A Model for Predicting the Erosion Rate Induced by the Use of a Selective Catalytic Reduction Denitrification Technology in Cement Kilns Flue Gas

Selective catalytic reduction(SCR)is a technology by which nitrogen oxides are converted with the aid of a catalyst into diatomic nitrogen and water.It is known that the catalyst can be easily eroded if a cement kiln with a high-dust content is considered.To understand this process,numerical simulations have been carried out considering a single catalyst channel in order to study the collision and erosion of fly ash and catalysts at meso scale.Based on a response surface methodology,the effects of five factors on the erosion rate have been studied,namely,the catalyst particle velocity,the particle size,the particle concentration,the incidence angle and the catalyst porosity.The results show that the influence of particle velocity,particle size and particle concentration is statistically significant and the particle size and incidence angle have a significant effect on the erosion rate.A quadratic polynomial prediction model for the erosion rate of honeycomb catalysts in cement kiln SCR reactors is finally proposed to support the future optimization of these systems.

Digital Kilns and Furnaces——the Development Direction of Industrial Kilns and Furnaces in the 21st Century

The digital manufacturing theory is applied to the special manufacturing equipments——industrial kilns and furnaces; the concept of digital kilns & furnaces is put forward. The present status of research and application for digital technologies in fuel industrial kilns & furnaces is also introduced. Then,take the case of gas fuel kilns & furnaces,their main key technical issues are discussed. Digital kilns & furnaces as an important constituent of the digital equipments are the crucial base of the digital manufacturing. The value of research on digital kilns & furnaces and the application prospect are undoubted. It will improve product quality,reduce the manpower cost,enhance product market competitive ability,promote comprehensively tradition industries such as ceramics,metallurgy industry,and so on.

A History of Industrial Kilns and Furnaces——Lessons for Future Energy Conservation and Environmental Protection

This is a historical compilation and analysis of the world-wide development of kilns and furnaces, covering those ones ranging from ancient earthenware kilns to modern high-tech furnaces、 including nuclear reactors and fuel cells. Special emphasis is on energy conservation and environmental protection. the historical lessons from which can be applied to future activities.

Direct-bonded Magnesite-Chrome Bricks for Kilns and Furnaces of Building Materials Industry

JC 497-92 (96)1 Contents and Applied ScopeThis standard specifies the classification, shapes and dimensions, technical requirements, test methods, inspection rules, marking, packing, transportation, storage and quality certificate of direct-bonded magnesite-chrome bricks for building materials industry. This standard is applicable to the direct-bonded magnesite-chrome bricks for cement kiln, glass melting tank and other industrial furnaces.2 Normative ReferencesGB 2997: Test method for the apparent porosity, water absorption, bulk density and true porosity of dense shaped refractory productsGB 5070: Chemical analysis method for magnesite-Chrome refractoriesGB 5072: Test method for cold crushing strength of dense shaped refractory productsGB 5989: Test method for refractoriness under load of dense shaped refractory products (Differential, with rising temperature)GB 7320: Test method for thermal expansion of refractory productsGB 7321: Sample preparation for testing of dense shaped refractory productsGB 10324: Type definition of refractory productsGB 10325: Piling, sampling, acceptance, storage and transportation of refractory products

Effects of Municipal Sewage Sludge on Fixation of Cr,Ni,Cu,and Zn during Co-processing of Heavy Metal-containing Waste in Cement Kilns

Cement raw meal with MSS and different heavy metals was blended to examine the fixation ratios, chemical species, and cement crystalline phases in clinkers. The results showed that blending MSS could decrease the fixation ratio of Cr, Ni, Cu, and Zn in the produced clinker by 5% to 25%. And Cr, Cu, and Zn were mainly incorporated into clinkers as metal silicates, Ni was mainly solubilized in Mg O to form magnesium nickel oxides, and the transition phases were mainly metal aluminum oxides as indicated by X-ray diffraction. The reduction of fixation ratios was likely attributed to the presence of impure elements, such as sodium and phosphorus in MSS. In addition, high concentrations（eg, 1.7 wt%） of chlorine in MSS led to metal chloride formation that could vaporize Cu, Cr, Ni, and Zn. To summarize, introducing MSS would decrease the fixation ratios of heavy metals due to the presence of impure elements, such as sodium and phosphorus and chlorine.

