R O T A F L A M

PRESENTATION
2002
PILLARD R O T A F L A M

Rotary Kiln Burner

Development and actual Design
ROTAFLAM

The flexible combustion tool for rotary kilns

(protected by patent)
History
PILLARD burner type VR
First multi channel burner
developed over 30 years ago.
Over 600 burners have been
operated successfully.
Initial requirements
for new burner development
Significant reduction of NOx emission
Most efficient adaption of heat transfer to the product
Energy saving
ROTAFLAM

/ VR burner design
Axial air channel
Coal channel
Radial air channel
Axial air channel
Coal channel
Radial air channel
Flame stabilizer
VR burner:
Static pressure 120 mbarg
Pressure at tip Pu 85 mbarg
Flow Q 10 12 % of total
Specific kinetic energy:
Q x Pu = 10 x 850 = 850
ROTAFLAM:
Static pressure 160 mbarg
Pressure at tip Pu 150 mbarg
Flow Q 6% of total
Specific kinetic energy:
Q x Pu = 6 x 150 = 900
ROTAFLAM

characteristics
Flame stabilizer
Coal duct
Radial air swirler
Axial air slots
Axial ring
ROTAFLAM

main targets of development

More equal heat distribution avoiding
temperature peaks to decrease NO
formation and reduce thermal stress
on kiln lining
Concentration of fuel along burner axis by
arrangement inside swirl air duct, in order
to avoid that fuel particles leave the main
flame contour and burn in the hot secon-
dary air atmosphere under superstoichio-
metric conditions
Variations of the primary air flows for
flame adjustment by changing
burner tip geometry during operation
Flame stabilization without using the swirl
air component, thus reduction of total
primary air input for flame shaping and
decrease of oxygen concentration in the
primary combustion zone
Early fuel ignition and stable flame even
in cold kiln
Improved burner tip aerodynamics
allowing flame shaping with a minimum of
primary air input and maximum outlet
velocity
ROTAFLAM

type O
(single oil operation)
ROTAFLAM

type GO
(gas and oil operation)
ROTAFLAM

type KO
(coal and oil operation)
ROTAFLAM

type KGO
(coal, gas and oil operation)
ROTAFLAM

adjusting device
Mechanical adjusting device
Hydraulic adjusting device
ROTAFLAM

type KGO
Burner tip variation by longitudinal
adjustment

Reset
Flame shaping by air flow variation
START
100% 100%
Axial
Radial
STOP
ROTAFLAM

small scale test

Flame adjustment by air flow variation
with a small ROTAFLAM

test burner
showing short hot flame, long flame and wide soft flame
Click on picture to start and stop the video
Flame shape adjustment by variation
of fuel flow distribution
PILLARD MYS atomizer gun for rotary kiln burners
Atomizer system MYS
Flame shaping by variation of oil
differential pressure
START
40 bar
Primary
STOP
39 bar
Secondary
13 years of continuous improvement
Increasing flexibility to satisfy more critical process requirements
NOx reduction and low primary air consumption are no longer the cement producers
main requirements.
Stable kiln conditions and energy saving by substitution of primary fuels by low
cost secondary or alternative fuels without affecting the kiln operation have
become new main targets.
Revision of the former basic design criteria was essential:
ROTAFLAM - New generation
Designed for 8% of primary air
Fan capacity 10% of primary air
Static pressure 250 mbar
ROTAFLAM - 1. Generation
Designed for max. 6% of primary air
Fan capacity max. 7% of primary air
Static pressure 160 mbar
13 years of continuous improvement
Extended burner operation with low cost liquid (waste) fuels
Waste oil
Solvents
Residues from oil industry
Contaminated water
Complete individual fuel supply system is required.
Varying chemical properties and content of solid impurties have
to be considered for the design of equipment to prevent from
incredible wear and the risk of interruption of kiln operation
due to plugging of atomizer system.
Fuel pressure: 8-12 bar
Atomizing air: 6- 8 bar
Max. particle size: 6 mm
Liquid waste atomization
13 years of continuous improvement
13 years of continuous improvement
Flame stabilizer and central air circuit
allow installation of additional fuel
feeding systems
Liquid waste atomization
13 years of continuous improvement
Extended burner operation with low cost solid (waste) fuels
Petroleum coke
Bark powder
Wood powder
Municipal waste (depending on degree of preparation)
Tyres (depending on degree of preparation)
Agricultural derived fuels
Plastics
Paper
Animal powder
13 years of continuous improvement
Examples of solid (waste) fuels
Click on picture to start and stop the video
New development
The PILLARD solid (waste) fuel swirler unit
(protected by patent)
Portion of primary air
(pressure 250 mbar)
Solid waste
with transport air
Swirler
nozzles
The PILLARD solid waste swirler unit
Test arrangement : First sequence without swirl air
Click on picture to start and stop the video
The PILLARD solid waste swirler unit
Test arrangement : Second sequence with swirl air
Click on picture to start and stop the video
ROTAFLAM

Three ROTAFLAM

burners KO-S ready for shipment

Click on picture to start and stop the video
+20/-45
+10/-30
+10/-50
+20/-50
Coal: 15.000 kg / h
Heavy fuel oil: 11.000 kg / h
Plastics (Tetrapak): 12.000 kg / h
ROTAFLAM

burner KO-S 125 MW
for Rohrdorf Zement Plant
Actually 10.000 kg / h of Tetrapak
primary fuel substitution rate: 60%
Coal: 9.855 kg / h
Heavy fuel oil: 6.300 kg / h
Plastics (Tetrapak): 3.500 kg / h
ROTAFLAM

burner KO-S 93 MW
for HOLCIM Untervaz Zement Plant
Waste oil: 6.750 kg / h
Animal powder: 3.000 kg / h
Distillation residuals: 1.500 kg / h
Contaminated water: 500 kg / h
Solid wastes
Liquid wastes
Heavy fuel oil
Flame stabilizer
Petcoke: 10.000 kg / h
Heavy fuel oil: 9.050 kg / h
Natural gas: 9.970 Nm/ h
ROTAFLAM

burner KGO 98 MW
for Mrida Yucatan Plant Cementos Maya Kiln 5
Installation of the burner Start-up flame
Petcoke: 3.700 kg / h
Heavy fuel oil: 3.300 kg / h
Natural gas: 3.600 Nm/ h
ROTAFLAM

burner KGO 35 MW
for Plant Monterrey Kiln 5
More than 500
ROTAFLAM

burners
since 1989
testify success
ROTAFLAM

The most flexible combustion tool for rotary kilns