Empress Catherine II Saint Petersburg Mining University, Saint-Petersburg, Russia

E. R. Fedorova, Candidate of Engineering Sciences, Department of Automation of Technological Processes
and Productions, e-mail: apm_07_2@mail.ru
V. V. Morgunov, Post-Graduate Student, Department of Automation of Technological Processes and Productions,
e-mail: vova.morgunov2011@yandex.ru
E. A. Pupysheva, Post-Graduate Student, Department of automation of Technological Processes and Productions,
e-mail: elena.pupysheva1@gmail.com

Tubular rotary kilns are actively used in non-ferrous metallurgy, for example for sintering nepheline with limestone in alumina production. For the most effective heat exchange due to good mixing of the material in rotary kilns, a rolling regime characterized by the presence of an active layer and a stagnant area is maintained. Also the problem of formation of coating layers inside the kiln, which leads to a narrowing of the inner diameter of the aggregate, is known. In this paper, using the DEM-modeling method the influence of limes on the active layer parameters: the average speed of particles in the active layer and the share of the active layer in the aggregate at different rotational speeds and the degree of filling of the drum. With the increase of the coating layers thickness the average speed of particles in the active layer and the proportion of particles in the active layer in the entire profile of the kiln increases, changes in the shape of the profile of the speed of particles in the active layer and the proportion of particles in the active layer, depending on the thickness of coating layers are observed. The obtained conclusions are of qualitative nature and indicate a significant influence of the coating layers thickness on the active layer parameters and the need for further study of this process on the physical model with the real charge material.

1. Anisonyan K. G., Kopyev D. Yu., Olyunina T. V., Sadykhov G. B. Influence of Na₂CO₃ and CaCO₃ Additions on the Aluminate Slag Formation During a Single-Stage Reducing Roas ting of Red Mud. Non-ferrous Metals. 2019. No. 1. pp. 17–21.
2. Petrov P. A., Shestakov A. K., Nikolaev M. Yu. Use of Multifunctional Crust Breaker and Machine Vision System for Acquisition and Processing of Aluminium Reduction Cell Data. Tsvetnye Metally. 2023. No. 4. pp. 45–53.
3. Shestakov A. K., Petrov P. A., Nikolaev M. Y. Automatic System for Detecting Visible Emissions in a Potroom of Aluminum Plant Based on Technical Vision and a Neural Network. Metallurgist. 2023. Vol. 66, Iss. 9-10. pp. 1308–1319.
4. Bazhin V. Yu., Masko O. N., Martynov S. A. Automatic Burden Balance Monitoring and Control in the Production of Metallurgical Silicon. Tsvetnye Metally. 2023. No. 4. pp. 53–60.

