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  • 1.
    Hökfors, Bodil
    et al.
    Umeå University, Faculty of Science and Technology, Department of Applied Physics and Electronics.
    Boström, Dan
    Viggh, Erik
    Backman, Rainer
    On the phase chemistry of Portland cement clinker2015In: Advances in Cement Research, ISSN 0951-7197, E-ISSN 1751-7605, Vol. 27, no 1, p. 50-60Article in journal (Refereed)
    Abstract [en]

    This paper describes the formation of a phosphorous belite solid solution and its impact on alite formation. A sub-solidus phase relation for the ternary system silicon dioxide–calcium oxide–phosphorus pentoxide (SiO2–CaO–P2O5) is reported. The ternary system is based on Rietveld refinements of X-ray diffraction patterns from experimental tests. The overall picture is based on known phase diagrams, relevant Rietveld refinements models, stoichiometric relationships as a function of increasing phosphorus pentoxide concentration and vacancy theories for solid solutions of phosphate belites. A tool is developed for predicting the chemistry of the product as well as the chemistry during heating when producing Portland cement clinker. A thermodynamic database for phase chemistry calculations of clinkering reactions has been created and evaluated. Suitable compounds and solution species have been selected from the thermochemical database included in FactSage software. Some solution compositions have been uniquely designed to allow for the proper prediction of the cement clinker chemistry. The calculated results from the developed database for heating raw materials in cement clinker production and cooling of the product are presented in this paper. The calculated results provide a good prediction of the phases and quantities formed during heating and non-equilibrium cooling. The prediction of the amounts of alite, belite and aluminoferrite phases in the product according to the Scheil method is good. The temperature interval for the existence of all of the major phases is relevant. The thermodynamic data for a solution phase of alite with substituting ions of primarily magnesium oxide and phosphorus pentoxide would improve the predictability of the developed database.

  • 2.
    Hökfors, Bodil
    et al.
    Umeå University, Faculty of Science and Technology, Department of Applied Physics and Electronics. Cementa AB, Stockholm, Sweden.
    Eriksson, Matias
    NorFraKalk, Verdal, Norway.
    Viggh, Erik
    Cementa AB, Malmö, Sweden.
    Modelling the cement process and cement clinker quality2014In: Advances in Cement Research, ISSN 0951-7197, E-ISSN 1751-7605, Vol. 26, no 6, p. 311-318Article in journal (Refereed)
    Abstract [en]

    This paper presents a recently developed simulation model that can be used as a tool for evaluating sustainable development measures for cement and lime production processes. Examples of such measures are introducing new combustion technologies such as oxy-fuel combustion, using biomass fuel and using alternative materials in the raw material feed. One major issue when introducing process changes is the need to maintain product quality. In some ways, oxygen-enriched air combustion resembles oxy-fuel combustion. The model results were validated and found to be consistent with full-scale operational data for normal running conditions and for a full-scale test with oxygenenriched air. The model shows, for example, that with an additional 1500 m3/h of oxygen, fuel addition at the calciners can increase up to 108% and the raw material feed rate can increase up to 116% for a process with a raw meal feed of 335.5 t/h.

  • 3.
    Hökfors, Bodil
    et al.
    Umeå University, Faculty of Science and Technology, Department of Applied Physics and Electronics. Cementa AB, Stockholm, Sweden.
    Viggh, Erik
    Cementa AB, Malmö, Sweden.
    Eriksson, Matias
    Umeå University, Faculty of Science and Technology, Department of Applied Physics and Electronics. NorFraKalk, Verdal, Norway.
    Simulation of oxy-fuel combustion in cement clinker manufacturing2015In: Advances in Cement Research, ISSN 0951-7197, E-ISSN 1751-7605, Vol. 27, no 1, p. 42-49Article in journal (Refereed)
    Abstract [en]

    A thermodynamic process model is used as an evaluation tool. Full oxy-fuel combustion is evaluated for circulation of 20–80% of flue gases to the burn zone of a rotary kiln. The full oxy-fuel combustion simulations exhibit altered temperature profiles for the process. With 60% recirculation of flue gases, the temperature in the burn zone is comparable to the reference temperature, and carbon dioxide concentration in the flue gases increases from 33 to 76%. If water is excluded, carbon dioxide concentration is 90%. The partial oxy-fuel combustion method is evaluated for 20 and 40% recirculation of flue gases from one cyclone string to both calciners. Fuel and oxygen feed to the burning zone and calciners are optimised for the partial oxy-fuel scenario. The lowest specific energy consumption is desired while maximising the amount of carbon dioxide theoretically possible to capture. By introducing partial oxy-fuel combustion with 20% recirculation of flue gases in the carbon dioxide string, total carbon dioxide emissions increases by 4%, with 84% possible to capture. Within the limits of the model, the introduction of full oxy-fuel and partial oxyfuel combustion is possible while maintaining product quality. When simulating partial oxy-fuel combustion, the energy consumption will increase even when no power consumption for the production of oxygen is included.

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