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h i g h l i g h t s g r a p h i c a l a b s t r a c t
a r t i c l e i n f o a b s t r a c t
Article history: In this paper, a comprehensive computational fluid dynamics (CFD) methodology was adopted to inves-
Received 12 September 2015 tigate the characteristics of oxy-coal combustion in a cement kiln with a specially designed burner. The
Accepted 7 April 2016 simulation was conducted under five oxidant stream conditions with different O2/N2 volume ratios:
Available online 12 April 2016
21/79, 24/76, 27/73, 30/70, and 33/67. The results revealed that there is strong entrainment from the pri-
mary air to the secondary air, resulting in an inner recirculation zone and outside recirculation zone. The
Keywords: oxygen-enriched combustion increases the maximum temperature and improves the combustion effi-
Numerical simulation
ciency; however, the uniformity of the temperature field becomes worse. The temperature rises sharply
Oxy-coal combustion
Pulverized coal combustion
as the oxygen content increases; however, the enhancement is slight when the oxygen content exceeds
Rotary cement kiln 30%. At a lower oxygen content (<27%), the NOx emissions increase slowly as the oxygen content
NOx emissions increases, whereas NOx increases sharply when the oxygen content exceeds 27% in volume. This suggests
Burner that the optimal oxygen content is no more than 27% for pulverized coal combustion in a cement kiln. The
simulation results reasonably agree with the measured data. The findings of this work will help save fuel
consumption and decrease production cost.
Ó 2016 Elsevier Ltd. All rights reserved.
1. Introduction is composed of 21% O2, 78% N2, and 1% other gases. In conven-
tional combustion, a large amount of nitrogen is heated, and
The cement industry garners a great deal of attention due to some energy is lost through the high-temperature exhaust. Cur-
high coal consumption and severe environmental impact [1]. Air rently, there is an urgent need to improve the pulverized coal
combustion efficiency and reduce emissions. In contrast,
⇑ Corresponding author. oxygen-enriched combustion can decrease the energy loss in
E-mail address: tasklb@163.com (S. Wang). the exhaust as well as improve both the productivity and thermal
http://dx.doi.org/10.1016/j.applthermaleng.2016.04.028
1359-4311/Ó 2016 Elsevier Ltd. All rights reserved.
492 M. Wang et al. / Applied Thermal Engineering 103 (2016) 491–500
efficiency of the system [2]. Moreover, CO2 can be obtained easily where Gk is the production due to the mean velocity gradients, and
from the exhaust [3–5]. Gb represents the production due to buoyancy. Y M represents the
The burner is an important piece of equipment in the cement contribution of the fluctuating dilatation in compressible turbu-
clinker production process. The burner used in this paper is spe- lence to the overall dissipation rate. The quantities ak and ae are
cially equipped with swirl vanes in every channel, as shown in the inverse effective Prandtl numbers for k and e, respectively. Sk
Fig. 1. With this special structure, a strong inner recirculation zone and Se are user-defined source terms.
and outside recirculation zone can be established in the rotary kiln. The energy model is used in this paper, as following.
The recirculation zones can greatly enhance the mixing of pulver- @ * X *
ized coal and air, which favors combustion [6,7]. The oxygen con- ðqEÞ þ r v ðqE þ PÞ ¼ r ðkeff rT eff *
hj J j þ ðs v ÞÞ þ Sh
@t j
centration of the swirling flow channel is varied from 0.21 to 0.33.
Details on oxygen enriched combustion in a rotary kiln is discussed ð5Þ
in later sections.
The first three terms on the right-hand side of Eq. (5) represent
energy transfer due to conduction, species diffusion, and viscous
2. Numerical model dissipation, respectively. Sh is the heat of chemical reaction in this
paper.
This paper assumes that the flow regime is steady-state and the Radiation is the primary means of heat transfer in a rotary kiln,
fluid is incompressible. In the present study the kiln rotation as and the P-1 radiation model is used as Eq. (5).
been neglected as it has been done in the previous studies [8].
