Journal of Chemical Technology Metallurgy, 1, 2014 Journal of Chemical Technology andand Metallurgy, 49,49, 1, 2014, 82-89 GEOMETRICAL CHARACTERISTICS OF THE SOLID BED IN A ROTARY KILN Rayko Stanev1, Iliyan Mitov2, Eckehard Specht3, Fabian Herz3 Department of Physical Metallurgy and Thermal Equipment University of Chemical Technology and Metallurgy 8 Kl. Ohridski, 1756 Sofia, Bulgaria E-mail: [email protected] 2 “Rua Bulgaria” Ltd., 36 Bogatitsa str., 1421 Sofia, Bulgaria 3 University “Otto von Guericke”, Universitätsplatz 2, 39106 Magdeburg, Germany 1 Received 30 July 2013 Accepted 25 November 2013 ABSTRACT Rotary kilns are aggregates for high temperature thermal treatment of a wide range of materials in a continuous technological process. This type of furnaces is used �������������������������������������������������������������������������� intensively in many industrial branches such as chemical, metallurgical, silicate, pharmaceutical, etc. In the metallurgy these units find application for heat treatment of bulk materials (e.g. oxide ores reduction, limestone calcination, sulphide copper stock drying, cleaning of metal swarfs from machine oil, etc). The present study enlarges the opportunities for a fast and reliable thickness determination of the separate zones of the solid disperse bed at rolling motion as the most widespread regime of its transverse transport. Data published in a previous work of the authors are used. They are obtained by a mathematical model established on the basis of regularities in the particles movement in a cylindrical rotary kiln, allowing determination of the total thickness of the layer of processed material and the active part of it, occupying the area immediately below the free surface of the bed. Approximation equations for prediction of the maximal values of the enumerated indicators depending on the inner diameter of the rotary kiln, its rotation speed, the filling degree of the drum with material, the dynamic angle of its repose and the particles diameter are proposed. Keywords: rotary kiln, rolling motion, active layer. INTRODUCTION Rotary kilns serve for a high-temperature heat treatment of different materials in a continuous technological process. Their sphere of application gradually expands and develops [1��������������������������������������� -������������������������������������� �������������������������������������� 3]. ������������������������������������ These units are used in many industrial branches like chemical, metallurgical, silicate, pharmaceutical, etc. [4], as well as for burning the residuals from different factory installations or the municipal wastes. Drying processes, incineration, mixing, heating, roasting, cooling, humidification, calcination, reduction, sintering, melting, gasification, dehydration, as well as reactions between gas and solid phase are implemented [5]. 82 The application of the considered furnaces in the metallurgy is for heat treatment of bulk materials [6, 7] such as oxide ores reduction, limestone calcination, drying of sulphide copper stock, cleaning of swarfs from machine oil, etc. [8]. At many real production situations the rotary kilns prove to be the best and often the only solution for fulfillment of a number of processes. Depending on their function, the temperature of the gases in them can be higher than 1820 K, as is the situation at the treatment of the clinker in the cement production and the upper boundary of this parameter reaches to 2270 K [9]. The necessary heat for this purpose most often through combustion of primary fuel is supplied. This required Rayko Stanev, Iliyan Mitov, Eckehard Specht, Fabian Herz energy amount to the bed of processed material and to the inner surface of the furnace wall by convection [10, 11] and by radiation is transferred. For that reason the characteristics of the burners and the created by them jets and torches influence very essentially on the complete work of the equipment. The considered units allow a treatment of various materials with changing heat-physical properties. In addition, at appropriate control of their operating parameters, the load of these installations also permits considerable deviations from their nominal regime. Often their universality is a reason to use them for incineration of hazardous wastes, which in relatively deep beds is performed. Then after the rotary kiln a secondary combustion chamber is envisaged, which improves the heterogeneous burning of the corresponding material [3, 12]. Other application of these units except the typical fire treatment of different media is the gasification of the rubber waste products (for example of old car tyres) or wood particles [13, 14]. The analysis of the technological operations pointed out that the rotary kilns can be used for three main purposes. These processes are heating, fulfillment of chemical reactions and drying of solid materials. They usually run combined, which complicates their consideration from the positions of the individual scientific directions