Unitherm MAS-SW Gas Burner Staff-Training (Compatibility Mode)

M.A.S.
Burner TRAINING
Content
M.A.S. burner design Flame control by M.A.S. burner Burning of Natural gas Trouble shooting Position of the Burner Service and maintenance
Unitherm Cemcon Firing Systems
Company Experience
Establishment- 1949 Field of activity- engineering, production and installation of firing systems for industry and power stations Experience in rotary kiln burners- more than 300 pcs. 1992- technological breakthrough: development of a new burning system generation called M.A.S. (Mono Airduct System) 1997- reduction of product scope to firing equipment for cement industry
At the moment UNITHERM-CEMCON is one of the leading manufacturers of firing systems in the cement industry. Until now numerous M.A.S. burners all over the world have been supplied and commissioned to the full satisfaction of our customers. The excellent operational experiences and the low NOx levels convinced major cement producers to choose the M.A.S. burner for replacement and for new plants as well.
Kiln capacity, heat consumption and clinker quality are defined by:
1. Correct composition of raw meal
1.1 Chemistry Burnability 1.2 Meal fineness
2. Correct burning conditions

2.1 Fuel input and fuel distribution (kiln-calciner) Kiln atmosphere (oxidizing) 2.2 Kiln temperature profile flame shape control---burner design 2.3 Clinker residence time burner position in kiln 2.4 Clinker cooling
Process control
M.A.S. -Rotary Kiln Burner

Basic design
Primary air inlet Flexible air nozzles system for flame shape adjustment
Patent No: 0642645
Coal dust inlet Central air damper
Flame setting device with scale Primary (MAS) air damper Outer jacket tube Flexible swirl device Nozzle outstream system Unitherm Cemcon Firing Systems
M.A.S. -Gas Rotary Kiln Burner

Swirl setting device
Central air
M.A.S.- main air
3 Stages of clinker burning optimisation with M.A.S. burner

1st Stage: Control of flame shape by flame setting device 2nd Stage: Control of combustion intensity by adjustment of the M.A.S.-air pressure 3rd Stage: Control of flame core temperature by adjustment of the central air pressure
1st Stage: Control of flame shape

by flame setting device


Jets flow pattern

Burner Nozzle M.A.S. - system Burner Nozzle traditional three channel burner (basic)
Jet flow
Ring channel flow
M p ,a M s , a
m/s
M p,a
T 2 m Xl n p,a De Ts ,a
m/s
M p ,a M s ,a M p ,a
T 2m Xl p ,a De Ts ,a
nozzle
nozzle
nozzle
gap
gap
ring channel
The mixing zone for jets flow is shorter proportionally n

1/2
n- jets number

wide, short flame
FLAME SHAPE
LONG FLAME 1 2 3 4 5 6 7 8 9 SHORT FLAME
LONG FLAME
medium-sized flame
FLAME SHAPE
1 2 3 4 5 6 7 8 9 SHORT FLAME
narrow, long flame

FLAME SHAPE
LONG FLAME 1 2 3 4 5 6 7 8 9 SHORT FLAME

2nd Stage: Control of combustion intensity

by adjustment of the M.A.S.-air pressure
M.A.S. air damper
M.A.S. air pressure
2nd Stage: Control of combustion intensity

by adjustment of the M.A.S.-air pressure
high pressure 50 mbar hot, short flame
Flame temperature, C
2000
medium pressure 30-50 mbar
low pressure < 10-20 mbar soft, long flame
1800
1600
1400
1200
1000
800
kiln length Unitherm Cemcon Firing Systems
3rd Stage: Control of flame core temperature

by adjustment of the central air pressure
Central air pressure
Central air damper


By increasing the central-air pressure, the flame gets stable but the temperature drops in the flame root, close to the burner head. Central air pressure 10 mbar Central air pressure 60 mbar
Path lines of central air colored by temperature [k]; note: no stabilizing swirl on l.h.s

Central air pressure 10 mbar Central air pressure 60 mbar
Contours of temperature [k]

