The application of CFD modelling to support the reduction of CO2 emissions in cement industry

The cement industry is one of the leading producers of anthropogenic greenhouse gases, of which CO2 is the most significant. Recently, researchers have invested a considerable amount of time studying ways to improve energy consumption and pollutant formation in the overall cement manufacturing process. One idea involves dividing the calcination and clinkering processes into two separate furnaces. The calcination process is performed in a calciner while the clinkering process takes place in a rotary kiln. As this is new technology in the cement manufacturing process, calciners are still in the research and development phase. The purpose of this paper is to demonstrate the potential of CFD to support the design and optimization of calciners, whose use appears to be essential in reduction of CO2 emission during cement production. The mathematical model of the calcination process was developed, validated and implemented into a commercial CFD code, which was then used for the analysis. From the results obtained by these simulations, researchers will gain an in-depth understanding of all thermo-chemical reactions in a calciner. This understanding can be used to optimize the calciner's geometry, to make production more efficient, to lower pollutant formation and to subsequently reduce greenhouse gas emissions.

► The potential of CO2 emissions reduction, by using a cement calciner was presented.
► When a cement calciner is used, CO2 emissions reduction of 3–4% can be achieved.
► The calcination model was developed, validated, and then used for the analysis.
► Shown method can be applied for investigation and optimization of cement calciners.