bulb depression of 15 to 20°C.     

Optimization of Kiln Drying for Softwood through Simulation of Wood Stack Drying,Energy Use,and Wood Color Change

An integrated modeling system was developed to simulate the drying processing, energy use, and wood color change in kiln drying of softwood timber. The model has been applied for a temperature range from 50 to 70°C and an airspeed from 3 to 9 m/s. The model is based on theoretical analysis and contains components such as kiln configuration and practical operations. From the model simulation, optimized drying schedules for minimizing color change and energy use are recommended with dry bulb temperature of 60 to 70°C and wet bulb depression of 15 to 20°C.     

A novel reverse flow reactor coupling endothermic and exothermic reactions. Part I: comparison of reactor configurations for irreversible endothermic reactions

A new reactor concept is studied for highly endothermic heterogeneously catalysed gas phase reactions at high temperatures with rapid but reversible catalyst deactivation. The reactor concept aims to achieve an indirect coupling of energy necessary for endothermic reactions and energy released by exothermic reactions, without mixing of the endothermic and exothermic reactants, in closed-loop reverse flow operation. Periodic gas flow reversal incorporates regenerative heat exchange inside the reactor. The reactor concept is studied for the coupling between the non-oxidative propane dehydrogenation and methane combustion over a monolithic catalyst.Two different reactor configurations are considered: the sequential reactor configuration, where the endothermic and exothermic reactants are fed sequentially to the same catalyst bed acting as an energy repository and the simultaneous reactor configuration, where the endothermic and exothermic reactants are fed continuously to two different compartments directly exchanging energy. The dynamic reactor behaviour is studied by detailed simulation for both reactor configurations. Energy constraints, relating the endothermic and exothermic operating conditions, to achieve a cyclic steady state are discussed. Furthermore, it is indicated how the operating conditions should be matched in order to control the maximum temperature. Also, it is shown that for a single first order exothermic reaction the maximum dimensionless temperature in reverse flow reactors depends on a single dimensionless number. Finally, both reactor configurations are compared based on their operating conditions. It is shown that only in the sequential reactor configuration the endothermic inlet concentration can be optimised independently of the gas velocities at high throughput and maximum reaction coupling energy efficiency, by the choice of a proper switching scheme with inherently zero differential creep velocity and using the ratio of the cycle times.In this first part, both the propane dehydrogenation and the methane combustion have been considered as first order irreversible reactions. However, the propane dehydrogenation is an equilibrium reaction and the low exit temperatures resulting from the reverse flow concept entail considerable propane conversion losses. How this ‘back-conversion’ can be counteracted is discussed in part II Chemical Engineering Science, 57, (2002), 855-872.     

Towards sustainable production and consumption: A novel DEcision-Support Framework IntegRating Economic,Environmental and Social Sustainability (DESIRES)

The idea of sustainable production and consumption is becoming a widely-accepted societal goal worldwide. However, its implementation is slow and the world continues to speed down an unsustainable path. One of the difficulties is the sheer complexity of production and consumption systems that would need to be re-engineered in a more sustainable way as well as the number of sustainability constraints that have to be considered and satisfied simultaneously. This paper argues that bringing about sustainable production and consumption requires a systems approach underpinned by life cycle thinking as well as an integration of economic, environmental and social aspects. In an attempt to aid this process, a novel decision-support framework DESIRES has been developed comprising a suite of tools, including scenario analysis, life cycle costing, life cycle assessment, social sustainability assessment, system optimisation and multi-attribute decision analysis. An application of the framework is illustrated by a case study related to energy.     

Reaction Engineering Approach (REA) to Modeling Drying Problems: Recent Development and Implementations

Among the drying models available in the literature, the REA model (which was first proposed in 1996) is semi-empirical. It was described based upon a basic physical chemistry principle. The “extraction of water from moist material” is signified by applying the activation energy concept. The single expression of the extraction rate represents the competition between evaporation and condensation. It also encompasses the internal specific surface area and mass transfer coefficient, and thus is linked to material characteristics. The REA can be classified into two categories—Lumped (L) REA and Spatial (S) REA—which can be used to deal with drying a material as a whole or considering the local phenomena within the material, respectively. Both models have been proven to be very effective. The REA is effective for generating parameters since only one accurate drying run is required to establish the relative activation energy function. Both internal and external resistances are modeled by the REA. In its lumped format, the REA is employed to describe the global drying rate, while in the S-REA, the REA is used to model the local evaporation rate. This article covers fundamentals of the REA which have not been fully explained, as well as the most recent development and applications. The application of the S-REA as a non-equilibrium multiphase model is highlighted.     

