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Article history:
Received 24 February 2016
Received in revised form 4 October 2016
Accepted 7 October 2016
Available online 28 October 2016
Keywords:
Heat transfer
Rotary kiln
Rutile titanium dioxide
Simulation
a b s t r a c t
This paper presents a computational heat transfer model of a rotary kiln used for the production of rutile
titanium dioxide by the calcination of paste-like hydrous titanium dioxide. The work details the modelling of several chemical reactions occurring in the solid bed region along with turbulent convection
of gas, radiation heat exchange among hot gas, refractory wall and the solid surface, and conduction in
the refractory wall. Finite-difference techniques are used and the steady state thermal conditions are
assumed. The kiln is divided into axial segments of equal length. The solution is of marching type and
proceeds from the solid inlet to the solid outlet. The direction of gas flow is opposite to that of the solids.
Mass balance of each species in the solid charge, and mass and energy balances of the solid and gas in an
axial segment are used to obtain solids and gas temperatures, and species concentration at the exit of that
segment. The kiln length predicted by the present model is 45.75 m as compared to 45 m of an actual kiln
reported by Ginsberg and Modigell (2011). The steady-state axial gas and solid temperature profiles have
been also satisfactorily validated with the numerical results of the aforementioned paper. The output
data consist of refractory wall temperature distribution, the axial solids and gas temperature profiles,
axial solids composition profile, the length required for drying of the solid charge and the total kiln length
required to achieve 98% conversion of anatase TiO2 to rutile TiO2. A detailed parametric study with
respect to the controlling parameters such as percent water content (with respect to dry solids), solids
flow rate, gas flow rate, kiln inclination angle and kiln rotational speed lent a good physical insight into
the rutile-TiO2 production process in a rotary kiln.
2016 Elsevier Ltd. All rights reserved.
1. Introduction
This paper presents a computer model of heat transfer during
production of titanium dioxide white pigment in rutile form in a
rotary kiln.
1.1. Production of rutile titanium dioxide (TiO2) in a rotary kiln
Titanium dioxide is a white solid inorganic substance which is
used as a pigment or whitener in paints, paper, plastics, textiles,
and other products. It occurs in several polymorphs, among them,
anatase and rutile are manufactured in the chemical industry as
white pigments. The pigment properties of rutile titanium dioxide
are better than that of anatase titanium dioxide and are of more
economical importance. Titanium dioxide white pigments are produced from a variety of ores by two different processes, namely,
the sulphate process using concentrated sulphuric acid and the
Corresponding author.
E-mail address: psg@iitk.ac.in (P.S. Ghoshdastidar).
http://dx.doi.org/10.1016/j.ijheatmasstransfer.2016.10.024
0017-9310/ 2016 Elsevier Ltd. All rights reserved.
chloride process using chlorine gas. The last process step of the sulphate method, named calcination is performed in rotary kiln and
has been considered in the present work.
1.2. Description of rotary kiln
A rotary kiln consists of a refractory lined cylindrical shell
mounted at a slight inclination from the horizontal plane (Fig. 1).
The kiln is rotated at a very low speed about its longitudinal axis
and the raw charge comprising hydrous titanium dioxide in a
moist cake form is fed into the upper end of the cylinder and a
hot combustion gas mixture at 1 bar flows from the other end.
The gas is a mixture of products on burning of natural gas in a separate combustion chamber.
