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Enhancing Alumina Cement Plant Efficiency with Mathematical Combustion Modeling

Collaborative project to develop a combustion model for an alumina cement plant to prevent ring formation and increase productivity through computational fluid dynamics. Implementation in OpenFOAM with advanced physics for optimal results. Presented at the Rome conference on industrial innovation.

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Enhancing Alumina Cement Plant Efficiency with Mathematical Combustion Modeling

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  1. “Boosting Productivity of an Alumina Cement Plant through Computational Fluid Dynamics” Kees Vuik and Domenico Lahaye; DIAM TUDelft Michele Pisaroni; EPFL Lausanne, Miguel Romero; BASF Frankfurt Rudi Sadi; Almatis Rotterdam “Models, Simulation, Optimization: Mathematical Technologies for Industrial Innovation in Europe” Rome, Italy 19-21 December 2016 Accademia dei Lincei

  2. The problem H2020SOCIETAL CHALLENGE • The Industrial Problems: • Pre-Cement Ring Formation inside the Furnace • Unscheduled Shutdown of the Plant • Waste of Fuel, Raw Materials, and Man Hours to Clean & Re-Start the Furnace • Brief description of the collaboration • To Develop a Mathematical Model of the Combustion in the Furnace Productive sector

  3. Model of Almatis Furnace

  4. FINAL PRODUCT: Alumina-Cement

  5. Application of Alumina-Cement: High Temperature Lining

  6. Production Suspension Due to Ring Formation Image by Kumar Pradeep, Technical Advisor for Baroda

  7. Ring Build-Up and Clean-Up

  8. Combustion Model to Prevent Ring Formation FIRST STEP: (GEOMETRY)

  9. Combustion Model to Prevent Ring Formation SECOND STEP: (MESH)

  10. Combustion Model to Prevent Ring Formation SECOND STEP: (MESH)

  11. Combustion Model to Prevent Ring Formation SECOND STEP: (MESH)

  12. Combustion Model to Prevent Ring Formation SECOND STEP: (MESH)

  13. CONTINUITY NAVIER-STOKES TEMPERATURE SPECIES Combustion Model to Prevent Ring Formation THIRD STEP: (PHYSICS)

  14. 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)

  15. Combustion Model to Prevent Ring Formation FOURTH STEP: (RESULTS)

  16. RINGS PRESENT RINGS ABSENT Combustion Model to Prevent Ring Formation FOURTH STEP: (RESULTS)

  17. HEAT ABSORPTION of Granular Material PHASE TRANSFORMATION of Granular Material Granular Flow Model to Predict Productivity of the Furnace

  18. Pleasant Side-Effect: Higher Productivity

  19. TEMPERATURE OF GAS TEMPERATURE OF MATERIAL Granular Flow Model for Higher Productivity

  20. Current Research Mohamed El Abbassi Implementation in OpenFOAM Add radiation Add lining Add advanced chemistry model

  21. NO MORE SHUTDOWNS HIGHER PRODUCTION OUTPUT LOWER OPERATIONAL COST

  22. 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

  23. GRAZIE MILLE!

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