Design Optimization of Waste Heat Recovery System around Cement Rotary Kiln
Publication: Journal of Energy Engineering
Volume 146, Issue 4
Abstract
Portland cement is produced by one of the highest energy-consumptive industrial processes. Within the process, the rotary kiln represents one of the major sources of thermal energy loss. Based on the lengthwise temperature profile of the kiln, an optimal placement for heat recovery is identified based on the highest surface temperatures. This study aims to optimize the design of an arc-shaped thermal absorber parallel to the rotary cement kiln for heat recovery by thermoelectric generators (TEGs). A comprehensive numerical study is carried out by considering the combined effects of convective heat transfer, thermal radiation, and rotation of the kiln to find the optimum properties of the thermal absorber. Thus, a two-dimensional (2D) incompressible and unsteady turbulent flow horizontally perpendicular to the kiln is investigated. Different parameters such as curvature radius, arc angle, and angular position of the absorber, temperature of the kiln surface, wind velocity, and kiln rotational speed are studied for optimal design of the absorber. Multiplication of the length and average temperature of the absorber is a conceptual definition applied to explore the optimum design. On the other hand, power generation by using several commercial TEGs (size of ) is evaluated for all studied absorbers. Given the kiln surface temperature of 500°C at an optimal position along the kiln, the results show that the case with the absorber radius of 2.5 m has the best performance of studied cases and can generate a total power between 26.449 and 48.889 kW, corresponding to the kind of studied commercial thermoelectric modules.
Get full access to this article
View all available purchase options and get full access to this article.
Data Availability Statement
All data, models, and code generated or used during the study appear in the published article.
Acknowledgments
This work was carried out within the framework of the Center for Thermoelectric Energy Conversion (CTEC) and funded in part by the Danish Council for Strategic Research, Programme Commission on Energy and Environment, under Grant No. 1305-00002B.
References
Atouei, A. A., A. A. Ranjbar, and A. Rezania. 2017. “Experimental investigation of two-stage thermoelectric generator system integrated with phase change materials.” Appl. Energy 208 (Dec): 332–343. https://doi.org/10.1016/j.apenergy.2017.10.032.
Cotfas, D. T., P. A. Cotfas, D. Ciobanu, and O. M. Machidon. 2017. “Characterization of photovoltaic–thermoelectric–solar collector hybrid systems in natural sunlight conditions.” J. Energy Eng. 143 (6): 04017055. https://doi.org/10.1061/(ASCE)EY.1943-7897.0000488.
Engin, T., and V. Ari. 2005. “Energy auditing and recovery for dry type cement rotary kiln systems—A case study.” Energy Convers. Manage. 46 (4): 551–562. https://doi.org/10.1016/j.enconman.2004.04.007.
EVEREDtronics. 2018. “Manufacturers’ data sheets.” Accessed October 15, 2018. http://www.everredtronics.com/.
Hajji, A. R., M. Mirhosseini, A. Saboonchi, and A. Moosavi. 2015. “Different methods for calculating a view factor in radiative applications: Strip to in-plane parallel semi-cylinder.” J. Eng. Thermophys. 24 (2): 169–180. https://doi.org/10.1134/S1810232815020071.
Hsu, C. T., C. C. Won, H. S. Chu, and J. D. Hwang. 2013. “A case study of thermoelectric generator application on rotary cement furnace.” In Proc., 8th Int. Conf. on Microsystems, Packaging, Assembly and Circuits Technology, 22–25. New York: IEEE.
Incropera, F. P., D. P. Dewitt, T. L. Bergman, and A. S. Lavine. 2007. Fundamentals of heat and mass transfer. 6th ed. Hoboken, NJ: Wiley.
Luo, Q., P. Li, L. Cai, P. W. Zhou, D. Tang, P. C. Zhai, and Q. J. Zhang. 2015. “A thermoelectric waste-heat-recovery system for portland cement rotary kilns.” J. Electron. Mater. 44 (6): 1750–1762. https://doi.org/10.1007/s11664-014-3543-1.
Man, E. A., E. Schaltz, L. Rosendahl, A. Rezaniakolaei, and D. Platzek. 2015. “A high temperature experimental characterization procedure for oxide-based thermoelectric generator modules under transient conditions.” Energies 8 (11): 12839–12847. https://doi.org/10.3390/en81112341.
Menter, F. R. 1994. “Two-equation eddy-viscosity turbulence models for engineering applications.” AIAA J. 32 (8): 1598–1605. https://doi.org/10.2514/3.12149.
