102 Fuel Firing Systems PDF

05-09: Fuel and Firing Systems
©FLSmidth A/S 2016, all rights reserved. The information contained or referenced in this presentation is confidential
Fuel & Firing Systems 1
and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Scope of lecture
 The combustion process

 Fuel types
 Main burner equipment
 Break
 Calciner burner and coal firing equipment

 How to handle your burner equipment
 Burner upgrades
 Trends for future
Filter Filter
Crusher
Analyzer
Limestone Clay Sand Iron
1 2 3 4 Raw meal
silo
Storage
Coal mill
1
2
4 3
Raw mill
Clinker
Silo
Separator
Packers
2 3
Cement Cement
silo silo
Cement
silo
Cement mill
Gear unit Ship unloading
Roller press
Ship loading
©FLSmidth A/S 2016, all rights reserved. 3

The information contained or referenced in this presentation is confidential
Typical In-Line Calciner system
Kiln burner
Calciner burner

Scope of lecture
The combustion process
Burning cement requires:
Fuel
Burner
Temperature Combustion air

Definitions
Tertiary air
(hot to calciner)
Primary air
(cold)
Fuel
Secondary air
(hot)
Where is air added Requirement for combustion
LP + LS + (LT) = Lmin + LO
Cold Hot Hot stoichiometric + Excess air

Kiln burner selection
•Flame formation & heat transfer
•Burner design
•Primary air momentum

Flame formation and heat transfer
 Important parameters:
- Fuel type/quality
- Combustion air
- Excess air Temperature
- Mixing rate
- Burner type

Heat radiation depends on the fuel used
Q    T 4
ecoal  up to 1,0
eoil  0,7 - 0,9
egas  0,3 - 0,9
Stefan-Boltzmanns
Constant:
  5 ,6697  10 8 W  m 2 K 4
NOTE: 90% of the heat input to the charge comes from
radiation!

Burner considerations
 Must be able to burn coal, coke, fuel oil, natural gas, waste
fuels and mixtures here of.
 A short, narrow, strongly radiant flame.
 Dense, stable coating on the refractory in the burning zone of

the kiln.
 Must use as little primary air as possible

Burner design
Parameters to be considered
 Primary air momentum
 Primary air swirl
 Number of burner channels

Burning requires mixing of fuel and air
 Flame formation in a rotary kiln
Fuel and
primary air
Swirl air Internal External

Hot recirculation recirculation
secondary air zone zone

Momentum is the deciding parameter for
flame formation [N/MW]
(Air mass flow rate) x (discharge velocity)/(heat release rate):

.
m air  c
N/MW
Q
or:
(% of Lmin) x (discharge velocity):
L p  c%m/s 
Example: Duoflex burner, 250 mbar: 10% x 210 m/s = 2100 %m/s
Conversion: 1 N/MW y 300 %m/s
Comparison of PA% versus momentum
Examples:
 Uniflow burner: 20% x 75 m/s = 1500 %m/s
 Swirlax burner FCO, 120 mbar: 10,7% x 140 m/s = 1500 %m/s
 Swirlax burner SCO, 160 mbar: 9,4% x 160 m/s = 1500 %m/s
 Duoflex burner, 250 mbar: 7,5% x 200 m/s = 1500 %m/s
 Centrax burner, 750 mbar: 4,3% x 350 m/s = 1500 %m/s
Conversion:
1 N/MW y 300 %m/s

Large operational flexibility is needed
Secondary fuels
Antracite, petcoke
Medium volatil coal
Fuel oil
Fuel gas
0,00 2,00 4,00 6,00 8,00 10,00 12,00

Total momentum N/MW
Scope of lecture
Fuel types
Fuel types
• Primary/main fuels
• Solid (Coal, Petcoke)
• Liquid (Fuel oil)
• Gaseous (Natural gas)
• Secondary fuels
• Solid, liquid or gaseous waste
Dried paper Wood chips Rice husk

RDF
sludge
Plastics
Used oils

Main fuels used in cement production
Alternative fuel substitution
Fuel types comparison
•Easy to ignite
•No preconditioning
•No ash -
•Low cost •No storage white cement
Advantages
•High radiation •Low S content •Usually back-up
•Low momentum fuel
required
Liquids
Alternative fuels Coal/petcoke
kcal/kg
3500 5.000 6.000 7.000 8.000 9.000 10.000
•Need for grinding •Expensive

