##### Document Text Contents

Page 4

"Hot Rotary Kiln Deformability for Cement Plant, Experimentation, and Numerical Simulation".

DOI: 10.9790/1684-1401071422 www.iosrjournals.org 17 | Page

Figure 5. A section ovalization on the ferrule

Numerical simulation using the finite element method

The objective of this study is to analyse the plastic behavior of kiln ferrule, in the case of static loads.

Firstly, a numerical task was (Zienkiewicz, 2005) and (Ventsel, 2001). conducted to take a decision on the

preventive maintenance of the kiln. All simulations were done by the method of calculation by finite elements

Patran/Nastran (Janati, 2015) and (Biron, 2011)

The model structure consists of two parts.

Definition of the simplified model.

Definition of the type of the calculation model including different modules which enable to write.

o The geometries.

o The used material.

o The boundaries and loading conditions types of unstructured grid.

We have a kiln with a big dimension (Kohar, 1995), so in order to see the limits conditions, the loading and the

grid structure in the model, we have enlarge the zones shown in Figure 6.

Figure 6. The kiln with boundary conditions, grid structure and loading

Numerical and experimental ovalization

To measure the ovalizations, we take some sections of the kiln ferrule, and then we determine the

maximal movement on each ferrule section. By choosing some landmarks of sections with experimental

measures ovalizations, we validate the numerical results in relation with those obtained by experimentation. For

this reason we have chosen a single section on the upstream kiln. Figure 7 shows the numerical ovalization by

Patran/Nastran upstream kiln.

http://appliedmechanics.asmedigitalcollection.asme.org/solr/searchresults.aspx?author=A.+Biron&q=A.+Biron

Page 8

"Hot Rotary Kiln Deformability for Cement Plant, Experimentation, and Numerical Simulation".

DOI: 10.9790/1684-1401071422 www.iosrjournals.org 21 | Page

Kiln thermal deformations representation (ovalization)

The comparison was elaborated between two different approaches. The first approach, which is based

on an experimental measurement campaign (Sonavane, 2009) and (Barr, 1989), this campaign is taken when the

heat kiln is in rotation. The second approach is based on the numeric simulation which uses the same

experimental load conditions. Figure 16 presents numeric and experimental displacements evolution, which is

function of kiln length.

Figure 16. Comparison between heat measurements and thermo-mechanical calculus

Kiln deformability experimental measurements and numeric calculus comparison

Figure 17 presents displacements values function of kiln length, which are obtained by the two approaches

experimental and numeric (Ghoshdastidar, 2002) and (Boateng, 1995). We can show that the resulted curves

present a sinusoidal evolution. This is due to the system support used.

Figure 17. Comparison between cold measurements with thermo-mechanical calculus, and the calculus

obtained from thermal and mechanical loads

V. Conclusion

A comparative study between the experimental results and those obtained by the numerical simulation

upon three critical zones of the rotary cement kiln is done. We notice that the three diagrams are close to each

other as shown in Figure 13 to Figure 17. The next step that we would conduct is a thermal calculation on

MARC, special thermal software. The main objective is to determine the complete deformability by measures,

and thermal deformations through numerical calculation. Based on these values, we would obtain the

mechanical deformation of the ferrule in which lodes are applied.

"Hot Rotary Kiln Deformability for Cement Plant, Experimentation, and Numerical Simulation".

DOI: 10.9790/1684-1401071422 www.iosrjournals.org 17 | Page

Figure 5. A section ovalization on the ferrule

Numerical simulation using the finite element method

The objective of this study is to analyse the plastic behavior of kiln ferrule, in the case of static loads.

Firstly, a numerical task was (Zienkiewicz, 2005) and (Ventsel, 2001). conducted to take a decision on the

preventive maintenance of the kiln. All simulations were done by the method of calculation by finite elements

Patran/Nastran (Janati, 2015) and (Biron, 2011)

The model structure consists of two parts.

Definition of the simplified model.

Definition of the type of the calculation model including different modules which enable to write.

o The geometries.

o The used material.

o The boundaries and loading conditions types of unstructured grid.

We have a kiln with a big dimension (Kohar, 1995), so in order to see the limits conditions, the loading and the

grid structure in the model, we have enlarge the zones shown in Figure 6.

Figure 6. The kiln with boundary conditions, grid structure and loading

Numerical and experimental ovalization

To measure the ovalizations, we take some sections of the kiln ferrule, and then we determine the

maximal movement on each ferrule section. By choosing some landmarks of sections with experimental

measures ovalizations, we validate the numerical results in relation with those obtained by experimentation. For

this reason we have chosen a single section on the upstream kiln. Figure 7 shows the numerical ovalization by

Patran/Nastran upstream kiln.

http://appliedmechanics.asmedigitalcollection.asme.org/solr/searchresults.aspx?author=A.+Biron&q=A.+Biron

Page 8

"Hot Rotary Kiln Deformability for Cement Plant, Experimentation, and Numerical Simulation".

DOI: 10.9790/1684-1401071422 www.iosrjournals.org 21 | Page

Kiln thermal deformations representation (ovalization)

The comparison was elaborated between two different approaches. The first approach, which is based

on an experimental measurement campaign (Sonavane, 2009) and (Barr, 1989), this campaign is taken when the

heat kiln is in rotation. The second approach is based on the numeric simulation which uses the same

experimental load conditions. Figure 16 presents numeric and experimental displacements evolution, which is

function of kiln length.

Figure 16. Comparison between heat measurements and thermo-mechanical calculus

Kiln deformability experimental measurements and numeric calculus comparison

Figure 17 presents displacements values function of kiln length, which are obtained by the two approaches

experimental and numeric (Ghoshdastidar, 2002) and (Boateng, 1995). We can show that the resulted curves

present a sinusoidal evolution. This is due to the system support used.

Figure 17. Comparison between cold measurements with thermo-mechanical calculus, and the calculus

obtained from thermal and mechanical loads

V. Conclusion

A comparative study between the experimental results and those obtained by the numerical simulation

upon three critical zones of the rotary cement kiln is done. We notice that the three diagrams are close to each

other as shown in Figure 13 to Figure 17. The next step that we would conduct is a thermal calculation on

MARC, special thermal software. The main objective is to determine the complete deformability by measures,

and thermal deformations through numerical calculation. Based on these values, we would obtain the

mechanical deformation of the ferrule in which lodes are applied.