-
“Models, Simulation, Optimization:Mathematical Technologies for
Industrial Innovation in Europe”
Rome, Italy19-21 December 2016
Accademia dei Lincei
“Boosting Productivity of an Alumina Cement Plant through
Computational Fluid Dynamics”
Kees Vuik and Domenico Lahaye; DIAM TUDelftMichele Pisaroni;
EPFL Lausanne, Miguel Romero; BASF FrankfurtRudi Sadi; Almatis
Rotterdam
-
The Industrial Problems:1. Pre-Cement Ring Formation inside the
Furnace2. Unscheduled Shutdown of the Plant3. Waste of Fuel, Raw
Materials, and Man Hours to Clean & Re-Start the Furnace
Brief description of the collaboration1. To Develop a
Mathematical Model of the Combustion in the Furnace
-
Model of Almatis Furnace
-
FINAL PRODUCT: Alumina-Cement
-
Application of Alumina-Cement: High Temperature Lining
-
Production SuspensionDue to Ring Formation
Image by Kumar Pradeep, Technical Advisor for Baroda
-
Ring Build-Up and Clean-Up
-
Combustion Model to Prevent Ring Formation
FIRST STEP: (GEOMETRY)
-
Combustion Model to Prevent Ring Formation
SECOND STEP: (MESH)
-
Combustion Model to Prevent Ring Formation
SECOND STEP: (MESH)
-
Combustion Model to Prevent Ring Formation
SECOND STEP: (MESH)
-
Combustion Model to Prevent Ring Formation
SECOND STEP: (MESH)
-
Combustion Model to Prevent Ring Formation
THIRD STEP: (PHYSICS) CONTINUITY
NAVIER-STOKES
TEMPERATURE
SPECIES
-
Combustion Model to Prevent Ring Formation
k-epsilon RANS for flow
eddy breakup for combustion
discrete ordinate model for radiation
Finite Volume Discretisation
transient segragated solution
implementation in CD-Adapco
THIRD STEP: (PHYSICS)
-
Combustion Model to Prevent Ring Formation
FOURTH STEP: (RESULTS)
-
RINGS ABSENT
RINGS PRESENT
Combustion Model to Prevent Ring Formation
FOURTH STEP: (RESULTS)
-
Granular Flow Model to Predict Productivity of the Furnace
HEAT ABSORPTION
of Granular Material
PHASE TRANSFORMATION of Granular Material
-
Pleasant Side-Effect: Higher Productivity
-
Granular Flow Model for Higher Productivity
TEMPERATURE OF GAS
TEMPERATURE OF MATERIAL
-
Current Research
Mohamed El Abbassi
Implementation in OpenFOAM
Add radiation
Add lining
Add advanced chemistry model
-
NO MORE SHUTDOWNSHIGHER PRODUCTION OUTPUT
LOWER OPERATIONAL COST
-
REFERENCES
[1] D. J. P. Lahaye. Almatis TU Delft promotion video:
www.youtube.com/watch?v=AxifpqOLPMQ.
[2] M. Pisaroni, R. Sadi, and D. Lahaye. Counteracting ring
formation in rotary kilns. Journal of Mathematics in Industry,
2(1):1–19, 2012.
[3] M. A. Romero-Valle, M. Pisaroni, D. Van Puyvelde, D. J. P.
Lahaye, and R. Sadi. Numerical modeling of rotary kiln productivity
increase. Technical Report 13-09, Department of Applied
Mathematics, TU Delft, 2013.1
-
GRAZIE MILLE!