In the present study, the kiln is considered to comprise three
sections. In the first section, the wet solids are heated to the saturation temperature of water. In the second section, the liquid evaporates at constant temperature until the charge is completely
devoid of moisture. In the third section, the solids are heated till
the required degree of conversion of anatase to rutile titanium
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A. Agrawal, P.S. Ghoshdastidar / International Journal of Heat and Mass Transfer 106 (2017) 263279
Nomenclature
Ae;k
Acg
Ag
ag
Ai
Aj,inner
Cp
D
Dh
_ k;z
dm
_ v;z
dm
Ea;k
Eb
f
Fgj
Fij
Gr
hcgw
hcj
hfg
ho
hws
Dhi
k
L
L1
L2
L3
_ g;z
m
_ k;z
m
_ s;z
m
Mwk
nk
N
Nk
Nr
Ns
NuDh
Pg
Pr
q1;z
q2;z
qcr;z
qgp;z
qj
qr;z
R
Rex
ReDh
Ru
T g;z
T j;inner
T s;z
Dt
To,av
U
vg
Vz
x
Xk
y
z
net heat transfer for jth surface element in an axial segment (wall or solids), (W)
net heat transfer from gas to solids and wall (W)
radius of the kiln, Fig. 2
Reynolds number based on relative velocity between
wall and air outside the kiln
Reynolds number based on hydraulic diameter Dh
universal gas constant (8.314 J/mol K)
gas temperature at axial position z (K)
inner wall temperature at jth surface element (K)
solids temperature at axial position z (K)
residence time (s)
average temperature at outer wall (K)
circumferential speed of the kiln (m/s)
mean velocity of gas (m/s)
axial velocity of solids (m/s)
radial coordinate (m), Fig. 2
mass fraction of the solid component k
circumferential coordinate (m), Fig. 2
axial coordinate (m)
Greek letters
a
fill angle (deg), Fig. 2
arf
thermal diffusivity, Eq. (4)
b
volumetric thermal expansion coefficient (K1)
C
fill angle (radian)
e
emissivity
fk;z
degree of conversion of kth reaction at axial position z
r
StefanBoltzmann constant (5.67 108 W/m2 K4)
h
as defined in Fig. 2 (deg)
l
dynamic viscosity (kg/m-s)
m
kinematic viscosity (m2/s)
n
Darcy friction factor, used in Gnielinski [35] correlation
q
density (kg/m3)
sg
transmissivity of the gas
Ds
time step (s)
/
kiln inclination angle (deg)
Subscripts
a
air
cr
chemical reaction
g
gas
gs
gas to solids
i
element number of the wall or the solid
j
element number of the wall or the solid
k
number of reaction, also number of component in solid
charge
l
liquid
oxygen
O2
s
solids
sh
shell or outer wall
SO2
sulphur dioxide
rf
refractory wall
v
vapour
w
water
ws
wall to solids
z
at an axial distance z from the solids inlet
z + Dz
at a distance z + Dz from the solids inlet
Abbreviations
CFD
Computational Fluid Dynamics
A. Agrawal, P.S. Ghoshdastidar / International Journal of Heat and Mass Transfer 106 (2017) 263279
265
dioxide is achieved and then are released from the kiln. The calcination process produces TiO2 pigment with a rutile content of
around 98%. The lengths of the first, second and third sections of
the kiln are denoted by L1, L2 and L3, respectively. The total length
of the kiln is L which is the sum of three individual lengths. Heat
transfer processes in the kiln, the nomenclature of the kiln and
the coordinate system are shown in Fig. 2.
Fig. 2. Schematic cross-section of a rotary kiln showing heat transfer processes, the fill-angle and the coordinate system.
266
A. Agrawal, P.S. Ghoshdastidar / International Journal of Heat and Mass Transfer 106 (2017) 263279
Their numerical predictions matched very well with the measurement data. Based on heat and mass transfer equations, Dumont
and Blanger [11] described a simplified process model for making
of titanium dioxide in a rotary kiln. Roubal et al. [12] developed the
Kalman Filter design based on the reduced model of the process in
an attempt to control the titanium dioxide production in a rotary
kiln. In both studies, dehydration and desulphurisation steps were
not considered. Also, Koukkari et al. [13] introduced the RATEMIX
model by combining multicomponent thermodynamics with
chemical kinetics and applied in calcination of metatitanic acid
to produce rutile titanium dioxide in a rotary drum calciner.
1.4.2.2. Production of other chemicals. Spang [14] developed a
dynamic partial-differential equation model of cement kiln incorporating a flame model. Manitius et al. [15] described a mathematical model for production of aluminium oxide by calcination of
basic ammonium aluminium sulphate. A steady state mathematical model of cement kiln was presented by Guruz and Bac [16]
using zone method. Watkinson and Brimacombe [17] performed
experimental work on pilot-scale rotary kiln for calcination of
limestone with parametric study. Watkinson and Brimacombe
[18] observed the effects of enriching the combustion air with oxygen in a rotary lime kiln. Hard and Mu [19] calculated sensitivities
of certain process variables on fuel rate and solids throughput in
modelling a phosphate nodulizing kiln. A detailed steady-state
heat transfer model of burning of Plexiglas in a rotary kiln was
developed by Ghoshdastidar et al. [20]. A 3D steady state model
of a rotary calcining kiln was presented by Bui et al. [21] for the
petroleum coke. Davis [22] reported a model for magnetite oxidation during iron ore pellet induration in a rotary kiln. A model was
developed for iron oxide pelletizing to simulate effects of under
bed injection on kiln fuel requirements and magnetite oxidation
by Davis [23]. Georgallis et al. [24] presented a 3D model for rotary
lime kiln which included evolution and combustion of species and
granular bed motion with calcination reaction. Marias et al. [25]
modelled pyrolysis of aluminium waste in a rotary kiln. Mintus
et al. [26] predicted solid composition and temperature profiles
and fuel requirement based on their one-dimensional cell model
for wet process rotary cement kilns. Mujumdar and Ranade [27]
presented a 1D model to analyse key processes occurring in solid
bed of cement kilns. Mujumdar et al. [28] developed Rotary
Cement Kiln Simulator by integrating the separate models for
pre-heater, calciner, rotary kiln and cooler. Flow and transport processes were modelled in a calciner for cement production by
Fidaros et al. [29]. Shahriari and Tarasiewicz [30] modelled a clinker rotary kiln using operating functions concept.
