Research Papers

Simulation of Combustion and Thermal-Flow Inside a Petroleum Coke Rotary Calcining Kiln—Part I: Process Review and Modeling

[+] Author and Article Information
Zexuan Zhang

Energy Conversion and Conservation Center, University of New Orleans, New Orleans, LA 70148-2220zzhang@uno.edu

Ting Wang

Energy Conversion and Conservation Center, University of New Orleans, New Orleans, LA 70148-2220twang@uno.edu

J. Thermal Sci. Eng. Appl 2(2), 021006 (Oct 28, 2010) (8 pages) doi:10.1115/1.4002524 History: Received February 06, 2010; Revised September 09, 2010; Published October 28, 2010; Online October 28, 2010

Calcined coke is an important material for making carbon anodes for smelting alumina to aluminum. Calcining is an energy intensive industry and a significant amount of heat is wasted in the calcining process. Efficiently managing this energy resource is tied to the profit margin and survivability of a calcining plant. To help improve the energy efficiency of the calcining process, a 3D computational model is developed to gain insight of the thermal-flow and combustion behavior in the calciner. Comprehensive models are employed to simulate the moving petcoke bed with moisture evaporation, devolatilization, and coke fines combustion with a conjugate radiation-convection-conduction calculation.

Copyright © 2010 by American Society of Mechanical Engineers
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Figure 1

Schematic of calcining process for petroleum coke

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Figure 2

Heat transfer mechanism in a rotary kiln (1)

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Figure 3

Petcoke calcination with tertiary air

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Figure 4

A 3D view of the simulated calcining rotary kiln

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Figure 5

Detailed view of calcined coke zone near the discharge end

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Figure 6

Detailed view of calcining coke zone including tertiary air injectors and tumblers

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Figure 7

(a) The cross-sectional view of the tumbler and (b) tertiary air injector arrangement

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Figure 8

(a) Relative coke bed and tertiary air inlet position (rotational angles) and (b) three different tertiary air injection angles

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Figure 9

Meshed geometry for the rotary calcining kiln

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Figure 10

Grid sensitivity study: gas centerline static temperature for various cell numbers

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Figure 11

Tertiary air injector locations and labeling





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