Rotary Kilns—rotating industrial drying ovens—are used for a wide variety of applications including processing raw minerals and feedstocks as well as heat-treating hazardous wastes. They are particularly critical in the manufacture of Portland cement. Their design and operation is critical to their efficient usage, which if done incorrectly can result in improperly treated materials and excessive, high fuel costs. This professional reference book will be the first comprehensive book in many years that treats all engineering aspects of rotary kilns, including a thorough grounding in the thermal and fluid principles involved in their operation, as well as how to properly design an engineering process that uses rotary kilns. This new edition contains an updated CFD section with inclusion of recent case studies and in line with recent developments covers pyrolysis processes, torrefaction of biomass, application of rotary kilns in C02 capture and information on using rotary kilns as incinerators for hydrocarbons. - Provides essential information on fluid flow, granular flow, mixing and segregation, and aerodynamics during turbulent mixing and recirculation - Gives guidance on which fuels to choose, including options such as natural gas versus coal-fired rotary kilns - Covers principles of combustion and flame control, heat transfer and heating and material balances - New edition contains information on pyrolysis processes with low temperatures and torrefaction of biomass. It also covers calcination of petcoke, how rotary kilns are used as incinerators for chlorinated hydrocarbons. - Includes updated material on CFD simulation of kiln gas and solids flow with a selection of recent case studies.

This is an indispensable reference source and training tool not only for kiln operators, but for supervisors and management staff as well. Extensive discussions on pre-heater and pre-calciner operations are included. The appendix includes a section with conversion tables, definitions of common terms relating to rotary kilns, and a suggested outline for a training program for new operators. CONTENTS: History; Types of Rotary Kilns; Refractories; Fuels; Combustion; The Flame; Heat Transfer; Heat Balances; The Chemistry of Kiln Feed and Clinker, Reaction Zones in the Rotary Kiln; Coating and Ring Formation in a Rotary Kiln; The Air Circuit in a Rotary Kiln: Movement of the Material Through The Kiln; Kiln Operating and Control Methods; Instrumentation; Burning Zone Control; Fuel Systems; Clinker cooler Control; Kiln Exit-Gas Temperature Control; Feed-Rate Control; Kiln Starts and Shutdowns; The 27 Basic Kiln Conditions; Kiln Emergency Conditions; Safety and Accident Prevention; Appendix: A KILN OPERATOR'S QUIZ; Glossary; Conversion Tables; Index. See also: F.M. LEA's, THE CHEMISTRY OF CEMENT AND CONCRETE, Third Edition: ISBN 978-0-8206-0212-7; Kurt Peray, The Cement Manufacturer's Handbook: ISBN 0820603686. Visit us at www.chemical-publishing.com

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This book deals with two important areas that directly affect kiln availability for production. These two aspects decide if the cement plant would make profit or loss during the year. At the moment there is no book that deals with these aspects. The literature on these subjects is scattered and the totality of the subject is missing. The book Refractory Engineering and Kiln Maintenance in Cement Plants is an utmost requirement for the Cement Industry and would fulfil the needs of the Cement Industry all over the world. It has brought out various developments of refractory with the changing technological scenario. The contents is totally comprehensive in every respect and has been planned in such a way that starting from Changing Phases of Kiln Systems and Choice of Refractories, Improving the Kiln Up-time, there are also important chapters on Inspection, Storage and Packing of Refractories, Refractory Management, Kiln Maintenance with a bonus of a glossary of the technical terms. The book will serve as a handbook for production managers, production engineers, Kiln operators, refractory engineers, maintenance managers, purchase engineers, inventory engineers, warehouse officers and storekeepers.

With a boom in the steel industry all over the world today, the demand of sponge iron has considerably increased as a feed (raw) material to steel making. The increase in the demand of sponge iron is also due to the fact that it is used for replacing coke making required for blast furnace processing. The primary objective of this book is to provide the basis, principles, fundamentals and theory of sponge iron production. This book, earlier titled as Sponge Iron Production in Rotary Kiln, is revised as per the feedback from students, faculty members and professionals. It, now, covers broad spectrum of alternative routes of iron making, therefore, the book is renamed as Alternative Routes to Iron Making. In this revised edition of the book, three new chapters have been added to fulfil the requirement of a textbook for various universities. NEW TO THIS EDITION • New chapters on: o Utilization of Sponge Iron o Environmental Pollution and Control in Sponge Iron Industries o Smelting Reduction Process • Inclusion of principle of fluidisation in fluidised bed processes • Description of Hyl III process with recent development of the process Primarily intended for undergraduate and postgraduate students of metal-lurgical engineering, this book is equally beneficial for researchers, and professionals engaged in DR processes and steel industries.

Structured into fourteen chapters, this volume covers various aspects of kiln maintenance and deals with the wear of components, operational parameters and their impact on the condition of the kiln, maintenance-friendly design considerations of kiln components, on-line techniques for condition monitoring, repair during operation, effective management of a kiln shutdown, and some management approaches. It presents systematic analyses of the problems encountered during the life span of the kilns and suggests appropriate method(s) to tackle them and meet the needs of engineers and operators involved. Written in simple language, containing a good blend of theory and practice, and supported with practical reference tables and figures, this book is intended for engineers, operators and maintenance workers working with cement kilns. The author, Dr. J.P. Saxena is an absolute expert in the field.

This book is the translated English version of a text on industrial surveys, originally published in Slovak by SPEKTRUM STU Publishing. This updated version is not only a translation of the original, but also a reviewed, extended version, which reflects up-to-date international standards and regulations. The book covers topics in engineering surveying not available in other publications in this complex form, and addresses the design methodology, data processing and implementation of geodetic measurements under specific conditions to make industrial work environments safer and more efficient. The book begins by introducing readers to these conditions, and then discusses design of maps, geodetic networks and information systems of industrial plants, the usage of cartesian and polar coordinate measuring systems, terrestrial laser scanning technology, as well as measurement of cranes, rotary kilns and special objects of nuclear power plants. The book will be of use to teachers, students, practitioners (e.g. surveyors), quality production managers, equipment designers and mechanical engineers.