Mirhosseini, M., A. Rezania, A. B. Blichfeld, B. B. Iversen, and L. A. Rosendahl. 2017a. “Experimental investigation of zinc antimonide thin film thermoelectric element over wide range of operating conditions.” Phys. Status Solidi 214 (11): 1700301. https://doi.org/10.1002/pssa.201700301.
Mirhosseini, M., A. Rezania, B. Iversen, and L. Rosendahl. 2018a. “Energy harvesting from a thermoelectric zinc antimonide thin film under steady and unsteady operating conditions.” Materials 11 (2365): 1–21. https://doi.org/10.3390/ma11122365.
Mirhosseini, M., A. Rezania, and L. Rosendahl. 2017b. “View factor of solar chimneys by Monte Carlo method.” Energy Procedia 142 (Dec): 513–518. https://doi.org/10.1016/j.egypro.2017.12.080.
Mirhosseini, M., A. Rezania, and L. Rosendahl. 2018b. “Numerical study on heat transfer to an arc absorber designed for a waste heat recovery system around a cement kiln.” Energies 11 (3): 671. https://doi.org/10.3390/en11030671.
Mirhosseini, M., A. Rezania, and L. Rosendahl. 2019a. “Effect of heat loss on performance of thin film thermoelectric: A mathematical model.” Mater. Res. Express 6 (Jan): 096450. https://doi.org/10.1088/2053-1591/aafba1.
Mirhosseini, M., A. Rezania, and L. Rosendahl. 2019b. “Harvesting waste heat from cement kiln shell by thermoelectric system.” Energy 168 (Feb): 358–369. https://doi.org/10.1016/j.energy.2018.11.109.
Mirhosseini, M., A. Rezania, and L. Rosendahl. 2019c. “Power optimization and economic evaluation of thermoelectric waste heat recovery system around a rotary cement kiln.” J. Clean. Prod. 232 (Sep): 1321–1334. https://doi.org/10.1016/j.jclepro.2019.06.011.
Mirhosseini, M., A. Rezania, L. Rosendahl, and B. B. Iversen. 2017c. “Effect of thermal cycling on zinc antimonide thin film thermoelectric characteristics.” Energy Procedia 142 (Dec): 519–524. https://doi.org/10.1016/j.egypro.2017.12.081.
Mirhosseini, M., and A. Saboonchi. 2011a. “Monte Carlo method for calculating local configuration factor for the practical case in material processing.” Int. Commun. Heat Mass Transfer 38 (8): 1142–1147. https://doi.org/10.1016/j.icheatmasstransfer.2011.05.003.
Mirhosseini, M., and A. Saboonchi. 2011b. “View factor calculation using the Monte Carlo method for a 3D strip element to circular cylinder.” Int. Commun. Heat Mass Transfer 38 (6): 821–826. https://doi.org/10.1016/j.icheatmasstransfer.2011.03.022.
Pradeep Varma, G. V., and T. Srinivas. 2017. “Power-augmented steam power plant in a cogeneration cement factory.” J. Energy Eng. 143 (1): 04016020. https://doi.org/10.1061/(ASCE)EY.1943-7897.0000374.
Qing, S., A. Rezania, L. A. Rosendahl, A. A. Enkeshafi, and X. Gou. 2018. “Characteristics and parametric analysis of a novel flexible ink-based thermoelectric generator for human body sensor.” Energy Convers. Manage. 156 (Jan): 655–665. https://doi.org/10.1016/j.enconman.2017.11.065.
Sztekler, K., K. Wojciechowski, M. Komorowski, and M. Tarnowska. 2017. “The thermoelectric generators use for waste heat utilization from cement plant.” Energy Fuels 14. https://doi.org/10.1051/e3sconf/20171401031.
TECTEG. 2018. “Manufacturers’ data sheets.” Accessed October 15, 2018. http://tecteg.com/thermoelectricpower-modules-sizes-selection/.
TEGMART. 2018. “Manufacturers’ data sheets.” Accessed October 15, 2018. http://www.tegmart.com/tegmodule.
Versteeg, H. K., and W. Malalasekera. 2007. An introduction to computational fluid dynamics: The finite volume method. 2nd ed. London: Pearson.
Information & Authors
Information
Published In
Journal of Energy Engineering
Volume 146 • Issue 4 • August 2020
Copyright
©2020 American Society of Civil Engineers.
History
Received: May 14, 2019
Accepted: Nov 7, 2019
Published online: May 15, 2020
Published in print: Aug 1, 2020
Discussion open until: Oct 15, 2020
Authors
Metrics & Citations
Metrics
Citations
Download citation
If you have the appropriate software installed, you can download article citation data to the citation manager of your choice. Simply select your manager software from the list below and click Download.