1.5. Objectives of the present work
The above literature review reveals that only a few models [10
13] of titanium dioxide rotary kiln are available. The main difference between the present and aforementioned ones is that the latter do not have the capability of predicting the kiln length required
to produce rutileTiO2 for a given set of input parameters. The present work is an attempt to fill this gap in the existing literature.
The objectives of the present study are as follows.
1. To develop a detailed computer model of heat transfer with
chemical reactions during the production of rutile titanium
dioxide in a rotary kiln;
2. To compare the total predicted kiln length required to achieve
the desired solids composition as predicted by the present
model with that of the actual kiln reported in Ginsberg and
Modigell [10];
3. To predict axial distributions of solid temperature, gas temperature, composition of the solid charge within the kiln;
4. To conduct a detailed parametric study with respect to moisture percent (dry basis), mass flow rate of the solid, mass flow
rate of the gas, kiln inclination angle and kiln rotational speed
in order to get a good physical insight into the manufacturing
process of rutile titanium dioxide in a rotary kiln.
2. Problem formulation
In this section the reaction processes, modelling of radiation
and conduction, gas convection, reaction kinetics, and, mass and
energy balances in the solids and gas are presented in detail.
2.1. Reaction Processes Occurring in a Rutile-TiO2 Rotary Kiln
In the sulphate process, ilmenite or titanium slag as raw material is digested with sulphuric acid and results in a solution containing TiOSO4 and FeSO4 . After removing iron and other
impurities by vacuum crystallization from the solution, titanium
sulphate is hydrolysed to hydrous titanium dioxide. It largely consists of slurry of TiOOH2 (metatitanic acid) and a relatively small
amount of TiOSO4 H2 O. This solid charge is then fed into a rotary
kiln to undergo calcination process and finally, rutile titanium
dioxide is produced. In addition to moisture evaporation at saturation temperature, following chemical reactions take place inside
the rotary kiln as wet solids move from the inlet to the outlet of
the kiln.
Dehydration of metatitanic acid and TiOSO4 H2 Ooccurs in the
range of 100250 C [31] (Reactions 1 and 2). Reaction 3 results
in loss of sulphur trioxide (which immediately decomposes into
SO2 and O2) from titanyl sulphate at about 650 C [32] and finally,
phase transformation of anatase to rutile takes place exothermally
in the range of 700950 C [32] (Reaction 4).
The above mentioned reactions are listed in Table 1a along with
their respective heat of reactions, pre-exponential factors, activation energies and orders of reaction. The composition of wet solids
at the solid inlet is given in Table 1b.
2.2. Radiation exchange among hot gas, refractory wall and the solid
surface
Since the gas temperature is high, thermal radiation plays an
important role. The radiation is modelled by dividing the wall into
surface elements as shown in Fig. 3. Each axial segment of the
refractory surface is divided into Nr surface elements of equal size.
The solid surface is divided into Ns surface elements. This can be
considered as a 2-D enclosure since the surface elements are quite
long. The temperature of the solid surface element and the gas are
assumed to be uniform in each axial segment. The wall surface elements are assumed diffuse and gray. It is to be kept in mind that
the surface elements exchange radiation only with the surfaces
of the same axial segment which is sufficiently long. Since the
hot gas contains CO2 and H2O and it is treated as radiatively
participating.
The radiation heat transfer is computed by using the theory of
Hottel [33] for a gray enclosure containing a gas which emits,
absorbs and transmits radiation. If the gas volume is enclosed by
N gray surface elements at different temperatures, the net energy
gain, qj at a particular surface can be expressed as
qj
e1
2
"
N
X
Ag F gj eg Eb;g
Ai F ij sg Eb;i Eb;j Aj
i1
267
A. Agrawal, P.S. Ghoshdastidar / International Journal of Heat and Mass Transfer 106 (2017) 263279
Table 1a
Reactions, kinetics and heat of reaction data (Ginsberg and Modigell [10]).
S. No.
Reaction Equation
Frequency Factor
Ae;k (s1)
Activation Energy
Ea;k (kJ/mol)
Heat of Reaction
Dhk (kJ/mol)
Order of Reaction
nk
1
2
3
4
TiOOH2 ! TiO2 a H2 Og
TiOSO4 H2 O ! TiOSO4 H2 Og
TiOSO4 ! TiO2 a SO2 g 0:5O2
TiO2 a ! TiO2 r
4.1 103
5.0 105
5.0 109
1.7 1023
45
75
230
491
90
90
396
-5.6
3.00
0.50
0.30
0.67
Table 1b
Mass fractions of reactants (Ginsberg and Modigell [10]).
