Reduciner
REDUSIM / USER GUIDE

How the simulator works

ReduSim calculates the kiln's mass and energy balances from your inputs: combustion, oxygen enrichment, flue-gas recirculation, thermochemical reduction of CO₂ into CO gas, and firing that gas back in the kiln. Fill in the tabs from left to right — each tab builds on the previous ones. Below is a section-by-section guide to every input and to comparing results.

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0
Tab · 0 Site

Simulation target and map

  • Enter the partner company, site / plant and the partner's contact person. These are stored with the calculation and shown in the saved-calculations list.
  • Set the person responsible for the simulation — press "Me" to use your own email address.
  • Draw the plant area (dashed line) on the map, then process locations inside it, plus CO₂ and CO transfer lines and power lines. Close a polygon by clicking its first point; finish a line by clicking its last point again.
  • Name the drawn features in the list below the map; they are saved with the simulation.
1
Tab · 1 Process

Kiln process and fuel

  • Enter kiln production (t CaO/h) and specific heat demand (default 1.05 MWh/t CaO). These give the total process heat demand in MW.
  • Select the primary fuel (e.g. natural gas or coke oven gas) and check its ultimate analysis and heating value — gaseous fuels also show LHV in MJ/Nm³.
  • Set the excess air ratio (default 1.05) and the cooling air flow. Cooling air affects total flue gas in a conventional PFR kiln.
  • The mass balance table shows combustion and calcination gas flows; check that "Total flue gas" matches the expected stack flow.
2
Tab · 2 Enrichment

Oxygen enrichment and flue-gas recirculation

  • Enable oxygen enrichment and set the combustion air O₂ content (vol-%). Higher O₂ reduces flue-gas volume and enriches its CO₂.
  • Optionally enable filter flue-gas recirculation: part of the flue gas is routed back to combustion, reducing the stack flow.
  • Select EcoKiln mode if cooling air is separated from the flue gas — the flue gas becomes clearly richer in CO₂.
  • Watch the cards: flue-gas CO₂ content (wet vol-%), flue-gas flow and change versus the base case.
3
Tab · 3 Reduction

Reduciner reducer and biochar

  • Choose how much flue gas is diverted to the reducer: flow (Nm³/h), share (%), CO energy (MW), electric power (kW) or the dynamic mode where the entire fuel demand is covered by CO gas.
  • Set the reducer electric power and its limit. The app warns if the limit curtails output.
  • Check biochar feed and properties; the reduction reactions (Boudouard, water-gas, partial oxidation) determine CO-gas yield.
  • The energy balance shows reaction heats, gas and char heating and electric power — the reactions are endothermic, so electricity covers the net demand.
  • Check reactor dimensions (diameter, length, fill) and residence time — a red value means the residence time is too short.
4
Tab · 4 CO firing

CO-gas firing in the kiln

  • Review the produced CO gas composition (CO, H₂, CH₄, CO₂, N₂, H₂O), flow (Nm³/h), thermal power (MW) and heating value (MJ/Nm³).
  • Decide whether CO gas substitutes the primary fuel: when substitution is on, the primary fuel flow decreases accordingly.
  • Set the CO-firing excess air ratio (default 1.05). The mass-balance row "CO-gas firing" is computed from the simulated gas composition and the actual combustion air — oxygen firing is taken into account.
  • Compare the cards: fuel power in MW and the CO-gas share (MW and %) of total fuel power.
5
Tab · 5 Capacity

Sizing of piping and equipment

  • Review the calculated pipe sizes for flue-gas, CO and air lines — size is derived from flow and the chosen velocity (default 15 m/s).
  • The CO line pressure is assumed at 350 mbar(g); adjust to match your plant if needed.
  • Use the results for preliminary sizing of transfer lines and to check the transfer lines on the map.
6
Tab · 6 Cost

Investment and operating costs

  • Enter or review CAPEX items (reactor, gas handling, electrification etc.). Reactor CAPEX is estimated from simulated electric power unless entered manually.
  • Set OPEX inputs: electricity price, biochar price, maintenance and personnel.
  • Compare the €/MWh levelised cost with alternative fuel prices — note the comparison is fair only with identical inputs.
  • All default prices are estimates; always replace them with site-specific figures before making decisions.
7
Tab · 7 Part load

Part load and comparison of simulations

  • The part-load tab shows how flue-gas composition (CO₂, O₂, H₂O, N₂), power and the mixture LHV (MJ/Nm³) change with load. The dashed line marks the current simulation setup.
  • In the comparison section you pick saved calculations (e.g. different options for the same site) and see their key results side by side — up to 12 simulations at once.
  • Save each scenario under its own name (Calculations menu) so they are available for comparison. Partner and site details help identify the right rows.
  • Compare especially: flue-gas CO₂ content, CO-gas flow and LHV, electric power, biochar consumption and the €/MWh cost.

Saving and comparing scenarios

Save every scenario with the save button in the simulator header — the owner updates the open calculation, others save a copy. Open saved calculations from the Calculations menu or your profile, and compare them side by side in the part-load tab's comparison section. This makes it easy to evaluate e.g. oxygen enrichment versus recirculation versus full CO operation for the same site.

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