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The document discusses modeling lime kilns used in pulp and paper mills. It provides an overview of the modeling process, which involves building a computer model of the real-size kiln and using computational fluid dynamics and other mathematical models to simulate processes within the kiln. The modeling can be used to optimize burner design, evaluate different fuel types, minimize emissions, and improve kiln performance and operations. Inputs to the kiln model include detailed measurements of the kiln and operating conditions as well as models of chemical and physical processes within the kiln. Model outputs provide detailed visualization and profiles of conditions throughout the kiln.
The document discusses modeling lime kilns used in pulp and paper mills. It provides an overview of the modeling process, which involves building a computer model of the real-size kiln and using computational fluid dynamics and other mathematical models to simulate processes within the kiln. The modeling can be used to optimize burner design, evaluate different fuel types, minimize emissions, and improve kiln performance and operations. Inputs to the kiln model include detailed measurements of the kiln and operating conditions as well as models of chemical and physical processes within the kiln. Model outputs provide detailed visualization and profiles of conditions throughout the kiln.
The document discusses modeling lime kilns used in pulp and paper mills. It provides an overview of the modeling process, which involves building a computer model of the real-size kiln and using computational fluid dynamics and other mathematical models to simulate processes within the kiln. The modeling can be used to optimize burner design, evaluate different fuel types, minimize emissions, and improve kiln performance and operations. Inputs to the kiln model include detailed measurements of the kiln and operating conditions as well as models of chemical and physical processes within the kiln. Model outputs provide detailed visualization and profiles of conditions throughout the kiln.
Process Simulations Ltd. #206, 2386 East Mall, Vancouver, BC, Canada www.psl.bc.ca
August 23, 2006 Lime Kiln Issues Kiln efficiency Lower fuel costs Burner characteristics Refractory life Dams and rings Stable operation Primary Air Secondary Air Gas/Oil Firehood Burner Motor Chains Limestone CaCO 3 Lime CaO DRYING ZONE CALCINING ZONE BURNING ZONE COOLING ZONE Principle of Conservation Mass Momentum Energy . IN = OUT IN OUT OUT Computational Modeling Build a real size kiln model Use computer to solve equations Simulate processes in kiln Mathematical Models for Kiln Fully three-dimensional Reynolds- averaged transport equations of mass, momentum energy, and chemical species Block-structure body-fitted coordinates with domain segmentation Two-equation k-e turbulence model Ray tracing model for 3D radiation heat transfer Gas combustion model Lagrangian solid fuel combustion models Refractory and Calcination Models Multi-layer refractory heat transfer model
Heat transfer and lime calcination CaCO 3 = CaO + CO 2
Heat absorbed 1.679 MJ/kg CaCO 3 @1089K Modeling Output: Gas Velocity 0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 Vmag [m/s] Case 6 Modeling Output: Gas Temperature 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 2100 2200 2300 2400 2500 2600 2700 2800 2900 3000 Tgas [F] Case 6 Modeling Output: Gas Species Concentrations * Other species include CO, H 2 O, NOx, etc. Modeling Output: Flame Shape 0 -5 Modeling Output: Refractory Temperature Modeling Output: Shell Temperature Average Shell Temperature 0 50 100 150 200 250 300 350 400 0 30 60 90 Axial Distance (m) T(C) Model Shell Scan Modeling Output: Kiln Axial Profiles Distance fromKiln Hood [m] T e m p e r a t u r e o f G a s a n d L i m e [ K ] V o l u m e F r a c t i o n o f O 2 , C O 2 , H 2 O i n F l u s G a s [ v o l % ] E m i s s i o n o f N O i n F l u e G a s [ p