•Expensive
Disadvantages •Storage •High H content
•Needs
•Large volumes •Low radiation preconditioning
•Needs high •High ignition •Needs storage
temperature –
momentum •High S content
explosion risk
Solid fuels
typical data
% Net. Air
volatile kcal/kg kg/kg
Lignite 40-50 4820 7,1
Bitum. coal 10-40 6310 9,2
Antracite 5 6900 9,9
Petcoke 11 8300 11,5

Solid fuels
typical data
Total Hygro Ash C H S (N+O)

moisture scopic % % % % %
% water
%
Lignite 40-50 10-25 5-25 56 4 1 19
Bitum. 5-10 1-3 10-20 70 3 1 3

coal
Antracite 0-3 1 5-10 78 2 1 2
Petcoke 0,6 0 0,2 87 3,8 5 2-3

Coal dust - proper fineness is essential
Coal to calciner
never coarser
than to kiln
Typ. Value, Petcoke:

As fine as possible

About petcoke firing
Advantages Disadvantages
Normally low cost per kcal Low volatile content
Consistent analysis High sulphur content

•Low ash content Build ups
•High calorific value
•Raw mix as for oil firing => Burner
easy shift
requirement
More chemically stable than coal Slow combustion
•Less tendency of spontaneous High momentum required
combustion High excess air amount
•low explosion tendency in the recommended (15-20%)
mill
Low wear Blending with coal often necessary
Finer grinding - 5 % on 90
microns– upgrade of mill system

Liquid fuels
Typical data
Fuel type Necessary Net. Air

temp. kcal/kg kg/kg
Gas oil 0 °C 10200 14,4
Light fuel oil

60 °C 9900 14,2
Heavy fuel oil

120 °C 9750 14

Gaseous fuels
Typical data
% Net. Air
CH4 kcal/Nm3 kg/Nm3
(Methane)
Dutch
81,7 7580 10,91
(Groningen)
Saharan 86,5 9750 13,96
North Sea
91,8 8760 12,6
(Typical)
Russian
97,6 8400 14,04

Alternative fuels
Typical data
% Net. Air
C kcal/kg kg/kg
Rubber
66,8 7090 9,66
~Equivalent
to 1 kg coal
Wood
47,2 4360 5,68
Rice husk
38,5 3230 4,65
Paper
43,4 3730 5,06
Can only be used with high calorific value fuels

Fuel characteristics influencing
flame formation
Ignition Theoretical
temperature flame temperature
°C
°C
Coal 450-600 2150
(Smouldering temp.) (200-300)
Oil 300-550 2120

Gas 600-700 2050

Scope of lecture
Main burner equipment

Kiln burner
Oil and gas firing equipment
Main burner evolvement
Single Multi Low Swirl & High

Channel channel Primary momentum
Brand Uniflow Swirlax, Centrax, Pyro- Duoflex, Novaflam,

names Rotaflam Jet JETFLEX
Max air 70-80 120-140 >300 210-260
nozzle
velocity
m/s
Fuel One Multiple Multiple Multiple
possibilities
Advantages Simple •PA% 10-12 PA% 4 •PA% 8-10 (up to
Low cost •Flame 15)
adjustment •High fuel
possible concentration in
flame core
•Suitable for
alternative fuels
Dis- •PA% 20-25 •Complicated Not suitable for High initial cost
advantages •Flame shape •Risk of alternative fuels
adjustment divergent flame
difficult

Installation overview
1) Kiln hood 8) Flame safety/Burner

2) Burner seal management
3) Trolley 9) Coal dosing system
4) Ignition gas burner 10)Emergency air fan
5) Flexible connections 11)Primary air fan
6) Primary air ducting 12)Burner sets for oil and/or
7) Valve trains gas
Main kiln burner – Duoflex type

Front end view - Duoflex

Front end of burner - Duoflex
Radial air
channel
Axial air
channel
Coal meal channel Central air duct Oil burner lance

Burner tip
2-nozzle burner, type B (FLS Duoflex)
>210 m/s
~30 m/s

Solutions for waste co-firing

Liquid fuel atomizers
 Main purpose
 Atomize liquid into droplets of suitable size
 Distribute the droplets in the combustion air
 Two solutions exists
1. Atomization by liquid pressure
2. Atomization by air

Pressure atomizing - TFSM
High liquid pressure is required
Oil burner head
Liquid fuel inlet

No particles allowed
Tangential slot
openings, adjustable

Air atomizing - OBA
Air or steam supply is required
Mixing
chamber Liquid fuel
Liquid fuel
Particles
Atomising air allowed
Nozzle holes Burner head Atomising
air

Oil valve train – safe control of flow and
function
Flow measuring unit Shut-off unit with double

with mass flow meter block function
Gas burner systems
•Burner lances
•Valve train

Fuel gas burner lance – Oil/Gas
Shown with oil burner mounted

Gas nozzle in Oil burner
closed position regulator
Gas nozzle in Gas inlet

open position pressure from
gas station
0-3 bar.

