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Volume 113
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Locally resolved DEM/CFD simulations of a generic oxy-fuel kiln for lime production (Open Access)
Maximilian Brömmer *, Enric Illana Mahiques, Viktor Scherer
Ruhr University Bochum, Institute of Energy Plant Technology, Universitätsstraße 150, 44780, Bochum, Germany
10.1016/j.partic.2026.03.028
Volume 113, June 2026, Pages 236-248
Received 2 February 2026, Revised 10 March 2026, Accepted 17 March 2026, Available online 1 April 2026, Version of Record 8 April 2026.
E-mail: broemmer@leat.rub.de
Highlights

• 3D DEM/CFD simulation of a single shaft kiln in oxy-fuel operation.

• Particle- and flame-resolved gas flow in a shaft kiln.

• Hybrid resolved-unresolved particle representation in gas flow.


Abstract

Limestones release CO2 during their decomposition in shaft kilns, which is typically initiated by the combustion of natural gas. Oxy-fuel technology is one option to mitigate CO2 emissions by enabling carbon capture methodologies but induces more challenging process conditions.

3D DEM/CFD simulations can compute the complex interaction of particles and gas flow but usually rely on spatial averaging of the gas-phase, which cannot capture all flow details. For a more detailed description of the processes, resolving the interstitial gas flow and the flame front inside the particle assembly is necessary. This study examines a down-scaled single-shaft lime kiln, utilizing an approach to locally resolve the gas flow in the most important region at the burner lances. The kiln has a height of 2.5 m, a diameter of 0.64 m, and contains 22,400 limestone particles of four different diameters. Two different simulation approaches are compared, the conventional unresolved method and the locally resolved approach. Results show minor differences in the average particle conversion degree. Higher differences are found in the local distribution of conversion degree and maximum particle temperatures. Unresolved simulations predict higher temperatures, leading to a deterioration of quicklime reactivity and potentially harming product quality, as details of the flow features are not captured. Consequently, the results indicate that unresolved simulations are a good approximation for the mean calcination degree of the particles but for more sensitive details, such as product quality, a higher-resolution simulation is necessary.


Graphical abstract
Keywords
DEM/CFD; Packed bed; Calcination; Oxy-fuel; Limestone
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