S. No.
Reactant
1
2
TiOOH2
TiOSO4 H2 O
0.8894
0.1106
Fig. 3. Section of the kiln showing surface elements of the wall and the solid.
sivity of the gas. The value of gas emissivity has been taken directly
from Ginsberg and Modigell [10]. The gas transmissivity has been
calculated using the expression,sg 1 eg , assuming gas reflectivity to be zero and Kirchhoffs law of radiation to be valid.
NuDh
n=8ReDh 1000Pr
1 12:7n=81=2 Pr2=3 1
where, n is the Darcy friction factor and for smooth tubes, which is
given by
n 0:79lnReDh 1:64
2
2a
Dh
4Acg
Pg
2b
Acg
C sin C
1
4
2p
2p
pD2
P g pD
a
360 a
D sin
360
2
2c
2d
where C and a are the fill angle of solids in radians and degrees,
respectively.
ReDh is expressed as
ReDh
qg v g Dh 4m_ g
lg
P g lg
2e
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A. Agrawal, P.S. Ghoshdastidar / International Journal of Heat and Mass Transfer 106 (2017) 263279
hcgw
NuDh kg
Dh
2f
@T
@2T
arf 2
@y
@x
where U is the circumferential speed of the wall and arf is the thermal diffusivity of the wall.
The boundary condition for the inner wall depends on whether
the surface element is exposed to the gas or it is covered by solids.
The radiation heat transfer, qj from the gas to the inner surface elements is obtained from Eq. (1). In addition, convection heat transfer is calculated from the local convective heat transfer coefficients
as discussed in Section 2.3. Surface elements of the kiln that are
ho
0:11ka
Dsh
"
! #0:35
Re2x
Gr Pra
2
where, Dsh is the outer diameter of the kiln, ka and Pra are the thermal conductivity and Prandtl number of the surrounding air respectively, Rex is the Reynolds number based on relative velocity
between the cylindrical wall and the external air surrounding the
kiln. Gr is the conventional Grashof number characterizing natural
convection.
Rex
pD2sh x
2ma
4a
where, x is the angular velocity of the rotary kiln and ma is the kinematic viscosity of surrounding air.and
Gr
ag bT o;av T a D3sh
4b
m2a
where, ag is the gravitational acceleration, b is the volumetric thermal expansion coefficient, T o;av is the average temperature on outer
wall of the kiln and T a is the surrounding temperature outside the
kiln.
2.5. Reaction rates
For any reaction, the rate of change in degree of conversion of
the reaction is assumed to be governed by kinetic expression (Eq.
(5)), which is a modified form of Arrhenius rate law:
dfk;z
Ea;k
1 fk;z nk
Ae;k exp
dt
Ru T s;z
fk;z
_ k;z
_ k;0 m
m
_ k;f
_ k;0 m
m
Table 1c
Molecular masses of various components in solid charge.
S. No.
k
Component
Molecular weight
Mw (g/mol)
1
2
3
4
5
6
7
TiOOH2
TiOSO4 H2 O
TiOSO4
TiO2 a
TiO2 r
H2 Ol
H2 Og
97.88
177.94
159.93
79.87
79.87
18.02
18.02
A. Agrawal, P.S. Ghoshdastidar / International Journal of Heat and Mass Transfer 106 (2017) 263279
_ k;0 and m
_ k;f are the initial and final mass flow rates of the
where m
_ k;z is its mass flow rate at
reactant of kth reaction respectively, m
any axial position z.
With the help of degrees of conversion of the reaction at any
axial segment, using Eq. (6), the amount of depletion per second
_ k;z ) are estimated. Using
for different species of solid charge dm
this information, based on stoichiometry of the chemical reactions,
updated mass flow rates of solid species (that is, the mass flow
_ k;z ) are estimated.
rates at the exit of that axial segment, m
Table 1c lists the components in solid charge with corresponding
index k and their respective molecular weights.
_ k;z exit are the mass flow rates of kth species at
_ k;z entry and m
If m
_ k;z is the amount of
the entry and exit of axial segment z and dm
depletion per second of reactant in kth reaction in that segment,
then using molecular masses Mwk , following expressions are
obtained for updated mass flow rates at the exit of the segment.
Eqs. (7)(12) show the expressions for updated mass flow rates
of solid components in each axial segment and are written based
on the stoichiometry of the chemical reactions.