NOxemission
Flame root temperature
10
20
30
40
50
60
70
80
central air pressure, mbar Unitherm Cemcon Firing Systems

Initial settings for medium-sized flame
Pressure of M.A.S. air M.A.S. swirl number Pressure of central air
Fuels in operation
mbar
Setting on scale
mbar
Natural gas Light fuel oil Heavy fuel oil Liquid secondary waste fuel oils
40-50 100 130 110 -140 100 -140
2-3 35 35 35
20-30 40 150 40 150 40 150
Coal dust high volatile Coal dust low volatile Solid secondary waste fuels
120 160 150 200 120 180
46 46 46
40 150 40 150 40 150

Initial settings for narrow, long flame
Fuels in operation Pressure of M.A.S. air M.A.S. swirl number Pressure of central air
mbar
Setting on scale
mbar
Natural gas Light fuel oil Heavy fuel oil Liquid secondary waste fuel oils
10-30 70 70 100 70 100
0 1 12 23 23
10-20 40 150 40 150 40 150
Coal dust high volatile Coal dust low volatile Solid secondary waste fuels
100 120 140 150 100 120
23 34 34
40 150 40 150 40 150

Initial settings for wide, short flame
Fuels in operation Pressure of M.A.S. air M.A.S. swirl number Pressure of central air
mbar 50-70 160 200 180 220 160 220 Liquid secondary waste fuel oils 160 220 Coal dust high volatile Coal dust low volatile Solid secondary waste fuels 200 220 180 220
Setting on scale 3-5 67 67 68
mbar
Natural gas Light fuel oil Heavy fuel oil
50-60 40 150 40 150 40 150
58 40 150 68 68 40 150 40 150
Burner position in rotary kiln

- especially for rotary kiln with grate cooler a proper axial position of the burner is very important! - 20 cm movement of the burner, moves the sinter zone up to 1m! - sometimes NOx - emissions depends on burner position drastically! - the clinker mass composition as well clinker characteristics depend on length of the cooling zone within the kiln, means also defined by burner axial position. We recommend to keep 1200-1250C clinker temperature at the kiln edge
Temperature [K]
Velocity [m/s]
Burner position in rotary kiln with grate cooler
Initial position X=0 for petcoke, solid secondary fuel, coal- following kiln axis for natural gas or fuel oil- turn more horizontal (rotate around fix point) up to maximum 3% less as kiln slope
Burner position in rotary kiln with satellite coolers
Initial position X=1000 for petcoke, solid secondary fuel, coal- following kiln axis for natural gas or fuel oil- horizontal (rotate around fix point)
Burner position in rotary kiln

Further optimisation
-move the burner tip to the clinker -keep the flame away from the coating -find the best axial position of the burner:
General considerations to burner axial position -burner tip deep inside the kiln >> 0,5 m
-risk of reduced kiln capacity and high flue gas temperature at kiln inlet -more straight flame -better fuel ignition -reduced risk of ring formation at kiln outlet
-burner tip inside the kiln < 0,5 m (usual position)

