DOI:
https://doi.org/10.14483/23448393.22204Published:
2025-12-10Issue:
Vol. 30 No. 3 (2025): September-DecemberSection:
Chemical, Food, and Environmental EngineeringModeling a Fixed-Bed System with Coal Volatiles Post-Combustion for Ceramic Kiln Firing
Modelamiento de un sistema de lecho fijo con poscombustión de volátiles del carbón para hornos de cocción de cerámicos
Keywords:
Secondary air, Ceramic firing, Coal combustion, down-draught kiln, Fixed bed grill, Post-combustion (en).Keywords:
aire secundario, cocción de cerámicos, combustión de carbón, hornos colmena, parrilla de lecho fijo, poscombustión (es).Downloads
Abstract (en)
Context: It is estimated that, in Colombia, more than 1300 brick industries consume around 5800 Tcal/year, which are supplied by coal, biomass, wood, and gas combustion. The most commonly used kilns are down-draught, wherein coal combustion is produced on fixed-grate beds, emitting greenhouse gases and other pollutants. As a contribution to solving this problem, this work presents the model of a fixed-bed system with coal volatiles post-combustion.Method: Temperature, time, coal consumption, and combustion products were monitored in a down-draught kiln, in order to determine their mass, energy, and thermal efficiency balances. Coal characterization was performed under ASTM standards, ashes were determined via XRD, XRF, and TGA, and emissions were obtained using a gas analyzer. The thermodynamic model used to design the 3D reactor was based on coal-burning analysis.
Results: The process lasted 3166 min, consuming 2150 kg of coal. The combustion gases exhibited a varying composition of CO2, CO, O2, and hydrocarbons. The temperature on the grate reached 900 °C, and we recorded 1000 °C in the dome and 600 °C at the chimney base. The temperature difference between the dome and the chimney base explains the heat transferred for ceramic baking. The calorific value of the char was 19.52% higher than that of the coal used. The composition of the ash showed silicon oxide, mullite, and goethite. The 3D model consists of a grate with preheater ducts for the secondary air post-combustion of the volatiles.
Conclusions: The outcome of this research was the 3D model of a fixed-bed grate for coal combustion and volatiles post-combustion. With its implementation, we expect to improve air quality and reduce the effects of the process on human health, as well as its operating costs.
Abstract (es)
Contexto: Se estima que, en Colombia, más de 1300 industrias ladrilleras consumen alrededor de 5800 Tcal/año, provenientes de la combustión de carbón, biomasa, leña y gas. Los hornos más comunes son los de tiro descendente, en los cuales la combustión del carbón se realiza sobre parrillas fijas, emitiendo gases de efecto invernadero y otros contaminantes. Como contribución a la solución de este problema, este trabajo presenta el modelo de un sistema de lecho fijo con poscombustión de volátiles del carbón.
Método: Se monitorearon la temperatura, el tiempo, el consumo de carbón y los productos de combustión en un horno de tiro descendente, a fin de determinar los balances de masa, energía y eficiencia térmica. La caracterización del carbón se realizó bajo las normas ASTM, las cenizas se analizaron mediante XRD, XRF y TGA, y las emisiones se determinaron utilizando un analizador de gases. El modelo termodinámico empleado para el diseño del reactor 3D se basó en el análisis de la combustión del carbón.
Resultados: El proceso tuvo una duración de 3166 minutos, con un consumo de 2150 kg de carbón. Los gases de combustión presentaron una composición variable de CO₂, CO, O₂ e hidrocarburos. La temperatura en la parrilla alcanzó los 900 °C, y se registraron 1000 °C en la cúpula y 600 °C en la base de la chimenea. La diferencia de temperatura entre la cúpula y la base de la chimenea explica el calor transferido para la cocción de la cerámica. El poder calorífico del char fue 19.52 % superior al del carbón utilizado. La composición de las cenizas mostró la presencia de óxido de silicio, mullita y goethita. El modelo 3D consiste en una parrilla con conductos precalentadores para el aire secundario destinado a la poscombustión de los volátiles.
Conclusiones: El resultado de esta investigación fue el modelo 3D de una parrilla de lecho fijo para la combustión de carbón y la poscombustión de volátiles. Con su implementación, se espera mejorar la calidad del aire y reducir los efectos del proceso sobre la salud humana, así como sus costos operativos.
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Copyright (c) 2025 Marco Antonio Ardila Barragán , Maria del Pilar Triviño Restrepo, Luis Fernando Lozano Gómez, Naren Natalia Ardila Otálora, Brigith Daniela Cruz Molina, Fabián Rolando Jiménez López, Alfonso López-Díaz, Jaime Alberto Riaño Villamizar
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