5. Machalek D., Powell K. M. Model Predictive Control of a Rotary Kiln for Fast Electric Demand Response. Minerals Engineering. 2019. Vol. 144. 106021.
6. Zubov V. P., Yunpeng L. Slicing Mining of Thick Gently Dipping Coal in China: Problems and Improvement. MIAB. 2023. Iss. 7. pp. 37–51.
7. Bazhin V. Yu., Masko O. N., Nguyen Huy H. Increasing the Speed of Information Transfer and Operational Decision-Making in Metallurgical Industry Through an Industrial Bot. Non-ferrous Metals. 2023. No. 1. pp. 62–67.
8. Rozhkov V. V., Krutikov K. K., Fedulov A. S., Fedotov V. V. Simulation of Induction Motors with Energy Recuperation for Lifting Mechanisms of Non-Ferrous Metallurgy Enterprises. Non-ferrous Metals. 2021. No. 1. pp. 74–80.
9. Pancnehko S. V., Dli M. I., Bykov A. A. Simulation and Algorithmization of Analysis of Heat and Mass Transfer Processes in Chemical Electrothermy Units in Non-Ferrous Metallurgy. Non-ferrous Metals. 2022. No. 1. pp. 46–54.
10. Henein H., Brimacombe J. K., Watkinson A. P. Experimental Study of Transverse Bed Motion in Rotary Kilns. Metallurgical Transactions B. 1983. Vol. 14, Iss. 2. pp. 191–205.
11. Mellmann J. The Transverse Motion of Solids in Rotating Cylinders-Forms of Motion and Transition Behavior. Powder Technology. 2001. Vol. 118, Iss. 3. pp. 251–270.
12. Pieper C., Wirtz S., Schaefer S., Scherer V. Numerical Investigation of the Impact of Coating Layers on RDF Combustion and Clinker Properties in Rotary Cement Kilns. Fuel. 2021. Vol. 283. 118951.
13. Khodorov E. I. Cement Industry Furnaces. 2nd ed., revised. Leningrad: Stroyizdat, 1968. 456 p.
14. Mujumdar K. S., Ranade V. V. CFD modeling of rotary cement kilns. Asia-Pacific Journal of Chemical Engineering. 2008. Vol. 3, Iss. 2. pp. 106–118.
15. Cundall P. A., Strack O. D. L. A Discrete Numerical Model for Granular Assemblies. Geotechnique. 1979. Vol. 29, Iss. 1. pp. 47–65.
16. Moncada M., Toledo P., Betancourt F., Rodríguez C. G. Torque Analysis of a Gyratory Crusher with the Discrete Element Method. Minerals. 2021. Vol. 11, Iss. 8. 878.
17. Ilyushin Y. V., Martirosyan A. V. The Development of the Soderberg Electrolyzer Electromagnetic Field’s State Monitoring System. Scientific Reports. 2024. Vol. 14. 3501.
18. Kukharova T.V., Ilyushin Y. V., Asadulagi M. M. Investigation of the OA-300M Electrolysis Cell Temperature Field of Metallurgical Production. Energies. 2022. Vol. 15, Iss. 23. 9001.
19. Shklyarskiy Y. E., Skamyin A. N., Jiménez Carrizosa M. Energy Efficiency in the Mineral Resources and Raw Materials Complex. Journal of Mining Institute. 2023. Vol. 261. pp. 323–324.
20. Skamyin A., Shklyarskiy Ya., Lobko K., Dobush V., Sutikno T., Jopri M. H. Impedance Analysis of Squirrel-Cage Induction Motor at High Harmonics Condition. Indonesian Journal of Electrical Engineering and Computer Science. 2024. Vol. 33, Iss. 1. pp. 31–41.
21. Korobkov G. E., Yanchushka A. P., Zakiryanov M. V. Numerical Modeling of a Stress-Strain State of a Gas Pipeline with Cold Bending Offsets According to in-Line Inspection. Journal of Mining Institute. 2018. Vol. 234. pp. 643–646.
22. Sebastian Escotet-Espinoza M., Foster C. J., Ierapetritou M. Discrete Element Modeling (DEM) for Mixing of Cohesive Solids in Rotating Cylinders. Powder Technology. 2018. Vol. 335. pp. 124–136.
23. Hlosta J., Jezerská L., Rozbroj J., Žurovec D., Necas J., Zegzulka J. DEM Investigation of the Influence of Particulate Properties and Operating Conditions on the Mixing Process in Rotary Drums: Part 2-Process Validation and Experimental Study. Processes. 2020. Vol. 8, Iss. 2. 184.
24. Santos D. A. Investigation of Particle Dynamics in a Rotary Drum by Means of Experiments and Numerical Simulations Using DEM. Advanced Powder Technology. 2016. Vol. 27, Iss. 2. pp. 692–703.
25. Xiao Y. L., Specht E., Mellmann J. Experimental Study of the Lower and Upper Angles of Repose of Granular Materials in Rotating Drums. Powder Technology. 2005. Vol. 154, Iss. 2-3. pp. 125–131.
26. Chatterjee A., Mukhopadhyay P. K. Flow of Materials in Rotary Kilns Used for Sponge Iron Manufacture: Part III. Effect of Ring Formation Within the Kiln. Metallurgical Transactions B. 1983. Vol. 14, Iss. 3. pp. 393–399.
27. Zheng X., Jin B., Zhang Y., Zhang Y., Zhou C. Numerical Simulation of Flow Characteristics in an Inclining Rotating Kiln with Continuous Feeding. International Journal of Chemical Reactor Engineering. 2019. Vol. 17, Iss. 10. 20180203.
28. Scatena R., Ferreira L. C., Santos D. A ., Duarte C. R., Barrozo M. A. S. Tambor Rotatório Operando No Regime De Rolamento: Um Estudo Experimental E Numérico. Anais Do XX Congresso Brasileiro de Engenh aria Quimica. 2015. pp. 6305–6312.
29. Santos D. A., Petri I. J., Duarte C. R., Barrozo M. A. S. Experimental and CFD Study of the Hydrodynamic Behavior in a Rotating Drum. Powder Technology. 2013. Vol. 250. pp. 52–62.
30. Alexandrov A. V., Nemchinova N. V. Calculation of the Expected Economic Efficiency of Aluminum Production by Increasing the Use of Alumina of Domestic Production. Proceedings of Irkutsk State Technical University. 2020. Vol. 24. pp. 408–420.