Dynamic Simulation of Heat Distribution and Losses in Cement Kilns for Sustainable Energy Consumption in Cement Production

Moses Charles Siame, Tawanda Zvarivadza (), Moshood Onifade, Isaac N. Simate and Edward Lusambo
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Moses Charles Siame: School of Engineering, University of Zambia, Great East Road, Lusaka 32379, Zambia
Tawanda Zvarivadza: Division of Mining and Geotechnical Engineering, Luleå University of Technology, 971 87 Luleå, Sweden
Moshood Onifade: Institute of Innovation, Science and Sustainability, Federation University Australia, Ballarat, VIC 3350, Australia
Isaac N. Simate: School of Engineering, University of Zambia, Great East Road, Lusaka 32379, Zambia
Edward Lusambo: School of Engineering, University of Zambia, Great East Road, Lusaka 32379, Zambia

Sustainability, 2025, vol. 17, issue 2, 1-19

Abstract: Sustainable energy consumption in cement production involves practises and strategies aimed at reducing energy use and minimising environmental impact. The efficiency of a cement kiln is dependent on the kiln design, fuel type, and operating temperature. In this study, a dynamic simulation analysis is used to investigate heat losses and distribution within kilns with the aim of improving energy efficiency in cement production. This study used Computational Fluid Dynamics (CFD) with Conjugate Heat Transfer, Turbulent Flow, and the Realisable k−ϵ turbulence model to simulate heat transfer within the refractory and wall systems of the kiln, evaluate the effectiveness of these systems in managing heat losses, and establish the relationship between the heat transfer coefficient (HTC) and the velocities of solid and gas phases. The simulation results indicate that a temperature gradient from the kiln’s interior to its exterior is highly dependent on the effectiveness of refractory lining in absorbing and reducing heat transfer to the outer walls. The results also confirm that different thermal profiles exist for clinker and fuel gases, with clinker temperatures consistently peaking at approximately 1450 °C, an essential condition for optimal cement-phase formation. The results also indicate that phase velocities significantly influence heat absorption and transfer. Lower velocities, such as 0.2 m/s, lead to increased heat absorption, but also elevate heat losses due to prolonged exposure. The relationship between the heat transfer coefficient (HTC) and the velocities of solid and gas phases also indicates that higher velocities improve HTC and enhance overall heat transfer efficiency, reducing energy demand.

Keywords: computational fluid dynamics; energy efficiency; heat transfer; process simulation (search for similar items in EconPapers)
JEL-codes: O13 Q Q0 Q2 Q3 Q5 Q56 (search for similar items in EconPapers)
Date: 2025
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