and imposes a complex approach to the corresponding unit [14]. Several important aspects of engineering and technical standpoint at the design of the rotary kilns should be had in mind: the heat transfer; the material motion through the cylindrical workspace; the mass transfer between gas and solid phase; the chemical reactions. The experimental data collected from different rotary kilns by many parameters are influenced. Such are the diameter of the set, its rotation speed, the feeling degree with a processed material, as well as the own characteristics of the stuff like the coarseness of its particles, their shape and state of the surface [15]. An essential significance has also the transverse motion mode of the bed. The orientation in this variety of factors conditioning the transport phenomena in the rotary kilns is a difficult task even for skilled researchers and specialists in their exploitation. For that reason one of the disposable approaches is the creation and provision of opportunity for using of mathematical models, predicting the above mentioned parameters individually for each of the materials without physical experiments or with a minimum of the empirical determining quantities [16]. Among the most substantial transport phenomena running in a given rotary kiln is the particles motion of the processed solid material. It can be important for its exploitation [2], because this factor limits the bed ability to absorb the heat flux evolved by the flame. Furthermore, the outflow of the disperse stuff from the concrete equipment, which also is an element of the problems connected with the media motion in it, has an elaborate and decisive influence on the complete situation in the workshop. On the one hand, it designs the position of the following apparatuses in the technological flow. On the other hand, the parameters at the running out from the furnace define the initial conditions for modeling of the bed axial height and its heat exchange surface area. In the literature this altitude simplified as zero is accepted, which does not correspond to the physical reality [9]. That is why the mixing and the transportation of the granular materials treated in the unit have essentially influence on all other processes and it is an object of continuously extending researches. In view of the considerations expressed above, the aim of the present work is the opportunities for rapid and reliable thickness determination of the separate zones of the disperse material bed in a rotary kiln at rolling motion as the most widespread regime of its transverse transport to be extended. BED MOTION IN ROTARY KILNS The operation knowing of a given rotary kiln requires exhaustive investigations to be conducted with the aim to determine the key parameters like particles residence time in the furnace, the temperature field in it, the filling degree of the cylinder with material, etc. The big diversity of the processed products in these installations leads to the necessity for considerable resources to determine the mentioned above parameters individually for each material. So, the creating and the possibilities for using of mathematical models, which to allow their prediction without physical experiments to be imposed or at reducing to a minimum the number of the empirical specified quantities is important. 83 Journal of Chemical Technology and Metallurgy, 49, 1, 2014 A. Motion modes The motions of the solid bed in a rotary kiln can be differentiated in six basic groups [1]. The possible ways for transverse particles transportation with the rotational Froude number, Fr, –, are characterized, which represents a measure of the ratio between the forces of inertia and weight [1, 17]: Fr = n2 R g (1) where n , s–1, is the rotation speed of the kiln, R , m, is its inner radius, and g , m/s2, - the gravitational acceleration. The boundary values are shown in Table 1, within the frames of which can be confidently asserted that the regime is the pointed out type. There is an impression that intermediate areas exist, where the transition from one mode to another occurs. Except on the cylinder rotation speed, the bed motion in the kiln depends also on the kind of material, the feeling degree of the drum and the friction forces between the particles and the wall of the vessel. As shown in Table 1, with the increase of the rotation speed, and thence – of the rotational Froude number, the transportation modes from slipping motion to centrifuging one are changed [18]. These regimes are presented in Fig. 1. The slipping motion begins to run at weak friction between the bed and the cylinder wall, i. e. at smooth surfaces of the vessel and the particles. When the kiln wall has a low roughness, the sliding of the material with a constant initial point is characterized. Then it turns out that the cylinder rotates under the treated material, and the bed remains with a small deviation angle from its original state, as certain “slipping” is observed. With the increase of the friction between the wall