Effects of grate cooler dynamics on cement process

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Effects of grate cooler dynamics on cement process simulation

EFFECTS OF GRATE COOLER DYNAMICS ON CEMENT PROCESS SIMULATION by Herbert Allen Johnson A Dissertation Submitted to the Graduate Faculty in Partial Fulfillment of The Requirements for the Degree of DOCTOR OF PHILOSOPHY Major Subject: Chemical Engineering De Iowa State University Ames, Iowa 1969 Approved: fharge of Magor Work

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"Effects of grate cooler dynamics on cement process ...

Recommended Citation. Johnson, Herbert Allen, "Effects of grate cooler dynamics on cement process simulation " (1969). Retrospective Theses and Dissertations.

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Effects of grate cooler dynamics on cement process ...

Effects of grate cooler dynamics on cement process simulation By Herbert Allen Johnson Get PDF (2 MB)

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PERFORMANCE EVALUATION OF A GRATE COOLER IN A

2.3.1 Conventional Grate stCoolers: These are 1 generational grate coolers that have ability to handle large capacities, capable of achieving low clinker temperature, favorable heat recuperation and permits take out of hot tertiary air. Figure 2.3 gives a typical example of conventional grate cooler. Fig 2.3: The Conventional Grate Cooler ...

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Experimental research on cement grate cooler system and ...

Nov 25, 2020  The dry cement production technique, which always consumes a large quantity of energy , , , and emits significant amounts of CO 2, is the most common in cement manufacturing . Fig. 1 shows the three main processes of the technique: preheat decomposition in the decomposing furnace, high-temperature calcination in the rotary kiln, and clinker cooling process in the grate cooler.

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GRATE COOLER - Page 1 of 1 - International Cement Review

In addition, lower grate speed has had a positive effect upon grate wear rates. High undergrate pressures and airflows adversely affect the conveying action of a reciprocating grate. High air pressures can reduce the friction between the clinker and the grate, which in turn can speed up the movement of the clinker toward the cooler discharge.

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Optimization Design of the Grate Cooler Based on the Power ...

10%  Dec 18, 2019  As an important process during the cement production, grate cooler plays significance roles on clinker cooling and waste heat recovery. In this paper, we measured experimentally the heat balance of the grate cooler, which provided initial operating parameters for optimization. Then, the grate cooler was simplified into a series-connected heat exchanger network

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GRATE COOLER (IN CEMENT PRODUCTION)

Geyser effect terjadi ketika terlalu banyak udara diatas grate cooler dan udara secara kuat/langsung menembus clinker bed. Tindakan yang dilakukan Naikkan pressure undergrate dengan menurunkan speed grate cooler, ini akan menaikkan ketebalan clinker bed. Turunkan airflow Geyser Effect

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HEAT EXCHANGE MODELING OF A GRATE CLINKER COOLER

The concept of the exergy analysis is applied to a grate cooler of a cement production facility. The cooling of the clinker is modelled by a gas-solid series of cross-current contacting stages fully mixed for the calculation of the temperatures of the clinker and the air with their thermodynamic properties along the cooler.

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(PDF) Clinker Coolers Holcim Khaled el-emam - Academia

Academia is a platform for academics to share research papers.

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Cement Process Energy Saving - ECCJ

Chemistry of Cement Process 100 ... cooler to grate cooler 1)Conversion from wet process to dry process 2)Replacement of ball or tube ... erosive effect. This leads to gradual increase of raw mill SEC. Filling level of grinding balls is also important in grinding efficiency.

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Energy benchmarking of cement industry, based on Process ...

Jul 01, 2017  The best practice of grate cooler for maximum heat recovery from hot clinker is the case with secondary air temperature of 1100 °C. However, examining the case studies indicated that the secondary air temperature has a range of 600–1100 °C. The Pinch Analysis has been implemented in each case study by considering two practices of grate cooler.

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PID-fuzzy controller for grate cooler in cement plant

For the cement production process, the optimization method of the grate cooler is important in reducing energy consumption and ensuring product quality.

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A Review On Environmental and Health Impacts Of Cement ...