Reaction 1:
269
_ 4;z exit m
_ 4;z entry dm
_ 4;z
m
Mw4
Mw4
_ 1;z
_ 3;z
dm
dm
Mw1
Mw3
10
_ 4;z entry is the mass flow rate of TiO2 a at entry of axial segwhere m
_ 4;z is the decomposed amount during this reaction in
ment and dm
that axial segment. Mw4 is the molecular weight of TiO2 a.
Mass flow rate of TiO2 r, as it is generated from reaction 4, is
updated as well in a similar way,
_ 5;z exit m
_ 5;z entry dm
_ 4;z
m
11
Mw7
Mw7
_ 1;z
_ 2;z
dm
dm
Mw1
Mw2
TiOOH2 ! TiO2 a H2 Og
_ 7;z
dm
_ 1;z exit m
_ 1;z entry dm
_ 1;z
m
_ 1;z Dh1 dm
_ 2;z Dh2 dm
_ 3;z Dh3 dm
_ 4;z Dh4
qcr;z dm
TiOSO4 H2 O ! TiOSO4 H2 Og
Similarly, in reaction 2, reactant TiOSO4 H2 O is decomposed into
TiOSO4 and water vapour. TiOSO4 H2 O is denoted by index 2, as
shown in table. Its new mass flow rate at exit of axial segment is
given by following expression.
_ 2;z exit m
_ 2;z entry dm
_ 2;z
m
_ 3;z exit m
_ 3;z entry dm
_ 3;z
m
Mw3
_ 2;z
dm
Mw2
12
13
where, Dh1 , Dh2 , Dh3 and Dh4 are the heat of reactions for Reactions
1 to 4 and are given in Table 1a.
2.6. Mass and energy balances in solids and gas
As mentioned earlier, the kiln is considered to be consisting of
three sections. In the first section, wet solid charge is heated to
the saturation temperature of the entrained liquid. In the second
section, liquid evaporates at constant temperature and in the third
section dry solid charge is heated till the required conversion of
anatase TiO2 to rutile TiO2 is achieved.
The mass and energy balance of the solid in each segment either
in first and third segment gives the expression for exit solid temperature of that segment, T s;zDz for that section while the same
performed on an axial segment in second section of the kiln gives
_ v;z . The end of the secthe expression for the rate of evaporation, dm
_ v is equal to the
ond section is indicated where the cumulative m
predetermined amount of water to be evaporated per second. Similarly, mass and energy balance of hot gas contained in an axial
segment in any of the three sections of the kiln gives the expression for T g;zDz for that section.
2.6.1. Mass balance in Sections I and III
In solids region (Fig. 5),
_ s;z dm
_ g;z
_ s;zDz m
m
14
_ 3;z entry is the mass flow rate of TiOSO4 at entry to axial segwhere m
_ 3;z denotes the amount depleted per second in that
ment and dm
segment. Mw2 and Mw3 are the molecular weights of TiOSO4 H2 O
and TiOSO4 respectively.
Reaction 4:
TiO2 a ! TiO2 r
TiO2 a is produced from reactions 1 and 3. It is consumed in reaction 4, where it is converted into final product that is TiO2 r.
TiO2 a is denoted by index 4, as shown in table. According to sto-
Fig. 5. Mass balance of any axial segment in first and third sections of the kiln.
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A. Agrawal, P.S. Ghoshdastidar / International Journal of Heat and Mass Transfer 106 (2017) 263279
_ s;z and m
_ s;zDz are the mass flow rates of the solids at any
where m
_ g;z is the total amount
axial position z and z + Dz respectively. dm
of released gaseous products from chemical reactions in an axial
segment.
_ g:z dm
_ H2 Og;z dm
_ SO2 g;z dm
_ O2 g;z
dm
15
_ H2 Og;z , dm
_ SO2 g;z and dm
_ O2 g;z are the amounts of H2 Og,
Here, dm
SO2 g and O2 g releasing from chemical reactions in solids in that
axial segment.
In gas region (Fig. 5),
_ g;z dm
_ g;z
_ g;zDz m
m
16
Dt
Dz
Vz
23
q1;z
Ns
X
j1
qj
Ns
X
hcj Aj T g;z T s;z
_ g;z and m
_ g;zDz are the mass flow rates of the gas at any axial
where m
position z and z + Dz respectively. and,
q2;z
_ w;g
_ w;s m
m
_ H2 Og;z cp;v dm
_ SO2 g;z cp;SO2 dm
_ O2 g;z cp;O2
qgp T s;z dm
17
24
j1
25
j1
26
T g;zDz
where qr;z is the total heat transfer from gas to solids and wall. cp;g is
the specific heat of gas at constant pressure.