and the material, their mutual translation from sliding turns into a rocking and it reaches to a slumping motion of Fig. 1. Material motion modes on the cross section of a rotary kiln. the bed. It is characterized with a periodical alternation of an immovable state and of a particles sliding on the cylinder wall. Such motion should be avoided, because it is not material mixing, and this leads to an aggravation of the quality. This regime is especially undesired in industrial conditions, but unfortunately not at all cases avoidable and it often springs up locally in separated zones at some technological processes. The rolling motion is preferable to all other modes, because it ensures a best mixing of the particles, and thence also a maximal intensive heat transfer between the wall of the kiln and the processed material. The cascading motion by clustering of many particles in the upper zone under the action of the increased rotation speed is characterized. As it is still insufficient to begin a material emitting in the freeboard of the furnace, a descent like avalanche (cascading drop) of the upper layer to the lower areas of the cross section in reverse direction of the rotation is observed. The cataracting motion is typical with the beginning of a particles throwing away from the bed in the freeboard of the cylinder. With the increase of the rotation speed, the quantity of the ejected particles and the Table 1. Limits of the particular motion modes according to the rotational Froude number. No. 1 2 3 4 5 6 84 Motion Slipping Slumping Rolling Cascading Cataracting Centrifuging Values of the rotational Froude number Fr < 1x10−5 1x10−5 < Fr < 0.3x10−3 0.5x10 −3 < Fr < 0.2 x10 −1 0.4 x10 −1 < Fr < 0.8x10 −1 0.9x10−1 < Fr < 1 1 < Fr Rayko Stanev, Iliyan Mitov, Eckehard Specht, Fabian Herz length of their trajectory grow, while a fully covering of the cylinder wall with the treated material is turned out. This motion mode finds an application at the ball crushers. In them with an enlargement of the rotation speed of the cylindrical cage, the used metal spheres and the processed material start to roll on the cylinder wall and thence also the breaking of the material is improved. At Fr > 1 an adhesion of the material to the kiln wall is observed and the motion from cataracting becomes a centrifuging one. B. Rolling motion mechanism As it was already mentioned, this regime of bed shifting is preferable to the other ones be-cause it ensures a best particles mixing and gives optimal conditions for heat exchange between the processed material and the hot gas, as well as from the kiln wall to the particles contacting with it. The rolling motion mechanism is presented in Fig. 2. The inclination angle of the material surface (the dynamic angle of repose) is approximately constant. The whole volume occupied with particles with two layers is characterized: a thin active and a deep passive one. Their geometrical characteristics in Fig. 2 are also shown. The boundary line between the two beds is through the turning point W. The particle flux on the surface of the active layer is with relatively high speed. In its lower area, at the boundary line WB, the particles pass from the active to the passive layer and there they start to raise upwards with the rotation speed of the cylinder, until they reach the upper section of the boundary line WA, where they return back in the active bed [19, 20]. In the rotary kilns with a direct burning of fuel above Fig. 2. Kinematic scheme of a rolling motion (1 - active layer; 2 - boundary line; 3 - passive layer; t A - thickness of the active layer, m; t B - vertical depth of the bed, m; t BA - vertical depth of the active layer, m). the material, the active layer plays an important role at the heat transfer from the gaseous to the solid phase. For this reason big efforts are made to predict the active bed thickness, the particles speed in it and their residence time on its surface. The study of the rolling motion at the rotary kilns with an indirect firing is also important, as on its complete fulfillment depends on the transport of the heat from the inner cylinder wall at the contact of the material with it. EXPERIMENTAL A previous work of the authors [21] presents an analytical model created on the ground of the regularities at the particles motion in a cylindrical rotary kiln. It allows the calculation of the general thickness of the bed moving rollingly on its cross section, by reason of what a “total model” is named, as well as this one of the active layer, occupying the zone immediately below the free surface of the material, through its vertical depth. On the basis of this mathematical apparatus the particles distribution at different rotation speeds of the unit, feeling degrees of it, f , –, and materials is determined. Moreover the influence of the diameters of the cylindrical kilns, D , m, and of the processed in them particles, d , m, is investigated. It is proved that the assumed preconditions at the development of the model correspond