<p>About 40% of the total energy used in cement production is wasted. More than 15% of this energy is wasted through the external surface of the rotary kiln. In this paper, simulation results of new model of heat recovery from the rotary kiln shell using thermoelectric generators are presented. In this new proposed model, their cold surfaces are cooled by being placed on rectangular aluminum tubes and by forced convection of water flow inside the tubes as the working fluid. To simulate the proposed model, the program was written and executed in the EES thermodynamic software environment. The simulation results showed that the maximum temperature difference for the cold surfaces of the TEGs occurs at a distance of 24.9 m from the beginning of the rotary kiln <InlineEquation ID="IEq1"> <EquationSource Format="TEX">$\left( {{\text{as}}: W_{{{\text{tegs}}}} = 314.2 \left( {{\text{W}}\,{\text{m}}^{{{ - }{2}}} } \right)} \right)$</EquationSource> <EquationSource Format="MATHML"><math> <mfenced close=")" open="("> <mrow> <mtext>as</mtext> <mo>:</mo> <msub> <mi>W</mi> <mtext>tegs</mtext> </msub> <mo>=</mo> <mn>314.2</mn> <mfenced close=")" open="("> <mrow> <mtext>W</mtext> <mspace width="0.166667em" /> <msup> <mrow> <mtext>m</mtext> </mrow> <mrow> <mo>-</mo> <mn>2</mn> </mrow> </msup> </mrow> </mfenced> </mrow> </mfenced> </math></EquationSource> </InlineEquation>. From the analysis of the results of changes in the temperature of hot water exiting the aluminum channels in the proposed model, it can be concluded that the proposed model is a system for simultaneous production of heat (e.g., hot water at a temperature of 360 K) and direct electricity by thermoelectric modules. As the simulation results show, the superiority of forced convection over natural convection is quite clear.</p>

Analysis of a new proposed method to prevent energy waste in rotary kilns in the cement industry

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发表日期：

2026年4月29日

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Behrooz M. Ziapour,
Aqeel Hassoun

摘要

About 40% of the total energy used in cement production is wasted. More than 15% of this energy is wasted through the external surface of the rotary kiln. In this paper, simulation results of new model of heat recovery from the rotary kiln shell using thermoelectric generators are presented. In this new proposed model, their cold surfaces are cooled by being placed on rectangular aluminum tubes and by forced convection of water flow inside the tubes as the working fluid. To simulate the proposed model, the program was written and executed in the EES thermodynamic software environment. The simulation results showed that the maximum temperature difference for the cold surfaces of the TEGs occurs at a distance of 24.9 m from the beginning of the rotary kiln $\left( {{\text{as}}: W_{{{\text{tegs}}}} = 314.2 \left( {{\text{W}}\,{\text{m}}^{{{ - }{2}}} } \right)} \right)$ $(as : W_{tegs} = 314.2 (W m^{- 2}))$ . From the analysis of the results of changes in the temperature of hot water exiting the aluminum channels in the proposed model, it can be concluded that the proposed model is a system for simultaneous production of heat (e.g., hot water at a temperature of 360 K) and direct electricity by thermoelectric modules. As the simulation results show, the superiority of forced convection over natural convection is quite clear.