Search Results (120)

In this work, lightweight aggregates (LWAs) were prepared from an Italian red clay, pumice scraps, and spent coffee grounds. Chemical and physical characterization was first performed on the raw materials and then on the finished products. By studying the thermal behavior of the materials, the correct firing temperature was evaluated. The obtained aggregates were fired in two different modes: in a rotary kiln and in a static kiln; the influence of the firing processes on the finished products was assessed. This study can be useful for industrially scaling up this process. Firing in a rotary kiln reduced the average diameter of the aggregates (negative expansion index), resulting in a higher compressive strength and dry particle density compared to an aggregate containing only clay. The pH and electrical conductivity values address their use in agronomy without causing problems to crops, while the higher compressive strength, density, and porosity values could allow their use in construction. Full article

The energetic valorization of digestate obtained from anaerobic digestion (AD) of the organic fraction of municipal solid waste (OFMSW) was investigated via pyrolysis in a bench-scale rotary kiln. The mass rate of dried digestate to the rotary kiln pyrolyzer was fixed at 500 gr/h. The effect of the pyrolysis temperature was investigated at 600, 700, and 800 °C. The pyrolysis products, char, oil, and gas, were quantified and chemically analyzed. It was observed that with the increase in the temperature from 600 to 800 °C, the char decreased from 60.3% to 52.2% and the gas increased from 26.5% to 35.3%. With the aim of increasing the methane production and methane concentration in syngas, the effect of CaO addition to the pyrolysis process was investigated at the same temperature, too. The mass ratio CaO/dried digestate was set at 0.2. The addition of CaO sorbent has a clear effect on the yield and composition of pyrolysis products. Under the experimental conditions, CaO was observed to act both as a CO₂ sorbent and as a catalyst, promoting cracking and reforming reactions of volatile compounds. In more detail, at the investigated temperatures, a net reduction in CO₂ concentration was observed in syngas, accompanied by an increase in CH₄ concentration. The gas yield decreased with the CaO addition because of CO₂ chemisorption. The oil yield decreased as well, probably because of the cracking and reforming effect of the CaO on the volatiles. A very promising performance of the CaO sorbent was observed at 600 °C; at this temperature, the CO₂ concentration decreased from 32.2 to 13.9 mol %, and the methane concentration increased from 16.1 to 29.4 mol %. At the same temperature, the methane production increased from 34 to 63 g/kg_digestate. Full article

Gasification of municipal solid waste and other biogenic residues (e.g., biomass and biowaste) is increasingly recognized as a promising thermochemical pathway for converting non-recyclable fractions into valuable energy carriers, with applications in electricity generation, district heating, hydrogen production, and synthetic fuels. This paper provides a comprehensive analysis of major gasification technologies, including fixed bed, fluidized bed, entrained flow, plasma, supercritical water, microwave-assisted, high-temperature steam, and rotary kiln systems. Key aspects such as feedstock compatibility, operating parameters, technology readiness level, and integration within circular economy frameworks are critically evaluated. A comparative assessment of incineration and pyrolysis highlights the environmental and energetic advantages of gasification. The valorization pathways for main product (syngas) and by-products (syngas, ash, tar, and biochar) are also explored, emphasizing their reuse in environmental, agricultural, and industrial applications. Despite progress, large-scale adoption in Europe is constrained by economic, legislative, and technical barriers. Future research should prioritize scaling emerging systems, optimizing by-product recovery, and improving integration with carbon capture and circular energy infrastructures. Supported by recent European policy frameworks, gasification is positioned to play a key role in sustainable waste-to-energy strategies, biomass valorization, and the transition to a low-emission economy. Full article