to the nature of the described physical phenomena. RESULTS AND DISCUSSION In the referred literature source [21] graphical dependences are given, which reflect the behaviour of the enumerated above dimensionless geometrical characteristics of the whole bed and the active layer of material on the kiln cross section in a function of different constructive and operating parameters of the unit chosen for modeling. Since their assessment with the spending of considerable resources is connected, a form for describing of the most important results of the offered researches with simple and convenient for engineering application relations is sought. The analysis of the mentioned graphs shows that all they evince a clearly expressed maximum. Because of that in the present work their ordinates are statistically processed and presented in Figs. 3�������������������������������������������� ��������������������������������������������� -������������������������������������������� 10����������������������������������������� . On the highest values of the dimensionless thicknesses and vertical depths of the layers can be 85 Journal of Chemical Technology and Metallurgy, 49, 1, 2014 Fig. 3. Dependence of the maximum dimensionless vertical depth of the bed on the feeling degree of the furnace with material. Fig. ������������������������������������������������� 7. ���������������������������������������������� Dependence������������������������������������ ����������������������������������� of the maximum dimensionless thickness of the active layer on the particles diameter. Fig. 4. ������������������������������������������������� Dependence������������������������������������ ���������������������������������������������� of ����������������������������������� the maximum dimensionless vertical depth of the bed on the dynamic angle of repose of the material. Fig. 8. Dependence of the maximum dimensionless vertical depth of the active layer on the inner diameter of the kiln. Fig. ������������������������������������������������� 5. ���������������������������������������������� Dependence������������������������������������ ����������������������������������� of the maximum dimensionless thickness of the active layer on the inner diameter of the kiln. Fig. 9. Dependence of the maximum dimensionless vertical depth of the active layer on the dynamic angle of repose of the material. Fig. 6. ������������������������������������������������� Dependence������������������������������������ ���������������������������������������������� of ����������������������������������� the maximum dimensionless thickness of the active layer on the rotation speed of the kiln. Fig. 10. Dependence of the maximum dimensionless vertical depth of the active layer on the feeling degree of the furnace with material. obtained an initial notion for their distributions on the cross sections of the considered rotary kilns. As seen from the results presented in Figs. 3-10, all data are mathematically well describable. At this process approximation equations with different structures are feasible. That is why in the diagrams with a solid 86 Rayko Stanev, Iliyan Mitov, Eckehard Specht, Fabian Herz Table 2. Dependences derived on the basis of the presented data. To Fig. Тtype of the dependence Polynomial 3 Linear Logarithmic Polynomial 4 Exponential Linear Polynomial 5 Linear Exponential Polynomial 6 Exponential Linear Polynomial 7 Linear Exponential Polynomial 8 Exponential Linear Exponential Polynomial 9 Linear Polynomial 10 Linear Logarithmic Analytical expression R* t B / R = −3.0598 f 2 + 3.2293 f + 0.0639 0.9996 0.9966 t B / R = 2.4175 f + 0.0975 0.9709 t B / R = 0.2217 ln f + 0.9236 2 t B / R = 0.0001θ − 0.0028θ + 0.4466 0.9986 0.9954 t B / R = 0.3339 exp(0.0123θ ) 0.9914 t B / R = 0.0064θ + 0.2922 Boundaries of validity 0.02 ≤ f ≤ 0.25 0.4 m ≤ D ≤ 6 m θ = 30° 25° ≤ θ ≤ 45° 0.4 m ≤ D ≤ 6 m f = 0.15 ; ε = 54.2° 0.4 m ≤ D ≤ 6 m t A / R = 3x10−5 D 2 + 0.0006 D + 0.1023 0.9778 0.9765 f = 0.15 ; ε = 54.2° t A / R = 0.0008 D + 0.1021 0.9763 t A / R = 0.1021exp(0.0074 D ) d = 2.2x10−3 m 2 0.2 min −1 ≤ n ≤ 3 min −1 t A / R = 0.0005n + 0.0001n + 0.0985 0.9947 0.9735 t A / R = 0.0977 exp(0.018n ) D = 2 m; d = 2.2 x10−3 m 0.9729 f = 0.15 ; ε = 54.2° ; θ = 30° t A / R = 0.0018n + 0.0977 −6 2 t A / R = −7 x10 d + 0.001d + 0.0998 0.9944 2x10 −3 ≤ d ≤ 60x10 −3 m 0.9795 t A / R = 0.0006d + 0.1033 D = 2 m; n = 3 min −1 0.9686 f = 0.15 ; ε = 54.2° ; θ = 30° t A / R = 0.1037 exp(0.0051d ) −5 2 0.4 m ≤ D ≤ 6 m t BA / R = 7 x10 D + 0.0005 D + 0.125 0.9993 0.9934 f = 0 . 