Numerical analysis of behavior of active layer in rotary kilns by discrete element method

The behavior of the active layer of material bed within rotary kilns plays a key role in industrial applications.To obtain its influences on industrial process,different regimes of particle motion have been simulated by discrete element method(DEM) in three dimensions under variant rotation speeds,filling degree,based on the background of induration process of iron ore pellets.The influences of the mentioned factors on the maximum thickness of the active layer and the average velocity of particles have been investigated.The average velocity of particles increases with Froude number following the power function over a wide range,and the maximum thickness rises with increasing rotation speed in a way of logarithm.The influence of the filling degree f on the maximum thickness exhibits a good linearity under two classic regimes,but the increasing of the average velocity of the active layer is limited at f=0.4.This basic research highlights the impact of the active layer within rotary kilns,and lays a good foundation for the further investigation in mixing and heat transfer within the particle bed inside rotary kilns.

Present Synthesizing Situation and Application Mechanism of Hercynite in Cement Kilns

The magnesia -hercynite bricks offer a new lining to rotary cement kiln. They are well adopted and widely used in the high temperature zone of cement kiln, and have obtained good performance at rigorous and severe working conditions. The synthesis of hercynite requires a suitable atmosphere with proper O2 partial pressures which makes sure FeO can stably exist at the synthesizing temperature. Current industrial production of hercynite mainly adopts fused method. The other method, sinte- ring method, is not mature and needs further research. The magnesia - hercynite brick shows high hot toughhess, high adhesion strength to kiln crust, and good corrosion resistance to alkali salt in cement kilns. The mismatching of thermal expansion between magnesia and hercynite can improve the thermal shock resistance of the bricks, but the oxidation of partial Fe^2＋ , the high temperature solution, and low temperature exsolution of transgranular secondary spinel lead to cubical expansion, .formation of more cracks, and poor thermal shock resistance of the bricks.

Key Points of Monolithic Lining Engineering of Rotary Kilns

There are many factors affecting the monolithic lining engineering of rotary kilns,resulting in the difficult quality control.In this paper,the key points of the whole lining engineering were discussed from the aspects of lining structure design,personnel preparation,site construction management,maintenance and baking.

Corrosion of Disposing Urban Domestic Wastes on Refractories for Cement Rotary Kilns

Corrosion of burning urban domestic wastes to alkali-resistant bricks and spalling-resistant high alumina bricks was researched by static crucible method and SEM in order to choose refractories for cement rotary kilns for collaboratively disposing wastes. The result indicates that the main corrosion mechanism is slag permeation and corrosion ; the emitted high temperature gases containing alkali, sulfur and chlorine during burning the wastes re- act with refractories forming low melting point sulfate, chloride and compound salts, which metamorphose the refractories, and the loose metamorphic layer is easy to spall under thermal stress. So, corrosion resistance and spaUing resistance shall be taken into account when choosing refractories for cement rotary kilns for collaboratively disposing wastes. It is suggested that decomposition furnaces should adopt spaUing resistant high alumina bricks and anti-coating SiC castables, and preheating equipment should adopt high strength alkali-resistant bricks and castables.

Suggestions on Refractories in Nonferrous Metal Smelting Furnaces/Kilns

This paper introduces the refractories used in various nonferrous metal smelting equipment in China and the existing problems, and puts forward suggestions on the material of refractories, application of new technologies and production management of refractories, etc.

Damage Mechanism of Silicon Carbidemullite Bricks for Transition Zone of Cement Rotary Kilns

In order to improve the service performance and explore the damage mechanism of silicon carbide-mullite bricks for the transition zone of cement rotary kilns,the phase composition and the microstructure of a used brick in the transition zone of a cement rotary kiln were analyzed by XRD,SEM and EDS.The results show that the liquid and alkali vapor phases generated by the reaction between cement materials and the silicon carbide-mullite brick mostly enter the silicon carbide-mullite brick through the pores;meanwhile,Ca+and K+in the cement penetrate through the liquid maintaining a high chemical potential energy to dissolve Al2O3 and SiO2 at the top of the liquid phase thus enhancing the phase penetration;with the decreasing temperature,crystals such as gehlenite,potassium feldspar and potassium chloride are precipitated,which destroy the original structure and increase the difference of thermal expansion coefficient between the high temperature dense end and the metamorphic layer thus resulting in cracks,spalling,and rupture.