Most commonly cooling of the clinker can be performed in a grate cooler, a tube (rotary) cooler, or a planetary cooler. ... operating other process in cement manufacturing [23]. ... Pollutants from cement plants are causing harmful effects on human health and environment [13]. Sulphur Oxide (SOx):

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A new control strategy for IKN-type coolers - ScienceDirect

Sep 01, 2011  This paper presents a new system for the optimized control of IKN-type cement coolers based on adaptive predictive methodology. The new system introduces the concepts of ’layer on grate’ and ’thickness of slope’, which allow a decoupled multivariable control of the layer of clinker over the grate, and the flow rate of the cooler fans, solving a fundamental control problem for this type ...

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CFD MODELLING OF THE FLOW THROUGH A GRATE-KILN

cooler where heat is recovered by pre-heating ambient air being used in the process. The gas flow is thus in the opposite direction to the pellets and, in essence, the grate-kiln can be seen as a counterflow heat exchanger. A large amount of highly pre-heated air is supplied to the kiln for sufficient oxidation of magnetite pellets farther

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Advanced process control for the cement industry

Kiln cooler application Control challenges Controlling a cement kiln has always been a challenging task for cement plant operators. These days, a computer-based pyro control system is not merely nice to have, it is a practical necessity. Both the inherent complexity of the pyro process and the far-reaching consequences of

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(PDF) Seepage Heat Transfer Model and Numerical Simulation ...

PDF Based on the porous media characteristics of cement clinker accumulation body in grate cooler, a seepage heat transfer model of grate cooler is... Find, read and cite all the research you ...

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Different Possible Ways for Saving Energy in the Cement ...

2.3 Clinker Cooling Clinker cooling in the cement industry has the following tasks to perform; cooling the clinker produced in the kiln to the lowest possible temperature, pre-heating the secondary and tertiary air required for the combustion process to the highest possible temperature, cooling the clinker at such a rate, which are suitable to ...

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Introduction to the optimization and transformation of SJK ...

Patent name: a grate cooler of the gas box fixed grate bed Patent no. : 201810334554.3 Use position: fixed bed Remarks: designed specifically to ensure heat recovery efficiency Patent name: cement clinker grate cooler partition combination of air box fixed grate bed Specialist no. : 201820531642.8

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Parametric Studies of Cement Production Processes

The cement industry is one of the most intensive energy consumers in the industrial sectors. The energy consumption represents 40% to 60% of production cost. Additionally, the cement industry contributes around 5% to 8% of all man-made CO 2 emissions. Physiochemical and thermochemical reactions involved in cement kilns are still not well understood because of their complexity.

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Clinker Cooler - KHD International

Innovative development of grate cooler technology. This new cooler combines the best solutions for each of the two fundamental, mutually interacting functions a clinker cooler has to accomplish: Clinker conveying is based on the "moving floor" principle. Aeration is controlled by self-regulating valves.

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Energy and exergy analyses of a mixed fuel-fired grate ...

The cooler also consists of four different zones with decreasing temperatures: cooler I (ACI), cooler II (ACII), cooler III (ACIII), and cooler IV (ACIV).The green balls consisting of iron ore concentrate, binder, water, etc. are at first dried, preheated in the grate, and then fired in the kiln, and at last cooled to reach the set temperature ...

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Effect Of Temperature During Cement Grinding

Effects Of Grate Cooler Dynamics On Cement Process. Small quantity of gypsum is added during grinding to control the setting of the cement. The finished product is then packaged for shipment. Production of cement has grown steadily in the United States since the first plemt was built in 1871. During this growing period, the demand for finished ...

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CFD MODELLING OF THE FLOW THROUGH A GRATE-KILN

cooler where heat is recovered by pre-heating ambient air being used in the process. The gas flow is thus in the opposite direction to the pellets and, in essence, the grate-kiln can be seen as a counterflow heat exchanger. A large amount of highly pre-heated air is supplied to the kiln for sufficient oxidation of magnetite pellets farther

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NCV 2 9 2012 - EPA

Folax Cooler with a Fuller's Controlled Flow Grate (CFG) system. A total of 180 controlled flow grate plates are to be installed in the first 18 rows of the clinker cooler. Of the 18 rows of CFG grate plates, the first 9 rows are 9 grates wide and the remaining 9 rows are 11 grates wide.