_ s;z dm
_ g;z
_ s;zDz m
m
_ g;z cp;g m
_ w;g cp;v qr;z qgp;z
T g;z m
_ w;g cp;v
_ g;zDz cp;g m
m
27
18
2.6.4. Energy balance in Section II
In solids region (Fig. 8),
and,
_ w;s;z dm
_ v;z
_ w;s;zDz m
m
19
_ g;z dm
_ g;z
_ g;zDz m
m
20
and,
_ v;z
dm
21
_ v;z
_ w;g;z dm
_ w;g;zDz m
m
T s;zDz
_ s;z cp;s m
_ w;s cp;l q1;z q2;z qgp;z qcr;z
T s;z m
_ w;s cp;l
_ s;zDz cp;s m
m
T g;zDz
22
28
_ g;z cp;g m
_ w;g;z cp;v T s;z dm
_ v;z cp;v qr;z qgp;z
T g;z m
_ w;g;zDz cp;v
_ g;zDz cp;g m
m
29
T s;zDz
30
T g;zDz
31
C p;s
5
X
X k C p;k
32
k1
Fig. 6. Mass balance of any axial segment in second section of the kiln.
where X k and C p;k are the mass fraction and specific heat of component k respectively. k = 1 to 5 correspond to TiOOH2 , TiOSO4 H2 O,
TiOSO4 , TiO2 a and TiO2 r respectively.
A. Agrawal, P.S. Ghoshdastidar / International Journal of Heat and Mass Transfer 106 (2017) 263279
271
Fig. 7. Energy balance of any axial segment in first section of the kiln.
Fig. 8. Energy balance for solids in any axial segment in second section of the kiln.
A mixture density relation is used to calculate the effective density of wet solids from the densities of the components as given in
Table 1d.
qs
f
qs;dry solids 100
ql
f
1 100
33
qs;dry solids
1
5
X
X k =qs;k
34
k1
the new composition of the solids at the inlet of the second segment is determined, the new cross-sectional area of the solids
and the new fill-angle are estimated and hence, new shape factors
are computed. The solids and gas temperature, and species composition at the exit of the second segment can be calculated in the
same way as described earlier. The solution then proceeds by the
analysis of each succeeding segment. The process is continued till
the end of the kiln. The end of the kiln is indicated by the position
where the degree of conversion for the last reaction, that is, anatase to rutile titanium dioxide conversion has reached 98%. Thus
the kiln length can be computed.
A time step of Ds = 0.1 s is used for calculations. Since the initial
temperature distribution of the refractory wall is not known, an
arbitrary temperature is assumed at all grid points in the refractory
wall. The solution converges where there is no further change in
the temperature at each grid point as s ? 1. This temperature distribution represents the steady state temperature distribution of
the wall.
Grid independence tests have been performed to obtain the
optimum grid spacing values in the circumferential and radial
directions. The number of grid points used in the circumferential
direction is 150 and that in the radial direction is 61. In addition,
sensitivity analysis for axial segment length, Dz with respect to
predicted kiln length is also performed. It is found that the predicted kiln length and hence axial solid and gas temperature distributions remain more or less unchanged while Dz is changed from
0.10 to 0.25 m. The largest value of Dz in this range is taken in
order to save CPU time. Therefore, Dz used in this study is 0.25 m.
The simulations are performed on a high performance computing system (having Terra-flops rating). The CPU time required for a
simulation with the input data (Table 2) is approximately 46.43 h.
The output data consist of refractory wall temperature, solids temperature, gas temperature, solids composition, individual lengths
of first, second and third sections of the kiln (L1, L2, L3), and the
total kiln length (L). The capability of this model to predict the kiln
length is unique and has not been found in earlier TiO2-kiln models. The overall solution algorithm is described next in a step-bystep fashion.
Fig. 9. Energy balance for gas in any axial segment in second section of the kiln.
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Fig. 10. Energy balance of any axial segment in second section of the kiln.
Table 1d
Material properties of the solid components (Ginsberg and Modigell [10]).
S.No.
Component
Density (kg/m3)
1
2
3
4
5
6
TiOOH2
TiOSO4 H2 O
TiOSO4
TiO2 a
TiO2 r
H2 Ol
2540
2430
2890
3900
4240
1000
142
208
133
70
70
76
Table 2
Input data to the program (Ginsberg and Modigell [10]).