Study on the oxidation mechanism of Al-SiC composite at elevated temperature

Resin-bonded Al-SiC composite was sintered at 1100,1300,and 1500℃ in the air,the oxidation mechanism was investigated.The reaction models were also established.The oxidation resistance of the Al-SiC composite was significantly enhanced with temperature increase.SiC in the exterior of the composite was partially oxidized slightly,while the transformation of metastable Al_(4)C_(3) to stable Al_(4)SiC_(4) existed in the interior.At 1100℃,Al in the interior reacted with residual C to form Al_(4)C_(3).With increasing to 1300℃,high temperature and low oxygen partial pressure lead to active oxidation of SiC,and internal gas composition transforms to Al_(2)O(g)+CO(g)+SiO(g)as the reaction proceeds.After Al_(4)C_(3) is formed,CO(g)and SiO(g)are continuously deposited on its surface,transforming to Al_(4)SiC_(4).At 1500℃,a dense layer consisting of SiC and Al_(4)SiC_(4) whiskers is formed which cuts off the diffusion channel of oxygen.The active oxidation of SiC is accelerated,enabling more gas to participate in the synthesis of Al_(4)SiC_(4),eventually forming hexagonal lamellar Al_(4)SiC_(4) with mutual accumulation between SiC particles.Introducing Al enhances the oxidation resistance of SiC.In addition,the in situ generated non-oxide is uniformly dispersed on a micro-scale and bonds SiC stably.

Effects of Different Raw Materials and Additions on Wave Transparency of Alumina Fiber Products

Fiber products for microwave kilns were prepared using alumina fibers with alumina contents of 72 mass%and 80 mass%,and calcined alumina powder(4-6μm)as the main raw materials,silica sol as the binder,and cationic starch as the flocculant.Effects of different raw materials and their additions on the wave transparency of fiber products were researched.The results show that as the alumina fiber(72%)addition increases,the heating rate of the samples first decreases and then increases,and the corresponding wave transparency of the sample first increases and then decreases.When the alumina fibers addition is 40 mass%and the alumina powder addition is 30 mass%,the prepared microwave kiln lining material has a higher mullite content,which improves the wave transparency of the sample.The sample prepared from alumina fibers with an alumina content of 80%has a suitable glass-mullite phase ratio,performs lower overall dielectric constant and good wave transparency,and is a suitable lining material for microwave kilns.

Experimental study on the control of black smoke pollution from the ceramic kilns based on the mechanism of the surfactant and coagulant

Aiming at the characteristics of carbon black,a new method of controlling the black smoke from the industrial coal-burning ceramic kilns by wetting was brought forward.The carbon black in the flue of coal-burning ceramic kiln was collected for the experiments,and its physical and chemical properties were studied in detail.In order to change the sedimentation and wettabil-ity state of the carbon black,the complex solution of the coagulant and surfactant was applied.After a series of orthogonal experiments,the complex solutions with bet-ter effects were chosen.Then,the sedimentation percent-age of carbon black treated by the selected complex solutions was measured.The optimized complex solutions included Na 2 SO 4(100 mmol/L),sodium dodecylbenzene-sulfonate(SDBS)(1.2 mmol/L)and polyacrylamide(PAM)(40 mg/L).After carbon black was absorbed,the complex solutions were clear and colorless.The complex solutions can be recycled,and the sedimentation percent-age of carbon black is 94%.

Assessment of macro and micro nutrients around brick kilns agricultural environment

Brick kiln is well known as one of the main sources of air pollution;however,the pollutants produced from it do not remain in the air,they ultimately fall down to the soil and pollute the surroundings,therefore,this study was carried out to assess the status of macro(N,P,K and S)and micro nutrients(Fe,Mn and Zn,Cu)in the agricultural environment near the brick kilns of Young Brahmaputra and Jamuna Floodplain soils.Composite soil and plant samples were collected from four distances such as 250 m,500 m,1000 m,and 1500 m in three different sites.Sulphur(2352-3378 mg kg^-1),Zn(86-156 mg kg^-1)and Cu(24.7-46.9 mg kg^-1)are found in the elevated levels near brick kiln soils that is released due to burning of poor quality coal and fire woods.The alarming news is that plant uptake of S and micro nutrients in the nearest areas of the brick kilns are significantly higher than the areas far from the brick production and their concentration ranges from 23 mg kg^-1 to 101 mg kg^-1 for Zn,10-41 mg kg^-1 for Cu,35-1309 mg kg^-1 for Fe,26-126 mg kg^-1 for Mn and 2590-mg kg^-1 for S.Data indicates both soil and plant received maximum amount of micronutrients and S concentrations within 500-1000 m distances from brick kilns.Iron and Mn concentrations vary within a permissible limit but the plant uptake is high.Nitrogen concentrations is increasing with the distance from the brick kilns in both soils and plants but no definite pattern of P and K accumulation was found.Research suggested avoiding agricultural practice nearby brick kiln soils due to micronutrient contamination in order to preserve adjoined agricultural environment.

