REI provides research and consulting services for
rotary kiln applications including work for the cement industry.
Projects focus on enhancing product yield, improving kiln efficiency,
implementing alternate fuels, and controlling emissions. Applications
have studied designs to maximize gas-phase mixing for mid-kiln
injection, burner operation to optimize heat flux profiles to
bed material, the impact of fuel-air ratio and burner designs
on kiln performance, and the identification of fuel rich zones
to guide installation of corrosion-resistant refractory.
REI also works with the University of Utah to provide
two specialized measurement services for kiln clients. The first
technique utilizes measurements from a laboratory-scale rotary
reactor to characterize hydrocarbon release from cement samples.
The second utilizes a rotary kiln simulator to simulate the thermal treatment of
soils, the processing of minerals, and the recovery of energy
from waste materials.
REI experience with rotary kilns includes:
REI has developed Kilnview
, a Windows-based, one-dimensional, steady state rotary kiln model
with an easy-to-use graphical users interface (GUI) for performing
process calculations. Kilnview
can be configured for mineral processing and waste incineration
In addition to these applications, REI continues
to develop expertise in new areas. If your application is not
among those listed, please contact
us to discuss appropriate ways we may be able to work together.
The REI combustion simulation tool BANFF
was used to model a coal and waste-fired cement kiln with various
tertiary air injection systems to determine the best design for
mixing waste combustion products. Studies showed the best designs
used high velocity jets emanating from the center of the kiln.
This provided the best mixing of the stratified air-combustion
product flow during the full kiln rotation. The limiting factor
in the design was the pressure drop associated with the jets.
Combustion and Process Simulation in a Rotary Kiln
two-phase flow within the firing zone of a rotary kiln used to
process raw ore was simulated in order to predict and improve
kiln performance. The REI combustion simulation tool GLACIER
was used to model the combustion at the burner end of the kiln
and to predict the heat flux to the ore bed. The kiln is fired
with a combination of coal and gaseous fuel. The ore bed was modeled
with a plug flow model. The combustion flow field and the ore
bed model were fully coupled. Simulations were performed to predict
the impact of fuel-air ratio and burner designs on kiln conditions
and performance. Prediction of fuel rich zones near the kiln walls
were used to guide installation of corrosion-resistant refractory
and resulted in a significant reduction in kiln shut downs.