Burner operating and flame momentum calculation

Plant name Dudfield

Date 6/4/2018
Calculations by: SKY-IN

Inputs:

Barometer 1486 m 847.0 mbar

Relative Humidity 65% 11.4 g H2O/kg dry air
Ambient temperature 20 °C
Production 4000 tpd 167 t/h
Air density, at fan inlet 1.000 kg/m³ 1.284 kg/Nm³

Design data:
Type S-550- 9
Nominal heat consumption 398 kcal/kg cl
Maximum thermal output 96 MW

Operating data:
Heat to kiln 497 kcal/kg cl 2082 MJ/kg cl
Burner output 96 MW
Fuel Lmin,Heat (Average) 1.39 kg air/Mcal
Combustion air, Lmin,flow 32.0 kg/s 89793 Nm³/h
Specific primary air 0.081 kg/kg cl
Air temperature after fan 42 °C

Burner data:
Primary air flow, axial nozzle 250 mbar 25.0 kPa 0.889 kg/m³
Rotation of Jet nozzle 30 °
Calculated 2.666 kg/s 7478 Nm³/h 9601 m³/h
Measured 0.000 kg/s 0 Nm³/h 0 m³/h
Nozzle outlet temp 154 °C
Primary air flow, Swirl 250 mbar 25.0 kPa 1.108 kg/m³
Calculated 1.083 kg/s 3036 Nm³/h 3898 m³/h
Measured 0.000 kg/s 0 Nm³/h 0 m³/h
Nozzle outlet temp 69 °C
Total air flow 3.749 kg/s 10514 Nm³/h 13499 m³/h
Measured 0.000 kg/s 0 Nm³/h 0 m³/h
Deviation 3.749 13499 m³/h

Burner momentum:
m/s N N/MW % Lmin %m/s
Jet air 248 661 6.86 8.3%
-Axial 244 651 6.75 2034
-Radial 22 57 0.60
Swirl air 222 241 2.49 3.4%
-Axial 157 170 1.76 531
-Radial 157 170 1.76
Transport air Coal 29 24 0.25 2.7%
Transport air Solid AF 1 - - 0.00 1.8%

Momentum, Axial 8.52 N/MW 2034 %m/s

Momentum, Radial 2.36 N/MW 531 %m/s

Ratio 0.277 -
Swirl number 0.249 -

Total air from burner % of Lmin 16.2%

Total air - transport 11.7%
Burner operating and flame momentum calculation
Plant name Dudfield
Date 6/4/2018
Calculations by: SKY-IN

Primary air:
Critical pressure 0.76 bar
Isentropic exponent for air 1.40 -
Gas constant for air 289.0 J/kgK

Jet air:
Estimated temperature, burner nozzle 154 °C
Critical air velocity 379 m/s
Speed of sound 416 m/s
Jet nozzle coefficient 0.95 -
Total Jet nozzle area 15306 mm²
Jet diameter 472 mmØ
Flow function 0.222
Pressure ratio 0.772 -
Angle of axial nozzle 10 °

Swirl air:
Estimated temperature, burner nozzle 69 °C
Critical air velocity 340 m/s
Speed of sound 372 m/s
Swirler nozzle coefficient 0.95 -
Front plate cooling nozzle coefficient 0.85 -
Swirler nozzle area 5568 mm²
Swirler Di 388 mmØ
Flow function 0.222
Pressure ratio 0.772 -
Angle of swirl air 45 °

Coal:
Estimated coal temperature at burner tip 60 °C
Coal nozzle area 28055 mm²

Solid AF:
Estimated Solid waste temperature at burn 60 °C
Solid AF 1 nozzle area 0 mm²
Solid AF 2 nozzle area 0 mm²

