Advanced Computational Tools for Cement Plants

This paper describes the application of mathematical modelling, in particular computational fluid dynamics (CFD), to solve fluid flow, heat transfer, combustion and emissions problems for the cement industry. Whereas traditional physical modelling is limited to isothermal gas phase aerodynamics studies, CFD handles chemical reaction, convective and thermal radiation heat transfer, and the particle/gas flow interactions. In this paper, a new mineral interactive version (MI-CFD) is presented, in which mineral reactions are directly coupled to the flow, heat transfer and combustion processes. The procedure has been applied to over 100 plants worldwide. Example applications to cyclone, calciner and emissions- reduction problems are described herein. Very significant benefits to the cement industry have resulted in terms of fuel costs savings, reduced capital costs, increased production, the ability to comply with environmental legislation and the securing of environmental permits. MI-CFD has proven its value to both old and contemporary plants, including those under design/construction, where unconventional fuels or innovative pyro-processing arrangements have posed major engineering challenges. A specially-devised simpler mathematical model, enabling the effects of changing daily operational parameters to be forecast, is also described.