Gas firing
Velocity and flow, relative to pressure
450 3,50
400
3,00
350
Velocity 2,50
300
Flow, Nm3/h mm2

Velocity, m/s
250 Flow 2,00
200 1,50
150
1,00
100
0,50
50
0 0,00
0,0 0,5 1,0 1,5 2,0 2,5 3,0
Nozzle pressure, bar

Gas reduction station
Place in vented
room and close
to burner
Primary air fan – frequency drive
 Frequency motor drive:

High efficiency two stage centrifugal fan with direct frequency
motor drive.
 Less power consumption (-25%).
 Improved the possibilities for kiln burner operation
 Reduced noise emission level
 Programed as emergency air fan (300 rpm)
(Emergency air fan is not needed).

Scope of lecture
Calciner burner and coal firing

equipment
In-Line Calciner – high fuel input area
Calciner
burner
Coal injection – How and where
Velocity: 45 m/s
Inclination: 300
~150 mm above
spreader box

ILC LOW NOx CALCINER
Gas “Raw meal”
52 Fuel & Firing Systems
Oil firing Equipment Calciner (OEC)
1. Oil valve train

2. Shut-off unit
3. Distribution unit
4. Cooling air fan
5. Connection unit
6. Oil burner CBO
Cloud of distributed oil mixed
with air and material
Material
Fuel
Hot kiln oil
gasses Cooling air Atomizing air

Gas firing Equipment Calciner GEC

Burner equipment GEC
for gas firing in calciner
Calciner Gas Burners
ILC
RISER DUCT
CALCINER BURNER CBG

(4 OR 6 REQUIRED BASED ON CAPACITY)
Calciner burner CBG
Wear resistant design
©FLSmidth A/S 2016, all rights reserved. Fuel & Firing Systems
The short Duoflex burner for SLC-D
Well controlled flame Burner installation and

formation is required function identical to
main kiln burner

Start burners

Correct dosing is essential to kiln
performance
• Unstable dosing to burner results in

• unstable CO peaks
• unstable coating formation
• Pulsations
• Recommended transport velocities

• Start velocity, app. 25 m/s
• End velocity, app. 30 m/s
• Transport length maximum 120 m
• Dosing of solid alternative fuel depends on fuel characteristics
A coal feeding system
The Pfister feeder DRW

Scope of lecture
Installation and operation
Installation and operation
 Initial installation
 Flame shaping
 Liquid fuel problems
 Burner snowman (“rhino” formation)

Initial installation
FLS recommendation:
• X app. 0,5 m
• Burner tip in kiln center
• Burner parallel to kiln axis

Flame shaping – Plume is necessary
Instruments to use for flame shaping
(Example: Duoflex)
• Air nozzle – opening

Swirl air
• Radial air damper Axial air
Primary air inlet
• Axial air damper
(keep 70-100% open at all time)
• Primary air fan damper or speed regulation
• Oil and gas nozzle provide flame shaping possibilities

Initial setting of recommended momentum
Secondary fuels
Antracite, petcoke
Medium volatil coal
Fuel oil
Fuel gas
0,00 2,00 4,00 6,00 8,00 10,00 12,00

Total momentum N/MW
Oil burner back spill can happen

How to avoid oil back spill
Check;
leaks or damages
Oil temperature
max. 17 cSt is allowed
Oil pressure
For pressure atomizers
Atomising fluid flow
Oil nozzle position
clear of the burner front
Then;
Increase central air.
Reduce swirl air.
“Rhino” formation impact on flame shape
• Flame will lift due to ”bluff body” effect

• This may lead to increased kiln shell
temperature
• NOx emission drops
- in-effective heat transformation

Air blaster solutions for “Rhino” removal

Scope of lecture
Burner upgrades
Upgrade and modernisation
 Eliminating a couple of unplanned kiln stops can easily pay the cost of
a new burner system.
 Main reasons for upgrade