15 ; ε = 54.2° ; θ = 30° t BA / R = 0.1246 exp(0.0074 D ) 0.9929 t BA / R = 0.0009 D + 0.1246 d = 2.2 x10−3 m 0.9999 25° ≤ θ ≤ 45° t BA / R = 0.0262 exp(0.045θ ) 2 D = 2m t BA / R = 0.0001θ − 0.003θ + 0.0775 0.9998 0.9917 f = 0.15 ; ε = 54.2° t BA / R = 0.0059θ − 0.0719 2 0.02 ≤ f ≤ 0.35 t BA / R = −0.5575 f + 0.6283 f + 0.0746 0.9996 t BA / R = 0.4053 f + 0.09 t BA / R = 0.0614 ln f + 0.2835 line the curves obtained by the dependences with the highest adequacy degrees are displayed. The corresponding to them analytical expressions in Table 2 as a first proposal for each set of points are systematized. Then in a descending series of their statistical indicators by further two variants for mathematical description of the discrete values are arranged. All polynomial functions are chosen to be second-degree because their complicating with more terms does not lead to an improvement of the precision. At the indication of their boundaries of validity with ε , °, the half of the filling angle of the kiln cross section is marked. From Table 2 makes an impression that the correlation coefficients, R * , –, of each of the presented equation are enough high. This fact shows that the corresponding dependence describes adequately the data on the basis of which it is derived. The differences 0.9922 0.9896 D = 2 m; n = 3 min −1 d = 2.2x10−3 m; θ = 40° between the accuracy, with which they by each of the three chosen as most suitable formulae can be approximated are often practical negligible. Nevertheless, at a more careful analysis it is found that at seven from the whole eight figures best results offers the polynomial second-degree dependence and only once such priorities by the exponential correlation are ensured. The linear equation guarantees the second highest precision in four of the cases compared to three times on behalf of the exponential function and one – of the polynomial relation. The logarithmic dependence can be recommended solely as a third successive option, besides only regarding the data from two of the graphs, namely these ones shown in Fig. 3 and 10. The presented graphical and tabular data confirm the conclusions made in [21] that on the thicknesses and the vertical depths of the whole bed and the active part of 87 Journal of Chemical Technology and Metallurgy, 49, 1, 2014 it exert influence the inner diameter of the cylindrical cage, its rotation speed, the filling degree of the drum with stuff, the particles diameter, the dynamic angle of repose of the material, its motion regime through the cylindrical workspace determining where along the kiln a certain feeling degree would be obtained. The significance of the specified parameters for the forming of the separate zones of the bed at its rolling motion from the presented in [21] graphs can be more precise evaluated. Here is properly to be generalized that for the obtaining of a right idea for the transverse motion and the material mixing in a given rotary kiln the impact of each of the enumerated factors on it is necessary to be rendered an account. The overestimation of one of the listed indicators or conditions for the process running at the������������������������������������������������������� expense����������������������������������������������� ������������������������������������������������������ of ���������������������������������������������� another, as well as the still more inadmissible absolute disregard of some of them can lead to an essential distortion of the results. CONCLUSIONS The data obtained by specially created mathematical model and published in our previous work are analyzed. Their interpretation form a point of view of the maximum values manifesting in the individual functional dependences allows a rapid and convenient determination of the influence of the most important factors on the thicknesses and the vertical depths of the whole bed and the active part of it at rolling motion, which has a practical significance through its wide currency in the rotary kilns and the priorities of it over the remaining regimes. For each set of discrete values characterizing the height of the maximum in the concrete curve from the mentioned research by three equations are proposed. They are ranged in a descending series according to their adequacy degree, with which they describe the data, on the basis of what the separate formulae are derived. The lines corresponding to the dependences, which in best way the points from the figures in this work approximate in them are plotted. The implemented previous and present investigations allow to be generalized that on the thicknesses and the vertical depths of the whole bed and the active part of it exert influence the inner diameter of the kiln, its rotation speed, the degree of its feeling with material, its dynamic angle of repose and the particles diameter. The statistical analysis of all derived equations 88 shows that they can be successfully used for prediction of the height of the corresponding maximum. It is recommended this calculation to occur by the proposed in the lead correlation, which in more than 87 % of the cases is a second-degree. REFERENCES 1.A.A. Boateng, Rotary Kilns., Transport Phenomena and Transport Processes, Elsevier Inc., Amsterdam, Boston e. a., 2008. 2.P.V. Barr, Heat Transfer Processes in Rotary Kilns, Ph.D. thesis, The University of British Columbia, Vancouver, BC, Canada, 1986. 3.M. Rovaglio, D. Manca, G. 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