Barro Alto processes nickel laterite ore using rotary kilns and six-in-line rectangular electric arc furnaces. This study evaluated the briquetting of ferronickel ore to reduce kiln fines, improve furnace charge permeability, and enhance process safety. Binderless briquettes were produced from screened ore at two size fractions (−6.3 mm and −12.5 mm), with moisture contents of 16% and 24%, cured under closed and open conditions. The physical and metallurgical properties of the briquettes were assessed using ISO standard tests. The results confirmed successful agglomeration of the ore into binderless briquettes. Screening the run-of-mine (ROM) ore improved the feed quality, increasing the NiO grade from 2.0% to 2.2% in the −6.3 mm fraction. The briquettes from the −6.3 mm ore at 16% moisture exhibited the highest green strength (559 N). Higher moisture content reduced the briquette strength and increased both the reduction disintegration and decrepitation indices. The decrepitation index increased from 0.33% to 0.61% for the −6.3 mm briquettes when the moisture increased from 16% to 24%. The reduction levels were 33.4% and 39.2% for −6.3 mm and −12.5 mm briquettes with 16% moisture, respectively. This study concludes that optimal performance was achieved using −6.3 mm ore, 16% moisture, and open curing, thereby balancing reduction efficiency and mechanical stability. Full article

Cobalt ore resources are relatively scarce; thus, the recycling of cobalt-containing slag is highly significant in the economy and society. In this study, the effects of reduction temperature, the reduction agent ratio, reduction time, and particle size on the grade and recovery rate of cobalt in a concentrate were systematically investigated during the carbothermal reduction of cobalt-containing slag. The results revealed that the grades of cobalt, iron, and copper in the concentrate after magnetic separation were 4.02%, 2.48%, and 81.33%, respectively, and the recoveries were 94.17%, 74.80%, and 53.27%, respectively, under the reduction temperature of 1150 °C, the reduction agent ratio of 40%, the reduction time of 2 h, and the particle size of −3.0 mm. Furthermore, through static reduction roasting in a muffle furnace and dynamic reduction roasting in a rotary kiln followed by magnetic separation, a stable cobalt grade, high selective recovery, and effective enrichment were achieved under optimal conditions. Full article

The article examines the parameters of axial motion of bulk material in rotary kilns, including bed height, axial velocity, and mean residence time. The review includes summary tables of experiments from the scientific literature, detailing the conditions and ranges of operating parameter variations. Mathematical models from the literature are presented for each of the parameters discussed. The materials of the article cover studies from 1927 to 2025, including analysis of numerous works that were not published in international sources. Based on the review, the necessity of studying the impact of coating formation on the axial motion parameters is highlighted, along with the need for experiments on real facilities and pilot plants. Full article

In the recycling of semiconductor materials like Bi₂Te₃ or CdTe, TeO₂ may form as a by-product that can be directly reduced to recover metallic Te. The hydrogen reduction of TeO₂ offers an eco-friendly alternative to conventional carbothermic reduction by avoiding CO by-products. This study investigates the reduction of 99.99 wt.% purity level TeO₂ using hydrogen in an oscillating kiln furnace (200–800 °C, 2–7 h), with phase composition and microstructure analysed via XRD and SEM. Results demonstrate conversions of up to 89% (solid–gas) and 100% (liquid–gas), revealing that kinetics dominate over thermodynamics in controlling reaction progress. The work proposes a reaction mechanism based on morphological evolution observed in SEM images, suggesting that further parameter optimisation could enhance scalability. As the first lab-scale demonstration of hydrogen-assisted TeO₂ reduction, this study establishes a preliminary process window (temperature/time) and underscores the potential for industrial adoption. Future work should verify the proposed mechanism and refine operational parameters to maximize efficiency. Full article

Palm kernel shells, an abundant agro-industrial residue in countries like Ecuador, can be valorized through their conversion into activated carbon for industrial applications. This study investigates the physical activation of carbonized palm kernel shells using both a Nichols furnace at the pilot scale and a rotary kiln at the industrial scale. The progressive conversion model was used to explain how the activation process works and to calculate the reaction rate constants for CO₂ (kr_CO2) and H₂O (kr_H2O). The experimental results demonstrated that activation in an H₂O-rich atmosphere significantly enhanced porosity development and iodine index compared to CO₂ alone. Additionally, the study confirmed that activation kinetics are primarily controlled by the chemical reaction rather than mass transport limitations, as indicated by the negligible effect of particle size on gasification rates. At 850 °C, the reaction rate constants were calculated to be kr_CO2 = 0.75 (mol·cm⁻³·s)⁻¹ and kr_H2O = 8.91 (mol·cm⁻³·s)⁻¹. The model’s predictions closely matched the experimental data, validating its applicability for process optimization at both the pilot and industrial scales. These findings provide valuable insights for improving the efficiency of activated carbon production from palm kernel shells in large-scale operations. Full article

