Thermodynamics and fluid mechanics, as well as caloric- and material transmission play a central role in cement industry or the production of cement, respectively, which consists of a number of processes and process actions. Regarding these processes, our knowhow is especially usable in the following plant sections:
Rotary kiln: Through the combustion of various solid, liquid and gaseous fuels, the rotary kiln provides the necessary energy in order to transform and sinter the raw material into clinkers.
The heat is transferred to the material through thermal radiation. The combustion in the rotary kiln plays a central role in cement production and the quality of the produced clinker. But due to more stringent exhaust emission standards and the pressure of using more favourable fuels, the combustion process in the rotary kiln is far from trivial. This is where we come in to offer CFD simulations of the combustion in order to evaluate and improve the process.
Among our clients are suppliers of burners as well as plant manufacturers and -operators.
Calciner: Using calciners in modern plants is standard and already existing plants are being retrofitted with calciners too. Based on CFD simulations, we offer optimization- and engineering measures related to calciners.
Cyclones: Within cyclones, in various areas of the cyclone tower, constructional inadequacies or damaged components can occur, leading to imbalances which in further consequence lead to lessened quality of the clinker at the furnace inlet. The numeric simulation of processes in cyclone towers requires expertise regarding the processes which need to be illustrated as well as multiphase fluid mechanics.
Clinker coolers: The process of cooling the clinkers is vital to the quality of the product. So called satellites can by now only be found in outdated plants. Modern clinker coolers are listed as bed coolers. Using a specially developed software, we are able to illustrate the cooling process at the bed. This allows to optimize the cooler and keep the quality of the clinker in sight.
Heat shift and heat exchanges: Due to the (prospective) application of selective catalytic reduction (SCR), the flue gas has to be reheated after cleaning and before SCR. Optimizing these heat exchanges, based on flow simulations and using thermo dynamics-tools, is one of our core competencies.
SNCR: additive injections: The injection of urea or similar liquids in combination with NOx-minimisation can be optimized through flow simulations. Both the content of NOx as well as the amount of necessary urea can be minimized. Therefore it saves operational costs and limit values can be complied with more easily.