1. Rotary Kiln
(a) Diameter (inner)
(b) Refractory
(i) Thickness
(ii) Thermal Conductivity
(iii) Specific heat
(iv) Density
(v) Emissivity
(c) Rotational speed
(d) Angle of inclination
2. Solid
(a) Inlet temperature
(b) Mass flow rate (dry)
(c) Percent water (on dry basis)
(d) Emissivity
3. Gas
(a) Outlet temperature
(b) Specific heat
(c) Mass flow rate
(d) Emissivity
(e) Dynamic viscosity
4. Water Vapor
(a) Latent heat of vaporization$
(b) Specific heat $
5. Specific heat of sulfur dioxide$
6. Specific heat of oxygen$
7. Contact heat transfer coefficient
8. Ambient temperature outside the kiln
$
2.3 m
0.25 m
1.6 W/m K
950 J/kg K
2310 kg/m3
0.8
0.33 rpm
2.29
308 K
1.309 kg/s
75.14
0.8
648 K
1356 J/kg K
6.218 kg/s
0.422
3.58 105 kg/m-s
2.258 106 J/kg
2042.71 J/kg K
627.99 J/kgK
919.83 J/kgK
377 W/m2K
287.15 K
Chase [40].
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273
Fig. 11. Axial solid and gas temperature distributions: Comparison with the numerical solution of Ginsberg and Modigell [10].
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Table 3a
Predicted Kiln Length and Rutile TiO2 Production Rate vs. Moisture Percent (Dry Basis).
Moisture Percent (Dry Basis)
L1 (m)
L2 (m)
L3 (m)
L = L1 + L2 + L3 (m)
60.0
75.14
90.0
17.0
17.25
17.75
18.5
21.0
23.0
9.75
7.5
6.0
45.25
45.75
46.75
3649.68
3648.24
3646.80
Table 3b
Predicted Kiln Length and Rutile TiO2 Production Rate vs. Dry Solids Mass Flow Rate.
Dry Solids Mass Flow Rate (kg/s)
L1 (m)
L2 (m)
L3 (m)
L = L1 + L2 + L3 (m)
1.0
1.31
1.6
14.25
17.25
20.0
19.75
21.0
21.75
9.75
7.5
6.25
43.75
45.75
48.0
2789.28
3648.24
4458.96
Table 3c
Predicted Kiln Length and Rutile TiO2 Production Rate vs. Gas Mass Flow Rate.
Gas Mass Flow Rate (kg/s)
L1 (m)
L2 (m)
L3 (m)
L = L1 + L2 + L3 (m)
4.0
6.218
8.0
17.0
17.25
17.0
15.75
21.0
23.75
3.25
7.5
12.25
36.0
45.75
53.0
3641.76
3648.24
3651.12
Table 3d
Predicted Kiln Length and Rutile TiO2 Productiion Rate vs. Kiln Inclination Angle.
Inclination Angle (deg)
L1 (m)
L2 (m)
L3 (m)
L = L1 + L2 + L3 (m)
1.4
2.29
5.0
16.25
17.25
18.75
20.0
21.0
23.25
7.75
7.5
7.5
44.0
45.75
49.5
3651.12
3648.24
3642.48
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275
Table 3e
Predicted Kiln Length and Rutile TiO2 Production Rate vs. Kiln Rotational Speed.
Rotational Speed (r.p.m)
L1 (m)
L2 (m)
L3 (m)
L = L1 + L2 + L3 (m)
0.21
0.33
1.0
16.5
17.25
18.25
20.5
21.0
22.25
8.25
7.5
7.25
45.25
45.75
47.75
3651.12
3648.24
3639.24
the kiln. Table 3a shows that with the increase in moisture percent
from 60 to 90 the rate of production of rutile Titanium dioxide
decreases slightly from 3649.68 to 3646.8 kg/hr. This is because
of higher kiln length required for drying in the case of larger water
content in the solids. On the other hand, as dry solids mass flow
rate increases from 1 kg/s to 1.6 kg/s the production rate substantially rises from 2789.28 kg/hr to 4458.96 kg/hr (Table 3b). This is
because of higher amount of solid charge being processed and faster rate of final reaction per unit time. Table 3c indicates higher gas
flow rate results in larger production of rutile TiO2 per unit time.
This is because solid temperature is slightly higher in the third segment of the kiln which accelerates the rate of reaction. Increasing
kiln inclination angle and kiln rotational speed reduces the rutile
titanium dioxide production rate (Tables 3d and 3e) since the kiln
has to be longer and hence the solids residence time in the kiln is
more.
4.3.3. Axial solid and gas temperature distribution as a function of
various parameters
Fig. 13 shows that, with the increase in moisture content in wet
s
solids, axial gas temperature and @T
increase in third section of the
@z
kiln while axial solid temperature with respect to percentage kiln
length decreases. The explanation of this trend is as follows. For
a larger amount of water in the solid charge, the wet solid will have
to travel a longer distance to be totally moisture-free. This implies
that the same amount of dry mass of solid will have to be heated to
the same exit temperature. It may be noted that the fill angle
remains the same in the third section no matter what the original
moisture content is. So, the dry solid will be exposed to hotter gas
in the case of high moisture content as the heating starts close to
the kiln exit which is the inlet for the hot gas. Therefore, to reach
the requisite exit temperature, the dry solid will have to travel a
smaller percentage length of the kiln and hence the axial temperature gradient of the solid is larger. The axial solid temperature at
the same percentage kiln length will be obviously lower. Fig. 14
depicts that, for higher solid mass flow rate, gas temperature is
considerably higher in the third section of the kiln. This is because
for larger solid mass flow rate, the fill angle increases resulting in
reduction in the mean beam length as the gas volume decreases.
