Rotary Kilns

Rotary Kilns—rotating industrial drying ovens—are used for a wide variety of applications including processing raw minerals and feedstocks as well as heat-treating hazardous wastes. They are particularly critical in the manufacture of Portland cement. Their design and operation is critical to their efficient usage, which if done incorrectly can result in improperly treated materials and excessive, high fuel costs. This professional reference book will be the first comprehensive book in many years that treats all engineering aspects of rotary kilns, including a thorough grounding in the thermal and fluid principles involved in their operation, as well as how to properly design an engineering process that uses rotary kilns. This new edition contains an updated CFD section with inclusion of recent case studies and in line with recent developments covers pyrolysis processes, torrefaction of biomass, application of rotary kilns in C02 capture and information on using rotary kilns as incinerators for hydrocarbons. Provides essential information on fluid flow, granular flow, mixing and segregation, and aerodynamics during turbulent mixing and recirculation Gives guidance on which fuels to choose, including options such as natural gas versus coal-fired rotary kilns Covers principles of combustion and flame control, heat transfer and heating and material balances New edition contains information on pyrolysis processes with low temperatures and torrefaction of biomass. It also covers calcination of petcoke, how rotary kilns are used as incinerators for chlorinated hydrocarbons. Includes updated material on CFD simulation of kiln gas and solids flow with a selection of recent case studies.

This is an indispensable reference source and training tool not only for kiln operators, but for supervisors and management staff as well. Extensive discussions on pre-heater and pre-calciner operations are included. The appendix includes a section with conversion tables, definitions of common terms relating to rotary kilns, and a suggested outline for a training program for new operators. CONTENTS: History; Types of Rotary Kilns; Refractories; Fuels; Combustion; The Flame; Heat Transfer; Heat Balances; The Chemistry of Kiln Feed and Clinker, Reaction Zones in the Rotary Kiln; Coating and Ring Formation in a Rotary Kiln; The Air Circuit in a Rotary Kiln: Movement of the Material Through The Kiln; Kiln Operating and Control Methods; Instrumentation; Burning Zone Control; Fuel Systems; Clinker cooler Control; Kiln Exit-Gas Temperature Control; Feed-Rate Control; Kiln Starts and Shutdowns; The 27 Basic Kiln Conditions; Kiln Emergency Conditions; Safety and Accident Prevention; Appendix: A KILN OPERATOR'S QUIZ; Glossary; Conversion Tables; Index. See also: F.M. LEA's, THE CHEMISTRY OF CEMENT AND CONCRETE, Third Edition: ISBN 978-0-8206-0212-7; Kurt Peray, The Cement Manufacturer's Handbook: ISBN 0820603686. Visit us at www.chemical-publishing.com

Rotary Kilns—rotating industrial drying ovens—are used for a wide variety of applications including processing raw minerals and feedstocks as well as heat-treating hazardous wastes. They are particularly critical in the manufacture of Portland cement. Their design and operation is critical to their efficient usage, which if done incorrectly can result in improperly treated materials and excessive, high fuel costs. This professional reference book will be the first comprehensive book in many years that treats all engineering aspects of rotary kilns, including a thorough grounding in the thermal and fluid principles involved in their operation, as well as how to properly design an engineering process that uses rotary kilns. Chapter 1: The Rotary Kiln Evolution & Phenomenon Chapter 2: Basic Description of Rotary Kiln Operation Chapter 3: Freeboard Aerodynamic Phenomena Chapter 4: Granular Flows in Rotary Kilns Chapter 5: Mixing & Segregation Chapter 6: Combustion and Flame Chapter 7: Freeboard Heat Transfer Chapter 8: Heat Transfer Processes in the Rotary Kiln Bed Chapter 9: Mass & Energy Balance Chapter 10: Rotary Kiln Minerals Process Applications ·Covers fluid flow, granular flow, mixing and segregation, and aerodynamics during turbulent mixing and recirculation ·Offers hard-to-find guidance on fuels used for rotary kilns, including fuel options such as natural gas versus coal-fired rotary kilns ·Explains principles of combustion and flame control, heat transfer and heating and material balances

Industrial and Process Furnaces: Principles, Design and Operation, Third Editioncontinues to provide comprehensive coverage on all aspects of furnace operation and design, including topics essential for process engineers and operators to better understand furnaces. New to this edition are sections on production, handling and utilization of alternative fuels such as biomass, hydrogen and various wastes, modeling of the process, combustion and heat transfer, their benefits, advantages and limitations, mitigation and removal of CO2 , the role of solar and other renewable energy, recent research, and the practical approach of the Whyalla steelworks for harnessing solar energy for sustainable steelmaking, hydrogen and as a "clean fuel". The book also includes a discussion on the limitations of hydrogen supply owing to fresh water supply constraints, the difficulty of storing and transporting hydrogen, and the current sociopolitical impetus of CO2. Covers the manufacture and utilization of hydrogen as a clean fuel Includes process modeling and expands on computational fluid dynamics (CFD), with a special focus on flames and burners, costs, efficiencies and future trends Expands on future trends, including sociopolitical impacts on CO2 emissions and control