p m v ] M a s s F r a c t i o n o f L i m e C o m p o n e n t s [ w t % ] 0 20 40 60 80 100 5 0 0 1 0 0 0 1 5 0 0 2 0 0 0 0 5 10 15 20 25 30 35 40 0 1 0 0 2 0 0 3 0 0 4 0 0 5 0 0 0 10 20 30 40 50 60 70 80 90 100 F e e d E n d F i r e E n d Tgas CaCO 3 CaO Tck NO CO 2 O 2 H 2 O Predicted Axial Profile Data Modeling Output: Gas Flow Animation Modeling Output: Solid Fuel Flow Animation Value and Benefit of Kiln Modeling Optimize burner design Optimize kiln performance Evaluate alternative fuels Minimize Emissions Identify and eliminate thermal hot spots that lead to reduced brick lining lifetime Identify and fix problems with kiln performance Improve waste gas incineration Advantages of Kiln Modeling Model provides comprehensive information throughout kiln at relatively low cost Can evaluate what if scenarios to improve operation Supplements operator knowledge of lime kiln operations Assists mill managers in making decisions regarding kiln retrofits/replacements Assists in optimizing burner and kiln designs Modeling Application: Burning Different Fuels Heavy Oil Petroleum Coke Natural Gas Modeling Application: Oil/Gas Burner Design Modeling Application: Coal Burner Design & NOx Emission R1 R2 R3 Swirl Air 20 vanes groove width = 17.7 mm slot width =18.8 mm; 20 degrees R0 R4 R5 R6 Coal Transport Air Axial Air 24 holes 18 mm Dia R1 axial air 24 slots 0.0245 (1") wide 0.0130 (0.51") deep 21 degrees inward R2 R4 R3 R5 R0 Swirl air No swirl Transport air Swirl Air 20 vanes groove width = 17.7 mm slot width =18.8 mm; 20 degrees Modeling Application: Direct & Indirect Coal Combustion Axial Air Coal Air Axial Air Coal Air Swirl Air Swirl Air Coal Air Coal Air Modeling Application: Burner with Different Primary Air Oil Flame @ Primary Air Ratio of 22% Oil Flame @ Primary Air Ratio of 60% Modeling Application: Burning NCG in Kilns Case 2: NCG incineration with less HVLC Case 3: NCG incineration with more HVLC Case 4: No NCG incineration with less natural gas Gas temperature on a vertical cross section 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 Case 1: No NCG incineration with more natural gas T [K] Kiln Modeling Inputs: Overview Site Survey and Measurements Mass and Energy Balance Calculation Kiln Geometry Refractory Lining Burner Design Lime Feed Properties Air Supplies DCS Data Analysis Kiln Modeling Inputs: Site Survey and Measurements Measured streams: - air in - fuel in - flue gas out - mud in - product out Measured parameters: - flow rate - temperature - composition Kiln Modeling Inputs: Example of Mass Balance Mass In = Mass Out Kiln Modeling Inputs: Example of Energy Balance Energy In = Energy Out Kiln Modeling Inputs: Kiln Geometry - Fire End 10' 6" Dia. Barrel Tilt = 1.7899 = 3/8" per 12" o Burner 4' 2 3/4" 24" 24" 9" 5' 6" 2' 9" 17 3/4" kiln c L Z X Barrel Start (non rotated) Kiln Modeling Inputs: Kiln Geometry - Front View Hood dimension, kiln diameter and length, tilt angle, kiln rotation Location and size of any openings Location and tilt angle of burner 15" 5' 3" 6' 7" 7' 3" 6 1/2" 4 1/2" 2 3/4" 2' 4 3/4" 15" 24" 12" dia=? 24" 24" 2' 7/8" 15 o 20" Dia. Y X Kiln Modeling Inputs: Kiln Burner Design Kiln Modeling Inputs: Refractory Lining and Property 9" 70%Alumina 9" Magnel RSV 9" 70%Alumina 2-1/2" Greenlite HS 6" Clipper DP 3-1/2" Mix Refratherm Greenlite 3" Greenlite HS 6" Castable 6" Castable 0 ' 0 m 2 ' 0 . 6 0 9 6 m 9 . 5 ' 2 . 8 9 5 6 m 1 9 . 5 ' 5 . 9 4 3 6 m 3 9 . 5 ' 1 2 . 0 3 9 8 8 4 . 5 ' 2 5 . 7 5 5 6 m 1 3 4 . 5 ' 4 0 . 9 9 5 6 m 2 1 6 ' 6 5 . 8 3 6 8 m 2 2 1 ' 6 7 . 3 6 0 8 m 2 2 6 . 5 ' 6 9 . 0 3 7 2 m Burner 3' 0.9144m 6" 0.1524m 18" 0.4572m 39" 0.9906m 1 0 2 " 2 . 5 9 0 8 m 1 0 ' 3 . 0 4 8 m 6 '
7 " 2 . 0 0 6 6 m 9 7 " 2 . 4 6 3 8 m 1 0 2 " 2 . 5 9 0 8 m 1 0 8 " 2 . 7 4 3 2 m 54' 16.4592m Chain System 1 0 1 " 2 . 5 6 5 4 m 0 1 2 2 3 3 4 4 4 0 a T a T a T a T a T a j j j
thermal conductivity, W/mk