Hence, the loss of heat by the gas by radiation is smaller and hence
the gas temperature is high. Fig. 15 indicates that increasing gas
flow rate causes significant drop in gas inlet temperature. The reason is that higher gas flow rate means less gas residence time and
hence the kiln has to be longer (see Table 3c). Thus, solid temperature is higher at the same percent kiln length in the third segment
of the kiln. Gas on the other hand loses more heat to the solid and
hence the gas temperature drops in the last section of the kiln for
higher gas flow rates. Finally, lower kiln inclination angle and
lower rotational speed result in lower gas temperature and higher
solid temperature at the same percent kiln length in the third section of the kiln (graphs not shown). This is because of more residence time of the solids in the kiln which leads to shorter kiln
length.
Finally, lower kiln inclination angle and lower rotational speed
result in lower gas temperature and higher solid temperature at
the same percent kiln length in the third section of the kiln (graphs
not shown). This is because of more residence time of the solids in
the kiln which leads to shorter kiln length.
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Fig. 13. Axial solid and gas temperature distributions for different moisture percentages (dry basis).
Fig. 14. Axial solid and gas temperature distributions for different mass flow rates of the dry solids.
section of the kiln. As the third section comes latter for higher
moisture content case, these reactions along with the
decomposition of TiO.SO4 to TiO2 (a) and final reaction of
conversion occur later and relatively faster due to higher gas
temperature.
A. Agrawal, P.S. Ghoshdastidar / International Journal of Heat and Mass Transfer 106 (2017) 263279
277
Fig. 15. Axial solid and gas temperature distributions for different mass flow rates of the gas.
Fig. 16. Axial profiles of percent conversion of anatase TiO2 to rutile TiO2 for different moisture percentages (dry basis).
Fig. 17 depicts how solids mass flow affects the percent conversion of anatase TiO2. At higher dry solids mass flow rates Reaction 3
and the final reaction are delayed due to requirement of longer first
and second sections because of larger solid mass flow rate and also
larger amount of moisture to be evaporated per unit time. However, at the same percent kiln length near the exit reactions occur
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Fig. 17. Axial profiles of percent conversion of anatase TiO2 to rutile TiO2 for different mass flow rates of the solids in the last 20% of the kiln length.
Fig. 18. Axial profiles of percent conversion of anatase TiO2 to rutile TiO2 for different mass flow rates of the gas in the last 20% kiln length.
A. Agrawal, P.S. Ghoshdastidar / International Journal of Heat and Mass Transfer 106 (2017) 263279
5. Conclusions
This paper presents a computer simulation study of calcination
of hydrous titanium dioxide for the production of rutile titanium
dioxide in rotary kiln. The heat transfer model includes turbulent
gas convection, radiation heat exchange among the hot gas, refractory wall and the solid surface, conduction in the refractory wall,
and mass and energy balances in the gas and solids. The gas convection has been simulated using a stand-alone CFD model assuming the kiln to be non-rotating and solid bed to be stationary. Based
on the aforesaid CFD data the local convection heat transfer coefficients have been calculated. The present computer model predicts
steady-state axial distributions of solids and gas temperature that
are in excellent agreement with an earlier work [10]. The axial
chemical composition profile of the solid charge is consistent with
the trends found in literature. The kiln length predicted by the present model is 45.75 m as compared to 45 m of the actual kiln
reported in Ginsberg and Modigell [10]. The accurate prediction
of the kiln length is a major achievement of this work. The capability of the present model to predict the kiln length and the modelling of gas convection are two novel aspects of this work which
can greatly help in the design and optimization of such kilns. A
detailed parametric study reveals that higher moisture content in
the solids results in slightly larger kiln length and lower rutileTiO2 production rate. However, higher dry solids mass flow rate
requires slightly larger kiln length but gives rise to substantial
rutile-TiO2 production rate. For low speed gas flow kiln length is
much smaller although the rate of production of rutile titanium
dioxide is marginally lower. Smaller kiln inclination angles and kiln
rotational speeds result in shorter kiln length and higher rutileTiO2 production rate. On the whole the parametric study lent a
good physical insight into the rutile titanium dioxide production
process in a rotary kiln.
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