Gas:
Fuel gas inlet temp. (before gas station) 0 °C
Critical pressure 0.00 bar
Critical gas velocity #DIV/0! m/s
Speed of sound #DIV/0! m/s
Isentropic exponent for fuel gas 0.00 -
Gas constant for fuel gas #DIV/0! J/kgK
Nozzle coefficient for Gas 0.95 -
Flow function, Gas #DIV/0!
Pressure ratio 1.000 -
Gas nozzle area #VALUE! mm²
General information: Plant: Dudfield
Kiln type: 0
Project No.: 17-20250
PD diagram date: Questionaire
Country: South Africa
Norm. tpd: 4000
Norm kcal/kg: 398
Max. MW: 96
Jetflex burner type: S-550- 9
Height above sea level h: 1486 m
Ambient pressure pamb: 847 mbar
Ambient temperature (average) tamb: 20 °C
Kiln I.D.: 5.5 m
Kiln length: 66 m
Inclination: 4%
Blank field 1
Blank field 2
Net heat value: Coal: 5000 kcal/kg
Oil: 10000 kcal/kg
Gas: 0 kcal/Nm3
Blank field 1
Blank field 2
Theoretical air amount: Fuel gas firing Lgas: 0.00 kg air/Mcal
Fuel oil Lwoil: 1.41 kg air/Mcal
Waste oil Ltoil: 0.00 kg air/Mcal
Solid waste 1 LSD: 1.39 kg air/Mcal
Solid waste 2 LSD: 0.00 kg air/Mcal
Coal firing Lbri: 1.39 kg air/Mcal
Blank field 1
Blank field 2
Primary air nozzle: Axial nozzle Aax: 14356 mm2
Axial cool nozzle Aaxcool: 950 mm2
Angle of axial nozzle αax: 10 °
Number of nozzles n: 20
Total jet nozzle area Atot: 15306 mm2
Swirl nozzle Aswirl: 5568 mm2
Swirl cooling hole Aswirlcool: 550 mm2
Swirl cooling annulars/gaps Aswirlannu: 570.5 mm2
 Angle of swirl air αswirl: 45 °
Swirler Di 388 mm
Rotation of jet nozzle 30 °
Blank field 1
Primary air calculation: Estimated primary air temperature, axial nozzle tax: 153.6 °C
Estimated primary air temperature, swirl nozzle tswirl: 69.4 °C
Axial pressure pax: 250 mbar
Swirl pressure pswirl: 250 mbar
Axial mass flow ṁax: 2.57 kg/s
Swirl mass flow ṁswirl: 1.19 kg/s
Axial nozzle coefficient 0.95
Swirl nozzle coefficient 0.95
Axial cool nozzle coefficient 0.7
Swirl cooling hole nozzle coefficient 0.85
Swirl cooling annular/gap nozzle coefficient 0.6
Swirl number 0.2
Blank field 1
Fuel gas, kiln: Maximum flow Vmax: 0 Nm3/h
Fuel gas data: Fuel gas temperature tgas: 20 °C
Isentropic exponent for fuel gas k: 1.31
Fuel gas density ϱ: kg/Nm3
Fuel gas nozzle velocity vgas 374 m/s
Fuel gas nozzle coefficient 0.95
Blank field 1
Fuel gas calculation: Fuel gas temperature (IR measurement) tgas: 0 °C
Isentropic exponent for fuel gas k: 0
Fuel gas firing, max. 0 Nm3/h
Nozzle inlet gas pressure, max. 0 bar
Fuel gas density ϱ: 0 kg/Nm3
Fuel gas area, start A: 0.00 mm2
Fuel gas area, end A: 0.00 mm2
Fuel gas nozzle Di Di: 0 mm
Fuel gas nozzle Do Do: 0 mm
Gas sideways angle α: 10 deg
Gas outward angle α: #VALUE! deg
Coal channel: Coal channel area Acoal: 28055.2 mm
Estimated coal temperature at burner tip tc: 60 °C
Coal transport air volume flow Vtr: 51.0 m3/min
 Coal pipe Di Di: 189 mm
Maximum flow ṁmax: 16583 kg/h
Blank field 1
Fuel oil, kiln: Maximum flow ṁmax: 2600 kg/h
Atomiser type Type: OBA
Blank field 1
Blank field 2
Solid waste: Estimated solid waste temperature at burner tip tsolid: 60 °C
Solid waste channel 1: Solid waste nozzle area Atr: 0 mm2
Solid waste transport air volume flow Vtr: #VALUE! m3/min
Solid waste pipe Di Di: 0 mm
Solid waste channel 2: Solid waste nozzle area Atr: 0 mm2
Solid waste transport air volume flow Vtr: 0 m3/min
Solid waste pipe Di Di: 0 mm
Blank field 1
Blank field 2
Liquid alternative fuels, kiln:
Max. Flow,
No. Description kcal/kg Kg/h
1 0 0
2 0 0
Blank field 1
Blank field 2
Solid alternative fuels, kiln:
Max. Flow,
No. Description kcal/kg Kg/h
1 Common fuel pipe: 2986 4966
2 Side-by-side or single AF: 0 0
3 Special: 0 0
Blank field 2
Gas swirler positions
Position [%] Area [mm2] Nozzle pressure
0 #VALUE! 500
10 #VALUE!
20 #VALUE!
30 #VALUE!
40 #VALUE!
50 #VALUE!
60 #VALUE!
70 #VALUE!
80 #VALUE!
90 #VALUE!
100 #VALUE! 250