A 2-Dim CFD model development for petroleum coke calcination process in rotary kiln

Petroleum coke calcination is a chemical process during which the petroleum coke loses moisture and volatile combustible materials due to the increase in temperature and ultimately improves the physical properties of the calcined coke. In this study, A 2-Dim model was developed for the petroleum coke calcination process via rotary kiln using the CFD approach. Understanding the temperature, concentration, and fluid movement behavior are the main goals for developing the simulation model, by using which the rotary kiln control and design can be performed.

Comsol Multiphysics was applied to develop the simulation model. Petroleum coke rotary kiln calcination consists of two solid and gas phases, which cross each other counter-currently. All governing physics in the system, including chemical reactions, heat transfer via conduction, convection, and radiation, intra-phase and interphase mass transfer, evaporation or evolution of components from the solid phase into the gas phase, fluid turbulency and all complex relationships were considered. Using the finite element method, the governing equations of the model were solved, and consequently, the variation of temperature, components concentration, and fluid velocity was calculated.

It is concluded that tertiary air injection significantly affects the temperature profile and combustion reactions in the bed (About 100 degrees increase in temperature). In addition, the maximum temperature of 1910 °C has been achieved in the kiln. Concentration changes of components in the gas phase were also seen mainly in the bed entrance and in the areas near the tertiary air injection. Comparing the results with similar works showed the high accuracy of the developed model