The ‘‘SIMPLEC” algorithm was selected to couple velocity and pres- r qr ¼ aG 4an2 rT 4 ð6Þ
sure. Momentum, energy and continuity equations were used to
where a is the absorption coefficient, r is the Stefan–Boltzmann
solve the flow field. The following models were employed in the
constant, G is the incident radiation, n is the refractive index of
simulation: RNG k–e turbulence model, P-1 radiation model
the medium. r qr can be substituted into the energy equation
[9,10] for gas-phase radiation, Discrete phase model (DPM), and
to account for heat sources as a result of radiation. Additionally,
Eddy Dissipation model for coal combustion.
the P-1 radiation model is capable of considering the effect of ani-
sotropic scattering absorption, emitting, and scattering media
2.1. Gas phase
[12], which is based on the expansion of the radiation intensity I
into an orthogonal series of spherical harmonics. The P-1 radiation
The continuity equation was used in the paper, shown as Eq. (1).
model is more stable and precise for the heat radiation when optical
The source Sm is the mass added to the continuous phase from
thickness >1. The P-1 radiation model is responsible for exchange of
combustion particles. The velocities of the x, y, and z directions
radiation between coal particulates and gas. Furthermore, the P-1
are presented by the momentum equation, shown as Eq. (2). The
model is easy to converge and solve without much computing
source term in Eq. (2) results from the interaction between coal
effort. The Weighted-Sum-of-Gray-Gases model (WSGGM) was
particles and gas.
selected to calculate the variable absorption coefficient. The
WSGGM model in fluent computes the absorption coefficient for
@ H2O and CO2. Other gases, such as SO2, CO and NO, are usually sec-
ðqui Þ ¼ Sm ð1Þ
@xi ondary due to their low concentration [11].
@ @p @ sij
ðqui uj Þ ¼ þ þ q g i þ F i þ Sm ð2Þ
@xj @xi @cj 2.2. Particle phase
The RNG k–e turbulence model has greater predictive accuracy In this paper, the coal particle only occupies a very low volume
and greater convergence stability when a swirling flow exists [11] fraction. Trajectories of coal particles are computed in a Lagrangian
as the effect of swirl on turbulence is included. The model is frame [13], which particle trajectories are calculated individually
defined as: during the fluid phase compute. Using a discrete phase model,
@ @ @ @k reacting coal particles can be modeled and can exchange heat,
ðqkÞ þ ðqkli Þ ¼ ak leff þ Gk þ Gb qe Y M þ Sk ð3Þ mass, and momentum with the Eulerian frame continuous phase,
@t @xi @xj @xj
shown as Eq. (6).
@ @ @ @e e
ðqkeÞ þ ðqkei Þ ¼ ae leff þ C 1e ðGk þ C 3e Gb Þ
@t @xi @xj @xj k dlp g x ðqp qÞ
¼ F D ð l lp Þ þ þ Fx ð7Þ
e2 dt qp
C 2e q R e þ Se ð4Þ
k
Axial flow
Swirling flow
Coal flow
Central flow
where lp and l are particle and gas velocities, respectively. aC þ O2 ! 2ða 1ÞCO þ ð2 aÞCO2 ðR4Þ
F D ðl lp Þ represents drag force per unit particle mass, C þ CO2 ! 2CO ðR5Þ
g x ðqp qÞ=qp is gravity force, and F x are additional forces. C þ H2 O ! CO þ H2 ðR6Þ
The combustion of pulverized coal is treated as first the burning
of the released volatile matter t and then the burning of the char where a is determined by the kind of coal and ranges from 1 to 2
[14]. The single rate model was used to represent devolatilization. [17], as shown in Eq. (11).
The single rate model supposes that the rate of devolatilization is E
A0 exp RT þ1
first-order and depends on the residual volatiles in the particles a¼2 E ð12Þ
A0 exp RT þ 2
[15]:
dmp
¼ k½mp ð1 f x;0 Þð1 f y;0 ÞmA;0 ð8Þ 2.3. NOx model
dt
where mp is particle mass, mp;0 is initial particle mass, f x;0 is the There are generally three accepted mechanisms for NOx forma-
mass fraction of volatiles initially present in the particle, and f y;0 tion: thermal, fuel, and prompt NOx formation [18]. In this paper,
is the mass fraction of evaporating material. The kinetic rate k is the prompt NOx mechanism is not taken into consideration
shown as the following: because prompt NOx formation accounts for less than 5% of the
total emissions in pulverized coal combustion [18,19].
k ¼ A1 eðE=RTÞ ð9Þ
The primary reactions of the thermal NOx mechanism are as
where A1 is the pre-exponential factor, and E is the activation follows:
energy. The reaction mechanisms are given as Eqs. (R1)–(R3). The
kinetic parameters for reactions (R1)–(R3) are summarized in
O þ N2
N þ NO ð13Þ
Table 1. N þ O2
O þ NO ð14Þ
N þ OH
H þ NO ð15Þ
C1:16 H3:7 O0:6 N0:1482 S0:0186 þ 0:2986O2 ! 1:16CO þ 1:85H2 The expressions for the rate coefficients for these reactions are
þ 0:0741N2 þ 0:0186SO2 ðR1Þ given below. These were selected based on the evaluation by Han-
CO þ 1=2O2 ! CO2 ðR2Þ son and Salimian [20].
