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Rotary Kilns: Transport Phenomena and Transport Processes
Akwasi Boateng
Butterworth Heineman
Jan 2008
Hardcover 368 pp ISBN 9780750678773
£70.00
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Rotary Kilns or 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.
Of interest to Professional Mechanical Engineers working in heating and drying processes; Chemical Engineers;
Materials Engineers
Contents
Chapter 1: The Rotary Kiln Evolution & Phenomenon , The Rotary Kiln Evolution, Types of Rotary Kilns,
Wet Kilns, Long Kilns Short Dry Kilns Coolers and Dryers References
Chapter 2: Basic Description of Rotary Kiln Operation Bed Phenomenon Geometrical
Features and their Transport Effects Transverse Bed Motion Experimental Observations of Transverse
Flow Behavior Axial Motion Dimensionless Residence Time References
Chapter 3: Freeboard Aerodynamic Phenomena Fluid Flow in Pipes -
General Background Basic Equations of Multicomponent Reacting Flows Development of a Turbulent
Jet Confined Jets Swirling Jets Precessing Jets The Particle-laden Jet Dust Entrainment Induced Draft
Fan References
Chapter 4: Granular Flows in Rotary Kilns Flow of Granular Materials
(Granular Flows) The Equations of Motion for Granular Flows Particulate Flow Behavior in
Rotary Kilns Overview of the Observed Flow Behavior in a Rotary Drums Modeling the Granular
Flow in the Transverse Plain Particulate Flow Model in Rotary Kilns Model Description Simplifying
Assumptions Governing Equations for Momentum Conservation Integral Equation for Momentum
Conservation Solution of the Momentum Equation in the Active Layer of the Bed Velocity Profile
in the Active Layer Density and Granular Temperature Profiles An Analytical Expression for the
Thickness of the Active Layer Numerical Solution Scheme for the Momentum Equation Model
Results and Validation Application of the Flow Model References
Chapter 5: Mixing & Segregation Modeling of Particle Mixing and Segregation in Rotary
Kilns Bed Segregation Model The Governing Equations for Segregation Boundary Conditions Solution
of the Segregation Equation Numerical Solution of the Governing Equations Validation of the Segregation
Model Application of Segregation Model References
Chapter 6: Combustion and Flame Combustion Mole and Mass Fractions Combustion
Chemistry Practical Stoichiometry Adiabatic flame temperature Types of Fuels used in Rotary Kilns
Coal Types, Ranking, and Analysis Petroleum Coke Combustion Scrap Tire Combustion Pulverized Fuel
(coal/coke) Firing in Kilns Pulverized Fuel Delivery and Firing Systems Estimation of Combustion Air
Requirement Reaction Kinetics of Carbon Particles Fuel Oil Firing Combustion Modeling Flow
Visualization Modeling (Acid Alkali Modeling) Mathematical Modeling including CFD Gas-Phase
Conservation Equations used in CFD Modeling Particle-Phase Conservation Equations used in
CFD Modeling Emissions Modeling CFD Evaluation of a Rotary Kiln Pulverized Fuel Burner
Reference
Chapter 7: Freeboard Heat Transfer Overview of Heat Transfer Mechanisms Conduction Heat
Transfer Convection Heat Transfer Conduction-Convection Problems Shell Losses Refractory Lining Materials
Radiation Heat Transfer The concept of blackbody Radiation Shape Factors Radiation Exchange Between
Multiple Gray Surfaces Radiative Effect of Combustion Gases Heat Transfer Coefficients for Radiation in
the Freeboard of a Rotary Kiln Radiative Exchange from the Freeboard Gas to Exposed Bed and Wall
Surfaces Radiative Heat Transfer among Exposed Freeboard Surfaces Reference
Chapter 8: Heat Transfer Processes in the Rotary Kiln Bed Heat Transfer between the Covered
Wall and the Bed Modified Penetration Model for Rotary Kiln Wall-to-Bed Heat Transfer Effective Thermal
Conductivity of Packed Beds Effective Thermal Conductivity in Rotating Bed Mode Thermal Modeling of
Rotary Kiln Processes Description of the Thermal Model One-dimensional Thermal Model for Bed and Freeboard
Two-dimensional Thermal Model for the Bed The Combined Axial and Cross-sectional Model -
The Quasi 3-Dimensional Model for the Bed Solution Procedure Model Results and Application Single-Particle
Heat transfer Modeling for Expanded Shale Processing Reference
Chapter 9: Mass & Energy Balance Chemical Thermodynamics Gibbs Free Energy and Entropy Global
Heat and Material Balance Thermal Module for Chemically Reactive System Mass Balance Inputs Chemical
Compositions Energy Balance Inputs
Chapter 10: Rotary Kiln Minerals Process Applications Lime Making Limestone Dissociation (Calcination)
The rotary Lime Kiln The Cement Making Process The Cement Process chemistry Rotary Cement Kiln Energy Usage
Mineral Ore Reduction Processes in Rotary Kilns The Rotary Kiln SL/RN Process Roasting of Titaniferous Materials
The Rotary Kiln Lightweight Aggregate Making Process Raw Material Characterization Mineralogy Thermal History
References
Appendices
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