CPFD Modeling of an Industrial Oxy-Fuel Cement Calciner: Hydrodynamics, Temperature Distribution, and CO2 Enrichment
Year: 2025
Type: article
Abstract: Oxy-fuel combustion technology is a critical pathway for carbon capture in the cement industry. However, the high-concentration CO2 atmosphere significantly alters multiphysics coupling in the calciner and systematic studies on its comprehensive effects remain limited. To address this, a Computational Particle Fluid Dynamics (CPFD) model using the MP-PIC method was implemented using the commercial software Barracuda Virtual Reactor 22.1.2 to simulate an industrial-scale oxy-fuel cement calciner and validated against industrial data. Under oxy-fuel combustion with 50% oxygen concentration in the tertiary air, simulations showed a 38.4% increase in the solid–gas mass ratio compared to conventional air combustion, resulting in a corresponding 37.7% increase in total pressure drop. Flow resistance was concentrated primarily in the constriction structures. Local temperatures exceeded 1200 °C in high-oxygen regions. The study reveals a competition between the inhibitory effect of high CO2 partial pressure on limestone decomposition and the promoting effect of elevated overall temperature. Although the CO2-rich atmosphere thermodynamically suppresses calcination, the higher operating temperature under oxy-fuel combustion effectively compensates, achieving a raw meal decomposition rate of 92.7%, which meets kiln feed requirements. This research elucidates the complex coupling mechanisms among flow, temperature, and reactions in a full-scale oxy-fuel calciner, providing valuable insights for technology design and optimization.
Source: Energies
DOI: 10.3390/en18246419
Authors: Changhua Chen, Minyan Lin, Zhouzheng Jin, Xueping Peng, Chenghang Zheng
Language: English
Subfield: Computational Mechanics
Field: Engineering
Domain: Physical Sciences
Open Access status: gold
Estimated APC paid: $3,137
Award: G2955656848
OpenAlex ID: W7110065625