Destroying The Dragon Kilns

A television documentary and better transportation have brought illegal treasure hunters to Minqing County with devastating results for the region’s ancient kilns In Yiyou Village,Minqing County in south China’s Fujian Province ancient ceramic bowls,kettles and cups fitter the ground.The ancient treasures are relics from the Song and Yuan dynasties and date back almost a thousand years.

Assessment of popular techniques for co-processing municipal solid waste in Chinese cement kilns

Cement kiln co-processing techniques have been developed in the past 20 years in China,and more than 60 factories now use fermentation,screening,and gasification pre-treatment techniques to coprocess municipal solid waste(MSW).There three complete MSW pre-treatment techniques,coprocessing procedures,and environmental risk assessments have been described in few publications.In this study,we assessed the effectiveness of each technique.The results suggested that the pollutant content released by each pre-treatment technology was lower than the emission standard.To reveal the mechanisms of pollutant migration and enrichment,the substances in the kiln and kiln products are investigated.The input of co-processing materials(Co-M)produced by fermentation caused formation of polychlorinated dibenzo-p-dioxins and dibenzoftiran(PCDD/Fs)in the bypass flue gas(By-gas)in excess of the regulatory standard.The Co-M input produced by the screening and gasifier technologies caused the total organic carbon(TOC)concentration to exceed the standard.In addition,the NOx,TOC,and PCDD/Fs in the By-gas exceeded the regulatory standard.Raw meal was the primary chlorine and heavy metals input stream,and clinker(CK)and cement kiln dust(CKD)accounted for>90%of the total chlorine output stream.Flue gas and CKD were the primary volatile heavy metal(Hg)output streams.Greater than 70%of the semi-volatile heavy metals(Cd,Pb,T1 and Se)distributed in hot raw meal and bypass cement kiln dust.The low-volatility heavy metals were concentrated in the CK.These results indicated that co-processing techniques used in China still require improvement.

Multi-Objective Adaptive Optimization Model Predictive Control:Decreasing Carbon Emissions from a Zinc Oxide Rotary Kiln

The zinc oxide rotary kiln,as an essential piece of equipment in the zinc smelting industrial process,is presenting new challenges in process control.China’s strategy of achieving a carbon peak and carbon neutrality is putting new demands on the industry,including green production and the use of fewer resources;thus,traditional stability control is no longer suitable for multi-objective control tasks.Although researchers have revealed the principle of the rotary kiln and set up computational fluid dynamics(CFD)simulation models to study its dynamics,these models cannot be directly applied to process control due to their high computational complexity.To address these issues,this paper proposes a multi-objective adaptive optimization model predictive control(MAO-MPC)method based on sparse identification.More specifically,with a large amount of data collected from a CFD model,a sparse regression problem is first formulated and solved to obtain a reduction model.Then,a two-layered control framework including real-time optimization(RTO)and model predictive control(MPC)is designed.In the RTO layer,an optimization problem with the goal of achieving optimal operation performance and the lowest possible resource consumption is set up.By solving the optimization problem in real time,a suitable setting value is sent to the MPC layer to ensure that the zinc oxide rotary kiln always functions in an optimal state.Our experiments show the strength and reliability of the proposed method,which reduces the usage of coal while maintaining high profits.

Research on Remote Fault Detection System of Ceramic Kiln Based on 5G and IoT Technologies

In order to overcome the defects of the existing technology that the detection of ceramic electric kiln faults takes a long time and costs a lot,an electric kiln control and fault detection device was designed.The working process of the device includes detection module,control module,start⁃stop module and switch module.The detection module detects the resistance circuit and sends a fault signal to the control module.The control module generates stop signal and fault information according to the fault signal,and starts the electric kiln when the fault signal is not received within the preset time.The start⁃stop module can monitor the internal temperature of the electric kiln and control the closing status of the switch module.The switch module is used to control the connection status of AC power and each resistance circuit in the kiln.Based on the 5G DTU or 5G module,the control module could send the information to mobile terminal under the ultra⁃reliable and low⁃latency communication(uRLLC)technical characteristics of 5G communication.