回转焙烧炉在催化裂化催化剂行业的应用及其结构优化

介绍了回转焙烧炉在催化裂化（FCC）催化剂行业的应用,根据实际应用情况进行了设备结构优化,实现节能降耗,提高产品收率。     

Combined Electrohydrodynamic (EHD) and Vacuum Freeze Drying of Sea Cucumber

A combination of electrohydrodynamic drying (EHD) and vacuum freeze drying (FD) is examined as an improved method for dehydrating sea cucumbers. The energy consumption, shrinkage and rehydration ratio, protein content, and sensory properties, such as the color and trimness, of the dried product in the EHD–FD method are measured. Compared with FD, the combined process consumes less drying time and has lower energy consumption than EHD drying alone. Also, the product processed by combined drying displays lower shrinkage, higher rehydration rate and higher protein content, along with better sensory qualities.     

Hydrogenated hydroxy-functionalized polyisoprene (H-HTPI) and isocyanurate of isophorone diisocyanates (I-IPDI): reaction kinetics study using FTIR spectroscopy

The reaction between a hydrogenated hydroxyl-functionalized polyisoprene (H-HTPI) and isophorone diisocyanate isocyanurate (I-IPDI) is followed by using direct FTIR spectroscopy. The reaction kinetics is studied using a simple model taking into consideration the I-IPDI structure. The rates of individual isocyanate groups are described by a second order equation. Influence of dibutyltin dilaurate (DBTL) concentration and temperature on selectivity, defined as the ratio between the rate constant of secondary isocyanate group and the rate constant of the primary isocyanate group, is investigated. It is observed that selectivity decreases when temperature or DBTL concentration increases. Eyring parameters are determined for the catalyzed [ΔH^*=77/35 (kJ mol⁻¹), ΔS^*=12/−100 (J mol⁻¹ K⁻¹)] and uncatalyzed reactions [ΔH^*=48/43 (kJ mol⁻¹), ΔS^*=−179/−167 (J mol⁻¹ K⁻¹)] primary and secondary isocyanate groups being differentiated.     

Luminescence of (La,Dy)F3: Effect of solvent ratio (water/ethylene glycol) and Ce3+ co-doping

Luminescent LaF₃:Dy³⁺ and LaF₃:Dy³⁺ co-doped with Ce³⁺ have been successfully synthesized separately via co-precipitation method. Different ratios of ethylene glycol(EG)/water have been used for the synthesis of LaF₃:Dy³⁺ whereas LaF₃:Dy³⁺ co-doped with Ce³⁺ have been prepared only in ethylene glycol(EG) medium. The synthesized products have been characterized using powder X-ray diffraction (XRD), transmission electron microscopy (TEM), Fourier transform infra‐red (FT-IR) and photoluminescence spectroscopy. XRD results show all the samples prepared to be well crystallized in a pure hexagonal structure with no impurity phases. Photoluminescence, lifetime decay and energy transfer efficiency studies indicate the existence of an energy transfer between the Ce³⁺ and Dy³⁺ ions, which increases with increase of Dy³⁺ ions concentration. LaF₃:Dy³⁺ nanophosphor prepared in EG:water mixture(1:1) showed the highest luminescence intensity when compared with those prepared in EG or water alone. This enhancement in luminescence (when using EG-water mixture) might be related to the increase in crystallinity/particle size as well as to the decrease in agglomeration of particles in the corresponding solvent mixture medium.     

Kinetic studies of liquid phase ethyl tert-butyl ether (ETBE) synthesis using macroporous and gelular ion exchange resin catalysts

Ethyl tert-butyl ether (ETBE) synthesis from ethanol (EtOH) and tert-butyl alcohol (TBA) was studied with different macroporous and gelular ion exchange resin catalysts. Purolite^® (CT-124, CT-145H, CT-151, CT-175 and CT-275) and Amberlyst^® (15 and 35) ion exchange resins were used for the present work. Effect of various parameters such as catalyst type, temperature, reactants feed molar ratio and catalyst loading were studied for the optimisation of reaction condition. Among the catalysts studied, Purolite CT-124 gave the best results for TBA conversion and selectivity towards ETBE. Kinetic modelling was performed with this catalyst and activation energy and water inhibition coefficient were determined. Heterogeneous kinetic models [e.g., Eley-Rideal (ER), Langmuir-Hinshelwood-Hougen-Watson (LHHW)] were unable to predict the behaviour of this etherification reaction, whilst the quasi-homogeneous (QH) model represented the system very well over wide range of reaction conditions.