Rotary kiln installation forms a very complex system, as it consists of various components which affect cement production. However, some problems with particle settling are encountered during operation of tertiary air installation. This paper reports on the results of a study into gas-particle flow in a tertiary air duct installation. This flow was calculated using Euler method for air motion and Lagrange method for particle motion. The results in this paper demonstrate that study focus on the tertiary air installation is a practical measure without the analysis of other processes in the rotary kiln. A solution to this problem offers several alternatives of modifying the inlet to the tertiary air duct. As a result of numerical calculations, we demonstrate the influence of geometry of a rotary kiln modification on the number of large particles transported in the tertiary air duct. The results indicate that in order to reduce large particles, rotary kiln head geometry needs to be modified, and a particle settler should be installed at its outlet.

Clinker burning process has a decisive influence on energy consumption and the cost of cement production. A new problem is to use the process of decarbonization of alternative fuels from waste. These issues are particularly important in the introduction of a two-stage combustion of fuel in a rotary kiln without the typical reactor-decarbonizator. This work presents results of numerical studies on thermal-hydraulic phenomena in the riser chamber, which will be designed to burn fuel in the system where combustion air is supplied separately from the clinker cooler. The mathematical model is based on a combination of two methods of motion description: Euler description for the gas phase and Lagrange description for particles. Heat transfer between particles of raw material and gas was added to the numerical calculations. The main aim of the research was finding the correct fractional distribution of particles. For assumed particle distribution on the first stage of work, authors noted that all particles were carried away by the upper outlet to the preheater tower, what is not corresponding to the results of experimental studies. The obtained results of calculations can be the basis for further optimization of the design and operating conditions in the riser chamber with the implementation of the system.