`8.

6 Optimization of the Insulation in the Rotary Kiln

Rotary kilns operate at high temperature to cause chemical reaction in the raw mix to form
a clinker. This high operating temperature can destroy carbon steel pipe, thus refractory insulation
is used. Refractory insulation should be maintained to avoid unnecessary cooling of hot surfaces.
Large amount of heat loss is also prevented by installation of refractory insulations. A silica
firebrick is installed along with the stainless steel wall and the optimized thickness of insulation is
130.54 cm.

Data
Insulation (Silica Firebrick) Coal
𝑊 𝑘𝐽
𝑘 = 0.53 𝐻𝑣 = 32,247
𝑚𝐾 𝑘𝑔
2537.46 37
𝑎𝑐 = 𝑃ℎ𝑝 𝑏𝑐 = 𝑃ℎ𝑝
𝑐𝑚 ∙ 𝑚 𝑘𝑔
𝐾𝐹 = 0.2 Hours of Operation
𝑇𝑤 = 200℃ ℎ𝑟𝑠
𝐻𝑦 = 8640
𝑦𝑟

Steel Pipe
𝐷𝑠𝑜 = 464.46 𝑐𝑚 𝑇𝑜 = 875 ℃
𝐿 = 50 𝑚

Figure 1. Diagram of the rotary kiln with insulation

 For this equipment, the outer diameter of pipe was considered Dso because the insulation
is inside the rotary kiln as shown in Figure 1 above and insulation diameter was Do. In dry process
of cement manufacturing, the outside wall temperature of a rotary kiln is 200 C (Margin G.,
1932). Figure 2 below shows the temperature gradient in rotary kiln.

Figure 2. Temperature Gradient in Kiln

Calculations
1
1 2
𝐷𝑠𝑜 14.4 𝑏𝑐 𝐻𝑦 𝑘 𝜋 (𝑇𝑜 − 𝑇𝑤 ) ×
𝐷𝑜
ln ( ) = [ ]
𝐷𝑜 𝐻𝑣 𝐾𝐹 𝑎𝑐

1
1 2
464.46 14.4 (37)(8640) (0.53) 𝜋 (875 − 200) × 464.46
ln ( )=[ ]
𝐷𝑜 (32,247)(0.2)(2,537.46)

𝐷𝑜 = 203.54 𝑐𝑚

𝐷𝑠𝑜 − 𝐷𝑜 464.46 𝑐𝑚 − 203.54 𝑐𝑚

𝑋𝑜𝑝𝑡 = =
2 2

𝑋𝑜𝑝𝑡 = 130.46 𝑐𝑚
 3.6 𝑏𝑐 𝐻𝑦 2𝜋 𝑘 𝐿(𝑇𝑜 − 𝑇𝑤 ) 1 𝐷𝑠𝑜 − 𝐷𝑜
𝐶𝑇 𝑚𝑖𝑛 = [ ] + 𝑎𝑐 𝐾𝐹 𝐿
𝐻𝑣 𝐷 2
ln ( 𝐷𝑠𝑜 )
𝑜

3.6 (37)(8640)2𝜋(0.53)(50)(𝑇𝑜 − 𝑇𝑤 ) 1 464.46 − 203.54

𝐶𝑇 𝑚𝑖𝑛 = [ ] + (2,537)(0.2)(50)
32,247 464.46 2
ln (
203.54)

𝐶𝑇 𝑚𝑖𝑛 = 𝑃ℎ𝑝 3,317,623.57

Cost with no optimization
3.6 𝑏𝑐 𝑞 𝐻𝑦 𝐷𝑜 − 𝐷𝑖
𝐶𝑜𝑠𝑡 = + 𝑎𝑐 𝐾𝐹 𝐿
𝐻𝑣 2
𝑞 = 4,163,922.311 𝑊

3.6 (37)(4,163,922.31) (8640) 466.67 − 464.46

𝐶𝑜𝑠𝑡 = + (2,537)(0.2)(50)
32,247 2

𝐶𝑜𝑠𝑡 = 𝑃ℎ𝑝 4,044,365.28

𝐶𝑜𝑠𝑡 − 𝐶𝑇 𝑚𝑖𝑛
% 𝑑𝑖𝑓𝑓𝑒𝑟𝑒𝑛𝑐𝑒 = × 100 = 19.74%
𝐶𝑜𝑠𝑡 − 𝐶𝑇 𝑚𝑖𝑛
2
The resistance of the insulation was removed to compute for the cost without optimization.
The heat loss is higher in no optimization compared to the cost with optimization. Also, the cost
is also higher if it is not optimized. There is a 19.74% difference between the optimized minimum
cost and the not optimized cost.

References
Margin, G. Chemical engineering and thermodynamics applied to the cement rotary kiln.
London: Croshy Lockwood & Son, 1932. 31s 6d
De Keyser, L., Reactivity in the solid of state between the oxydes of the cement system.
Standard Grade Coal – Heat Value. Retrieved March 21, 2019 from
https://www.engineeringtoolbox.com/coal-heating-values-d_1675.html
Everything you need to know about heat transfer in cement kiln. Retrieved March 20, 2019
from https://www.cementequipment.org/home/kiln-and-cooler/everything-need-know-heat-
transfer-cement-kiln/