H2 þ 1=2O2 ! H2 O ðR3Þ kq;1 ¼ 1:8 108 e38370=T m3 =mol-s ke;1 ¼ 3:8 107 e425=T m3 =mol-s
For char combustion, the kinetic/diffusion surface reaction rate kq;2 ¼ 1:8 104 Te4680=T m3 =mol-s ke;2 ¼ 3:81 103 Te20820=T m3 =mol-s
model was used, which assumed that the surface reaction rate was kq;3 ¼ 7:1 107 e450=T m3 =mol-s ke;3 ¼ 1:7 108 e24560=T m3 =mol-s
determined either by diffusion or by kinetics rate [16]. The model
of the char combustion rate is defined by Eq. (9); Here, kq;1 ; kq;2 , and kq;3 are the rate constants for the forward reac-
tions of Eqs. (12)–(14), and ke;1 ; ke;2 , and ke;3 are the corresponding
dmp D0 R
¼ Ap pox ð10Þ reverse rate constants.
dt D0 þ R
Assuming that the O2, N2, O, and OH concentrations are at their
where Ap is the surface area of the particle, pox is the surrounding equilibrium values, the NO concentrations are much less than their
gas pressure, and R is the kinetic rate defined by Eq. (10); equilibrium values, and the N atoms are in the steady state. Thus,
the NO formation rate becomes:
R ¼ C 2 eðE=RT p Þ ð11Þ
k k ½NO2
where E is the reaction activation energy, and C2 is the kinetics- d½NO 1 kq;1e;1½N2e;2kq;2 ½O2
limited rate pre-exponential factor. The reaction mechanisms are ¼ 2kq;1 ½O½N2 ke;1 ½NO
mol=m3 -s ð16Þ
dt 1þ
given as Eqs. (R4)–(R6). The kinetic parameters for reactions (R4)– kq;2 ½O2 þkq;3 ½OH
Table 2
The kinetic parameters of char combustion.
Axial flow L
Swirling flow Second air
Primary air +
(Enriched air) D
Pulverized coal
Coal flow Second air
Table 4
The ultimate and proximate analyses of the coal.
Table 5
Coal particle properties.
In this section, the results and discussions are based on five dif-
ferent combustion environments, and the mass flow rate of the
gradually along the axial direction of the kiln. A local mesh refine- coal particles remains a constant.
ment technique is applied near the burner, where the temperature
and flow field change greatly. The mesh was generated after a 4.1. Flow fields
mesh independence study. Fig. 4 shows the temperature of moni-
toring point with different grid numbers. The monitoring point is The increase of O2 causes a composition change of the primary
located on the centerline of kiln and 7 m away from burner exit. airflow. It is necessary to determine whether this will result in
It can be seen that the temperature reveals a slight difference when significant changes in the overall flow field. The simulation results
M. Wang et al. / Applied Thermal Engineering 103 (2016) 491–500 495
Inside 0.5
recirculaon
0
-0.5
-1
Outside
recirculation -1.5
0 2 4 6 8 10
Distance from burner tip,/m
indicated that the increase of O2 did not lead to velocity field nearly the same flame shape. The flame shape is not significantly
change in the kiln. The velocity vectors of air combustion near affected when the oxidant stream composition changes. It is easily
the burner region are shown in Fig. 5. determined that a local low-temperature region exists near the
It can be seen clearly from Fig. 5 that both a strong inner recir- burner, which is beneficial for protecting the burner. As the volume
culation zone and an outside recirculation zone exists due to the concentration of O2 increases from 21% to 33%, the maximum tem-
swirl vanes in burner. It is evident that there exists a strong perature rises, thereby suggesting that a higher temperature can
entrainment phenomenon near burner, which the second air is easily be achieved through oxygen-enriched combustion. Increas-
entrained by primary air. The outside recirculation mainly entrains ing the O2 concentration reduced the amount of combustion air,
the second airflow of high-temperature to preheat the coal parti- thus the nitrogen concentration in the furnace atmosphere was
cles, where the inner recirculation can entrains coal particles and significantly reduced, thus leading to the temperature rise.