This paper presents a study on the ring formation phenomenon in lime kilns using simulation. The research focuses on the chemical recovery cycle integrated into the pulp production process at a pulp mill, with particular emphasis on the calcium cycle within the lime kilns. Lime kilns are critical components, as their unavailability can significantly impact the overall cost-effectiveness of the facility. The calcination of lime sludge occurs in a rotary kiln, where calcium carbonate in the lime sludge is converted into calcium oxide (lime). Under certain conditions, material can progressively accumulate, leading to ring formation and eventual kiln clogging, resulting in operational downtime. To investigate this issue, the authors developed a physics-based model using a finite-dimensional, one-dimensional approach that considers only longitudinal variation. Several approximations were made to maintain a reasonable simulation time without compromising accuracy. Simulations based on real operational data identified fluctuations in fuel flow rate and sulfur content from non-condensable gases as key contributors to ring formation. The results showed that these fluctuations caused instability in the temperature profiles of the solids and gas beds, leading to periods of cooling before the lime sludge reaches the outlet to the coolers. This cooling promotes the recarbonation of lime and, consequently, the formation of rings. The findings highlight that stabilizing fuel flow and managing sulfur content could mitigate ring formation and improve kiln efficiency. The developed model provides a valuable tool for predictive analysis and process optimization, potentially supporting the development of a digital twin to enhance real-time monitoring and operational control. Full article

The article presents the physico-mechanical properties of cement mortars modified with the addition of fly ash generated from municipal waste incineration (MSWI-FA) and dust from rotary kiln dedusting installations (CKD—cement kiln dust) produced during cement manufacturing. The waste materials were dosed separately and in combination—MSWI-FA in amounts of 10, 15, and 20% of the cement mass, with a volumetric adjustment of the standard sand mass, while CKD was used as a cement replacement in amounts of 10, 15, and 20% of the cement mass. Basic tests were conducted on the prepared mortars, including consistency and flexural and compressive strength after 7 and 28 days of curing, water absorption, bulk density, and resistance to freeze–thaw cycles. The results indicate that the addition of MSWI-FA and CKD reduces the strength of mortars compared to the control series, with CKD proving to be more effective and stable than MSWI-FA, especially over longer curing periods. The combination of MSWI-FA and CKD often resulted in the greatest decline in mechanical parameters, suggesting limited synergy between these materials. The best results were achieved using low additive concentrations, especially in the MSWI-FA-CKD/3–3 (i.e., after 3% of the MSWI-FA and CKD waste) combination. The research confirms the potential of utilizing MSWI-FA and CKD in sustainable cement compositions but highlights the need for further work on optimizing proportions and modification techniques. The importance of these efforts for reducing environmental impact and promoting a circular economy is emphasized. Full article

The hydrogen plasma smelting reduction process has the potential to drastically reduce the CO₂ emissions of the steel industry by using molecular, atomic and ionized hydrogen as a reducing agent for iron ores. To increase the hydrogen and thermal efficiency of the process, a pre-reduction and pre-heating stage should be incorporated in a future upscaling of an existing HPSR demonstration plant within the scope of the “SuSteel follow-up” project to a target capacity of 200 kg/h of iron ore. The determination of the optimal process parameters is followed by a review of possible reactor types. A fluidized bed cascade, a cyclone cascade and a rotary kiln are compared for this purpose. Their applicability for the hydrogen plasma smelting is discussed, based on their fundamental design and operational procedures. Additionally, critical features of the different reactor types are outlined. A cyclone cascade with at least 3 stages is proposed to be the optimal reactor for pre-heating and pre-reducing the input material for the upscaled hydrogen plasma smelting reduction demonstration plant, based on the assessment. Full article