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Modeling of the Thermal Efficiency of a Whole Cement ...

Clink Cooling unit (grate cooler) for the rapid cooling of hot clinker. Coal Grinding and Boiler of Air Quenching Cooler (AQC) unit (CAQC) for handling raw coal and cogeneration. Figure 1 shows the mass flow between the various units either as inputs or as outflow/output to be defined and clarified later for the whole system.

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(PDF) An exergy analysis for cement industries: An ...

Cooler exergy balance Because of the low value of the transiting thermo-mechanical Touil et al. [23] concluded that knowledge of exergetic losses in the exergy of air and clinker traversing the cooler which constitutes grate cooler of the cement industry is known by the exergy analy-

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PID-Fuzzy Controller For Grate Cooler in Cement Plant ...

PID-Fuzzy Controller for Grate Cooler in Cement Plant. ... some algorithm to adjust PID controller according § 1 to the dynamics of the process. In grate cooler, the dynamic U (s) K p ¨¨ 1 T d s ¸¸ E ... The low pass filter reduces the effect of the 3 Fuzzification, ...

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CFD analysis of an induration cooler on an iron ore grate ...

Iron ore pellet induration The thermo-fluid analysis comprised the development of comprehensive three dimensional computa- Computational fluid dynamics Computational modelling tional models of gas flow through the cooler coupled with the heat transport and exchange with the cool- Grate-kiln process

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CAD Versus Self-Tuning Control of a Clinker Grate Cooler ...

Sep 01, 1979  A study has been reported on computer identification and control of a Puller clinker grate cooler pilot plant cooperating with a wet-process clinker rotary kiln. Having briefly described the cooling process, its different experimental models have been analysed, both deterministic and stochastic ones.

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Construction Industry Research Papers - Academia

Grate coolers are widely used in cement industries to recover heat from hot clinker, coming out from the rotary kiln. This study focuses on improving the energy, exergy and recovery efficiencies of a grate cooling system through the optimization of its operational parameters such as masses of cooling air and clinker, cooling air temperature ...

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The grate-kiln induration machine - History, advantages ...

In a typical grate-kiln-cooler pellet production system, green pellets enter the induration system by feeding on the grate, then go through grate, kiln, and cooler successively, and finally ...

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Analysis of material flow and consumption in cement ...

Jan 20, 2016  1. Introduction. Over the last century, Portland cement-based concrete has become the highest manufactured product on Earth in terms of volume. Concrete is used worldwide as a building material and is the most consumed substance on Earth after water (Sakai, 2009).The volume of concrete produced globally is approximately 5.30 billion m 3 per year (Roskos et al., 2011), with more than

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NOx Emission Reduction by Advanced Reburning in Grate ...

The grate-rotary kiln process consists of three parts: The grate, the rotary kiln, and the cooler . Green pellets are dried and preheated through the four zones of the grate (i.e., updraft drying zone, downdraft drying zone, tempered preheating zone, and preheating zone), preheated pellets are then fed into the rotary kiln for roasting at a ...

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Energy and exergy analysis for waste heat cascade ...

Apr 01, 2014  Property variations of cooling air are taken into consideration because of the large temperature difference in the cooling process. (7) Heat conduction and convection are considered without radiation effects between sinter and cooling air. Walls of the trolly are adiabatic. Download : Download full-size image; Fig. 2. A typical sinter cooling ...

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Cooling process of iron ore pellets in an annular cooler ...

May 29, 2011  A 3-D mathematical model was presented for the cooling process of iron ore pellets based on the laws of mass, momentum, and heat transfer. The flow, pressure, and temperature fields were obtained by numerical simulation with the commercial software FLUENT. In order to verify the model, a mass and energy balance field test was systematically carried out on an annular cooler in

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Energy and exergy analyses of a mixed fuel-fired grate ...

The cooler also consists of four different zones with decreasing temperatures: cooler I (ACI), cooler II (ACII), cooler III (ACIII), and cooler IV (ACIV).The green balls consisting of iron ore concentrate, binder, water, etc. are at first dried, preheated in the grate, and then fired in the kiln, and at last cooled to reach the set temperature ...

Get price
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