T temperature, K Material 4 a 3 a 2 a 1 a 0 a Greenlite -2.554e-7 7.878e-4 5.248e-2 Refratherm 150 -3.571e-7 8.021e-4 0.1576 Magnel RSV 2.394e-12 -1.332e-8 2.771e-5 -0.02586 12.54 Kruzite - 70 5.908e-7 -0.0013 2.301 Clipper DP -3.571e-7 8.021e-4 0.1576 Kiln Modeling Inputs: Kiln Lime Mud Kiln Modeling Inputs: Kiln DCS Data Display Kiln Modeling Inputs: Kiln Operational Data Analyzer Kiln Modeling Inputs: Selected Data Windows - 1 Kiln Modeling Inputs: Selected Data Windows - 2 Kiln Modeling Inputs: Computed Secondary Air Area Kiln Modeling Inputs: Averaged Mill DCS Data Parameter Case 1 9/25/2003 8:30 to 10/2/2003 14:30 AIR Primary Air Flow (kg/s) 1.28 Excess O2 (%) 1.34% FEED Dry Feed rate (kg/s) 6.14 Dust Losses (% dry feed) 10.8% PRODUCT CaO Production Rate (kg/s) 2.99 CaCO3 Remaining (% of Product) 1.86% FUEL OIL Fuel flow-crude tall oil (kg/s) 0.444 MISCELLANEOUS Feed end draft (Pa) -535.1 Firing end draft (Pa) -124.1 Lime feed solids content 80% Inerts (% of Product) 4% AVERAGE DCS DATA Time period for data average SUPPLIED OR ESTIMATED DATA Kiln Modeling Inputs: Operation Conditions - Lime & Fuel Production rate 274.42 tpd 3.1761 kg/s Total feed rate 663.12 tpd 7.6750 kg/s Solids content 80% 80% CaCO3 462.23 tpd 5.3498 kg/s Dust 57.29 tpd 0.6631 kg/s Inerts 10.98 tpd 0.1270 kg/s Moisture 132.62 tpd 1.54 kg/s 663.12 tpd 7.6750 kg/s Oil flow rate 0.4440 kg/s Oil composition 100.00% Carbon 78.30% 0.3477 kg/s Hydrogen 9.88% 0.0439 kg/s Oxygen 11.57% 0.0514 kg/s Nitrogen 0.00% 0.0000 kg/s Sulphur 0.14% 0.0006 kg/s Ash 0.11% 0.0005 kg/s High heat value 44.7040 MJ/kg Density 935.0 kg/m3 Oil temperature 230 o F 383 K Stoichiometric air ratio for oil combustion 12.0178 kgAir/kgOil Stoichiometric air for oil combustion 5.3359 kg/s Atomizing steam flow rate lb/hr 0.08 kg/s Mixture flow rate 0.5240 Mass fraction of oil in mixture 0.8473 Total heat input 19.8 MW LIME FUEL Kiln Modeling Inputs: Operation Conditions - Air Supply Excess air ratio 8.51% Stochiometric air flow rate*(1+excess air ratio) 5.7900 kg/s PRIMARY AIR Primary air flow rate 1.2800 kg/s Primary air temperature 298.15 K Primary air density 1.1835 kg/m^3 Primary Axial Air 25.0% 0.3200 kg/s Primary Spin Air 75.0% 0.9600 kg/s SECONDARY AIR Secondary air temperature 298.15 K Secondary air density 1.1835 kg/m^3 Left side flow area 0.2027 m*m Right side flow area 0.2027 m*m Left side open area ratio 5.00% Right side open area ratio 5.00% Left side flow velocity 13.0334 m/s Right side flow velocity 13.0334 m/s Left side flow rate 0.1563 kg/s Right side flow rate 0.1563 kg/s BURNER/HOOD GAP AIR Burner/Hood gap air temperature 298.15 K Burner/Hood gap air density 1.1835 kg/m^3 Burner/Hood gap area 0.0488 m*m Burner/Hood gap open area ratio 80.00% Burner/Hood gap velocity 13.0334 m/s Burner/Hood flow rate 0.6018 kg/s DISCHARGE GRATE AIR Discharge grate air temperature 450 K Discharge grate air density 0.7841 kg/m^3 Discharge grate area 0.5226 m*m Discharge grate open area ratio 54.80% Discharge grate velocity 16.0120 m/s Discharge grate flow rate 3.5956 kg/s Total air flow rate 5.7901 kg/s Total air flow rate - stochiometric air flow rate 0.0001 kg/s Air Kiln Modeling Inputs: Flue Gas Calculation species Molecular Weight Volume % Mass % H2O 2.0098 kg/s 18 31.3% 19.7% CO2 3.6287 kg/s 44 23.1% 35.6% O2 0.1044 kg/s 32 0.92% 1.02% N2 4.4583 kg/s 28 44.6% 43.7% SO2 0.0012 kg/s 64 0.005% 0.012% Total 10.2024 kg/s 100.0% 100.0% species Molecular Weight Volume % Mass % CO2 3.6287 kg/s 44 33.7% 44.3% O2 0.1044 kg/s 32 1.33% 1.27% N2 4.4583 kg/s 28 65.0% 54.4% SO2 0.0012 kg/s 64 0.0% 0.015% Total 8.1926 kg/s 100.0% 100.0% mass flow True Flue Gas Calculation (dry based) mass flow True Flue Gas Calculation (wet based) Gas Constant 287.15 Ambient Pressure 101325 Pa Ambient Temperature 298.15 K Loss Coefficient 0.9 Firing End Draft -124.1 Pa kg/s to tpd (metric) 86.4 28 16 44 1 CO + 0.5*O2 = CO2 16 64 44 36 2 CH 4 + 2*O 2 = CO 2 + 2*H 2 O 2 16 18 3 H 2 + 0.5*O 2 = H 2 O 12 32 44 4 C + O2 = CO2 100 44 56 5 CaCO 3 = CO 2 + CaO 14 16 30 6 N + 0.5*O2 = NO 32 32 64 7 S + O2 = SO2 Species Reactions (with molecular weights)