Corundum–mullite refractory material is an important material in rotary kiln incinerators due to its excellent properties, e.g., high temperature stability and chemical resistance, etc. However, in the process of use, the complexity of the sintering process will inevitably produce a large amount of spent corundum–mullite refractory material. Therefore, it is important to study the failure mechanism of corundum–mullite refractory material to prolong its service life. In this manuscript, the scrapping mechanism for the corundum–mullite refractory material was studied by XRD, XPS, SEM-EDS, FTIR, etc. The results indicate that chemical corrosion caused by impurity elements, such as Fe, Ca, Mg, Ti, etc., is one of the important scrapping mechanisms. The corundum structure remains stable throughout the service life, while mullite exhibits the opposite phenomenon. The Al-O-Si bonds in the mullite structure are depolymerized by impurity elements to release free tetrahedral structures, including the [AlO₄] tetrahedron and [SiO₄] tetrahedron. In the intervention of iron, the free tetrahedra, including [AlO₄], [FeO₄], and [SiO₄] can bond with each other by sharing bridging oxygen (BO), probably forming Fe-O(BO)-Si, Fe-O(BO)-Al, and Al-O(BO)-Si in an Al₂O₃-SiO₂-Fe₂O₃-Me_xO_y (Me = Ca, Mg, Ti, etc.)-based amorphous phase. These findings provide theoretical support for prolonging the service life of refractory materials in rotary kiln incinerators. Full article

This study shows the results of the combustion of raw and torrefied municipal solid waste. The pellets made of waste were torrefied using a rotary kiln reactor. The average solid yield was 551 g/h. The ratio of solid product mass to the raw material mass (i.e., percentage solid yield, wt%) was 78%. The combustion of the waste/coal mixtures and the torrefied waste was stable, without major problems. The unstable combustion was observed during the combustion of single waste. It was probably caused by the blocking of the portion of raw pellets in the screw feeder. A significantly lower emission of SO₂ (i.e., 43–114 mg/m³ STP ref. to 6 v.% O₂) was observed during the single combustion of torrefied and raw waste. Significantly higher emissions of CO and H-C were observed during the combustion of single raw and torrefied waste. This higher emission should be reduced by the optimization of air distribution. Full article

It is of great significance to effectively identify the flame-burning state of cement rotary kilns to optimize the calcination process and ensure the quality of cement. However, high-temperature and smoke-filled environments bring about difficulties with respect to accurate feature extraction and data acquisition. To address these challenges, this paper proposes a novel approach. First, an improved denoising diffusion probability model (RE-DDPM) is proposed. By applying a mask to the burning area and mixing it with the actual image in the denoising process, local diversity generation in the image was realized, and the problem of limited and uneven data was solved. Secondly, this article proposes the DAF-FasterNet model, which incorporates a deformable attention mechanism (DAS) and replaces the ReLU activation function with FReLU so that it can better focus on key flame features and extract finer spatial details. The RE-DDPM method exhibits faster convergence and lower FID scores, indicating that the generated images are more realistic. DAF-FasterNet achieves 98.9% training accuracy, 98.1% test accuracy, and a 22.3 ms delay, making it superior to existing methods in flame state recognition. Full article

The global smelting business of nickel using rotary kilns and electric furnaces is expanding due to the growth of the secondary battery market. Efficient operation of electric furnaces requires consistent calcine temperature in rotary kilns. Direct measurement of calcine temperature in rotary kilns presents challenges due to inaccuracies and operational limitations, and while AI predictions are feasible, reliance on them without understanding influencing factors is risky. To address this challenge, various algorithms including XGBoost, LightGBM, CatBoost, and GRU were employed for calcine temperature prediction, with CatBoost achieving the best performance in terms of MAPE and MLSE. The influential factors on calcine temperature were identified using SHAP from XAI in the context of the CatBoost model. SHAP effectively assesses model impacts, accounting for variable interdependencies, and offers visualization in high-dimensional contexts. Given the correlation and dimensionality of variables predicting calcine temperature, SHAP was preferred over Feature Importance or PDP for the analysis. By incorporating seven out of twenty operational factors like burner fuel and reductant feed rate, combustion conditions inside of the rotary kiln and RPM, the calcine temperature increased from 840 °C in 2023 to 910 °C by October 2024, concurrently reducing the electricity unit consumption of the electric furnace by 7.8%. Enhancements to the CatBoost algorithm will enable the provision of guidance values after optimizing key variables. It is expected that managing the rotary kiln’s calcine temperature according to the predictive model’s guidance values will allow for autonomous operation of the rotary kiln through inputting guidance values to the PLC. Full article