| Dusting is one of the major problems in the operation of lime kilns because dust particles interfere with kiln operation and reduce its efficiency. A numerical model is developed to predict the rate of dust formation in rotary lime kilns. The model consists of four major components: 1) a 3D model for the kiln gas, solving fluid flow, heat transfer, and combustion in the gas region; 2) a 1D model for the kiln bed, solving for variation of the solids composition, including moisture content, along the kiln; 3) a 3D model to predict the motion of the solids in the bed, and to estimate the reaction rates; 4) a mathematical model to predict the rate of particle pickup from the bed. Additionally, motion of dust particles was modeled, for the first time, using Stochastic Separated Flow model (a Lagrangian approach). The developed model of particle tracking enables the user to predict distribution of dust particles in the gas section of the kiln. Different components of the model were validated using experimental data published in the literature.;The developed model was used to simulate operation of a full-scale lime kiln at typical operating conditions, i.e. at different fuel and air flow-rates. Dusting signatures were also estimated for each setting to determine the effect each operating condition has on dusting. The results presented in this thesis indicate that dust formation is mainly affected by the kiln gas velocity. Effect of other operating conditions was found to be negligible within the ranges studied. The results presented here suggest that dust formation can be controlled by minimizing the input gas flow rate. |