high-temperature gas. These phenomena contribute to the ignition Fig. 7 gives the center-line temperature profile of different O2
of coal and the stabilization of the flame [6,7]. rates in the swirling flow. The temperature rises as the O2 concen-
tration increases. At a lower oxygen content (<30%), the tempera-
4.2. Temperature predictions ture rises sharply with an increased oxygen content, but the
enhancement is slight when the oxygen content exceeds 30% in
Fig. 6 shows the temperature contour along the axial section of volume. Fig. 8 is local amplification figure. Fig. 9 presents the
the rotary kiln. The results indicate that each of the five cases had max and average temperature of five different oxidant stream
Fig. 6. Contours of temperature with different O2 concentrations in the swirling flow. (a), (b), (c), (d), (e).
496 M. Wang et al. / Applied Thermal Engineering 103 (2016) 491–500
The comparisons between the total heat transfer rate and the
radiation heat transfer rate of different O2 concentrations are dis-
played in Fig. 10. The results indicate that the heat transfer rate
rises as the O2 concentration increases. This phenomenon can be
Fig. 13. The mole fraction of CO along the kiln center-line. Fig. 15. The mole fraction of CO2 along the kiln center-line.
Fig. 14. The mole fraction of CO along the kiln center-line from 010m. Fig. 16. The mole fraction of CO2 along the kiln center-line from 08m.
Fig. 17. NOx concentration contours of cross-section along rotary kiln. (a), (b), (c), (d), (e).
498 M. Wang et al. / Applied Thermal Engineering 103 (2016) 491–500
Fig. 18. NOx concentration contours of cross-section (z = 5 m) (a), (b), (c), (d), (e).
explained that heat transfer from a flame in the kiln is primarily by that the combustion of pulverized coal is first the burning of vola-
thermal radiation [21], which leads to the heat transfer rise with tile matter and then the burning of the char.
the increase of O2 concentration in kiln. In an oxy-fuel combustion, The NOx concentration contours of the cross-section along the
the concentrations of H2O and CO2 increase significantly due to the rotary kiln and cross-section (z = 5 m) are displayed in Figs. 17
elimination of nitrogen, and these gases (CO2 and H2O) are primar- and 18. Fig. 19 shows the NOx concentration along the center-
ily responsible for thermal radiation [21–23]. line. Fig. 20 is local amplification figure. The comparison between
the total NOx emissions and the thermal NOx emissions are shown
4.3. Species concentration in Fig. 21. Both Figs. 19 and 21 indicate that the NOx concentration
increases as the O2 concentration increases when the mass flow
The mole fractions of O2, CO and CO2 are presented in Figs. 11, rate of the coal particles is kept constant, which seemingly agrees
13 and 15, respectively. Figs. 12, 14 and 16, is local amplification well with previous oxygen-enhanced combustion research [24].
figure respectively. According to the data shown in Fig. 13, it can Additionally, it can be seen from Fig. 17 that the growth rate of
be concluded that the CO concentration decreases as the O2 con- NOx slowly increases as the O2 concentration rises from 21% to
centration increases. Less CO is produced when the O2 concentra- 27%; however, the NOx emissions increase rapidly when the O2
tion is greater than 27%. Though the O2 concentration increases concentration is greater than 27%. The total NOx emissions at
in the primary flow, all five cases exhibit a complete lack of oxygen 33% O2 concentration are 55 times more than the total NOx emis-
at the center-line of the kiln, as displayed in Fig. 11. It can be found sions at 21% O2 concentration. The key factor leading to the
that at one point, the CO concentration increased, but the O2 con- increase in NOx is that the elevated O2 concentration and the ade-
centration was not reduced. The phenomenon mainly stems from quate N2 coupled with a high temperature promote the formation
the fact that the combustion has not yet started, and the CO pri- of thermal NOx [25]. Thermal NOx is considered unimportant
marily comes from the release of volatile matter. All this indicates for temperatures below 1800 K [26]; however, thermal NOx
Fig. 19. NOx concentration along the kiln center-line. Fig. 20. NOx concentration along the kiln center-line from 010m.
M. Wang et al. / Applied Thermal Engineering 103 (2016) 491–500 499
5. Experimental validation
Table 6
Temperature of simulation and experiment. Fig. 24. CO concentration of simulation data and experimental data.
6. Conclusions
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