Heat Transfer Modelling of a Plasma Heated Rotary Kiln for Calcination and Cement Production

Other conference contribution, 2024

The cement industry is a major source of global carbon dioxide emissions, originating both from fossil fuel combustion and the calcination of limestone. Replacing conventional burners in rotary kilns with electrically generated thermal plasma offers a pathway to reduce combustion-related emissions while enabling a highly concentrated carbon dioxide exhaust stream suitable for carbon capture. However, the absence of combustion products is expected to alter the heat transfer characteristics within the kiln, where radiative heat transfer plays a critical role.

This work investigates the operation of a demonstration-scale rotary kiln heated by an 8 MW electrical plasma system. Particular focus is placed on achieving both calcination and clinkerisation within the kiln without upstream preheating and on evaluating how operational and geometric parameters influence heat transfer and process performance. The objective is to identify suitable kiln configurations and operating conditions for efficient clinker production in plasma-heated cement processes, supporting the transition towards low-carbon cement manufacturing.