• Production capability
• Change of fuel
• Insufficient kiln availability
 Fast Pay-Back due to

• alternative fuel usage
• Increased production potential
• Increased kiln availability
• Longer lining lifetime
Test of new fuel
Plan for the future pays off
 Go for flexible upgradeable solutions

 Plan for future fuels

Burner suppliers
Different solutions exists
Scope of lecture
Trends for future / R&D work
Maximum AF substitution is often limited to 30-50%.
This is about to change.
AF not
suspended
sufficiently in
flame core is
commonly
seen
Research based approach to increase kiln
flame understanding
Kiln Top View Kiln Top View
Kiln Side View Kiln Side View

• Primary /secondary air mixing profile
• Smoke test
• Fuel test
• Laser sheet visualization
• Slow motion visualization
FLSmidth JETFLEX® burner
To be launch 2016
FLSmidth JETFLEX® kiln burner
JETFLEX
FLSMIDTH
kiln burner
meeting
tomorrows
fuel
requirements
Maximum flame adjustment made possible
Annular
configura
tion with
center
back and
center
out
(normal)
Nozzle Individua
adjustmen l nozzle
t and adjustme
tensioning nt
Separate or common fuel channels is
possible
Coal in annular or coal in center for reduced transport air
SRF dosing
SRF dosing
c
c Burner
Burner
4 5
6
4 5
x
b
b
Coal dosing
Coal dosing
3
3
a
a 1 2
1 2
Thanks for your attention


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05-09: Fuel and Firing Systems

 The combustion process

 Calciner burner and coal firing equipment

©FLSmidth A/S 2016, all rights reserved. 3

©FLSmidth A/S 2016, all rights reserved. 4

The combustion process

Temperature Combustion air

©FLSmidth A/S 2016, all rights reserved. 6

Where is air added Requirement for combustion

©FLSmidth A/S 2016, all rights reserved. 7

•Flame formation & heat transfer

•Primary air momentum

©FLSmidth A/S 2016, all rights reserved. 8

©FLSmidth A/S 2016, all rights reserved. 9

©FLSmidth A/S 2016, all rights reserved. 10

 A short, narrow, strongly radiant flame.

 Dense, stable coating on the refractory in the burning zone of

 Must use as little primary air as possible

©FLSmidth A/S 2016, all rights reserved. 11

 Primary air momentum

 Primary air swirl

 Number of burner channels

©FLSmidth A/S 2016, all rights reserved. 12

 Flame formation in a rotary kiln

Swirl air Internal External

©FLSmidth A/S 2016, all rights reserved. 13

(Air mass flow rate) x (discharge velocity)/(heat release rate):

©FLSmidth A/S 2016, all rights reserved. 15

Medium volatil coal

0,00 2,00 4,00 6,00 8,00 10,00 12,00

Dried paper Wood chips Rice husk

©FLSmidth A/S 2016, all rights reserved. 18

•Need for grinding •Expensive

Lignite 40-50 4820 7,1

Bitum. coal 10-40 6310 9,2

Antracite 5 6900 9,9

Petcoke 11 8300 11,5

©FLSmidth A/S 2016, all rights reserved. 22

Total Hygro Ash C H S (N+O)

Bitum. 5-10 1-3 10-20 70 3 1 3

Antracite 0-3 1 5-10 78 2 1 2

Petcoke 0,6 0 0,2 87 3,8 5 2-3

©FLSmidth A/S 2016, all rights reserved. 23

Typ. Value, Petcoke:

©FLSmidth A/S 2016, all rights reserved. 24

Consistent analysis High sulphur content

Low wear Blending with coal often necessary

©FLSmidth A/S 2016, all rights reserved. 25

Fuel type Necessary Net. Air

Gas oil 0 °C 10200 14,4

Light fuel oil

Heavy fuel oil

©FLSmidth A/S 2016, all rights reserved. 26

Saharan 86,5 9750 13,96

©FLSmidth A/S 2016, all rights reserved. 27

Can only be used with high calorific value fuels

Oil 300-550 2120

©FLSmidth A/S 2016, all rights reserved. 29

Main burner equipment

Single Multi Low Swirl & High

Brand Uniflow Swirlax, Centrax, Pyro- Duoflex, Novaflam,

©FLSmidth A/S 2016, all rights reserved. 31

1) Kiln hood 8) Flame safety/Burner