Impact of structure parameters on the critical performance of a novel calciner—a DEM-based study

Fracture in a revolving tube due to creep deformation and thermal-mechanical fatigue is a growing concern in industrial equipment research and production, especially after long-term exposure to corrosion and high-temperature conditions in roasting furnaces. The calcination temperature and residence time are crucial in the catalyst production process, with optimal conditions en-hancing catalyst activity and stability. To improve the longevity of roasting furnaces, optimizing the construction structure of the calciner is critical. This study develops a novel calciner structure and mathematical models to understand the effect of structural parameters on critical performance. Computer simulations, predictive modelling, and rotational velocity analysis of the novel calciner were performed using a DEM. The effects of the baffle angle and overlap ratio on the flow pattern and MRT were studied through simulations and experiments. The main conclusions are as follows: (1) The operating parameter with the greatest effect on the MRT was the rotational angular velocity, followed by the baffle angle and overlap ratio. (2) The MRT calculation based on the numerical method model showed an error of no more than 10.0% compared to the actual measurement data, confirming the model’s accuracy. Our study provides a theoretical foundation for a deeper understanding of the complex MRT and flow field processes within this novel calciner. It also aids in optimizing the working parameters, performance, and structure of pilot equipment while offering fundamental data for future industrial applications.

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Opracowanie rekordu ze środków MNiSW, umowa nr POPUL/SP/0154/2024/02 w ramach programu "Społeczna odpowiedzialność nauki II" - moduł: Popularyzacja nauki (2025).