Aerodynamic control of a diffusion flame to optimize materials' transition in a rotary cement kiln

The aim of this work is to deepen the understanding of the aerodynamics of a diffusion flame in a rotary cement kiln. The kiln is a rotary with a cylindrical shaped, long and equipped with a burner, and it is the seat of a diffusion flame with an axisymmetric turbulent jet. The kiln has a capacity of 8,000 Nm3 to 13,000 Nm3 of natural gas and primary air at T = 25 °C which interacts with a secondary hot air volume at T = 800 °C. The aerodynamic modelling of the furnace is achieved using the turbulence model RNG k–ε, which is able to handle the turbulence and capture the vortex shedding process. The Ansys/Fluent code, based on the finite volume approach to solve the Reynolds averaged Navier-Stokes (RANS), was used in this study. The interactions between turbulence and diffusion flame were handled by the PDF (Probability Density Function) approach. The numerical simulations have been validated by experiments from the kiln considered. Based on the findings obtained, it is concluded that the recirculation zone seems of paramount importance when combustion is taken into account because the reverse flow improves the flame stability and affects the combustion efficiency. In addition, limiting the secondary air flow through the furnace is major to improve combustion and avoid disturbing the advancement of the material along the kiln.