-increase of kiln capacity and reducing of the flue gas temperature at kiln inlet -risk of uneven flame due to kiln outlet eddy (high turbulence of sec. air) -worse fuel ignition -risk of ring formation at kiln outlet or snowman in cooler Unitherm Cemcon Firing Systems
Trouble shooting
Coating ring at kiln discharge
1.1 Move the burner into the kiln with 20 cm steps 1.2 Adjust more soft, long flame by swirl setting device 1.3 Decrease central air pressure 1.4 Decrease M.A.S.-air pressure
Trouble shooting
Permanent coating ring at the beginning of the sinter zone
1.1 Change the soft long flame to short hot flame each 4-8 hours 1.2 For example: Long flame : flame setting device Pos.0-2 Short flame: flame setting device Pos.3-5
Trouble shooting
Poor clinker burning, high free lime content in clinker, high CO-content in flue gas
1.1 Increase the M.A.S.-air pressure 1.2 Find the maximum flame core temperature with central air pressure 1.3 Adjust wide, short flame by flame setting device 1.4 Check oxygen content in flue gas and pressure difference through the kiln. Increase the secondary air flow. (If I.D. fan doesnt have sufficient power, decrease tertiary air flow)
Trouble shooting
Brown clinker, reducing burning condition
1.1 Check oxygen content in flue gas and pressure difference through the kiln. Increase the secondary air flow. (If I.D. fan doesnt have sufficient power, decrease tertiary air flow) 1.2 Increase pressure of the M.A.S.-air and central air 1.3 Change the position of the burner tip in kiln 1.4 Adjust soft, long flame by flame setting device
Trouble shooting
High kiln shell temperature, poor coating
1.1 Adjust soft, long flame by flame setting device 1.2 Decrease the M.A.S.-air pressure 1.3 Decrease the central air pressure 1.4 Decrease the secondary air flow with I.D. fan 1.5 Use the outer cooling of kiln shell with auxiliary fans
Trouble shooting
High kiln shell temperature, poor coating
1.6 Change chemistry of the raw meal
98
COATING CONDIT IONS

Norm al
96
Hard to burn clinker Difficultes to form coating
Lime saturation factor
94
92
Easy to burn clinker Possible coating ring formation
90
Norm al
88
86 1,5 2 2,5 3 3,5 4
Silica Ratio
Trouble shooting
To remove more sulfur with clinker (clogging problem)
1.1 Adjust more hot flame 1.2 Increase oxygen content of 1-3% more air through the kiln line
Trouble shooting
Parameters affecting NOx:

Pyroprocess
Burning zone temperature Free lime LSF Secondary air temperature Sec.air flow characteristics (cooler type) Thermal kiln loading Kiln design staged combustion in calciner Fuel grinding size and volatiles content Burner tip position in kiln
Trouble shooting
Parameters affecting NOx:

Burner design
Fuel surrounded by primary air (staged combustion) Low primary air amount (momentum) Close fuel ignition distance Mixing intensity of fuels (swirl number) Burner settings (avoid oxygen inside flame root)
Typical low NOx design
Trouble shooting
Impact of Central Air on NOx
Primary Air Pressure: 150mbar Central Air Pressure: 25 mbar NOx (Kiln Inlet): 1300 mg/m
Primary Air Pressure: 150mbar Central Air Pressure: 125 mbar NOx (Kiln Inlet): 2700 mg/m
Trouble shooting
Decreasing of NOx Emissions
1.1 Decrease M.A.S.-swirl on the swirl setting device to a narrow, long flame shape 1.2 Decrease pressure of the M.A.S.-air 1.3 Adjust pressure of central-air (try the upper and lower limit) 1.4 Increase coal-dust injection velocity 1.5 For solid secondary fuel burning - decrease pressure of Pneumoswirlair 1.6 Change the position of the burner tip in kiln 1.7 Decrease temperature of secondary air (if possible)
Service and Maintenance

Daily inspections During operation, the rotary kiln firing equipment must be inspected at least once per working shift and at least the following controls carried out: Check functioning of the burner and visible damage or defects Check flame shape Visual check of burner insulation Check equipment for sealed tightness (flange and tube connections, etc.) Check functioning of operating displays (thermometer, pressure gauges, flow control instruments, etc.) Check equipment for suspicious sounds and vibrations

Periodical inspections The following inspections should be carried out about every 3 months, or in the case of a plant standstill: Inspection of burner insulation; Inspection of the all burner / lance nozzles for wear or deposits; Inspection of input pipe at the pulverized coal connection and the centering ribs for the coal dust nozzle for wear and tear Inspection of the flexible flame setting device for smooth running Inspection of oil / gas and air hoses Inspection of the smooth functioning of fittings and gears Inspection of bearings lubricated with oil and grease, and the carrying out of service work in accordance with detailed descriptions of devices Inspection of the solid secondary fuel channel for wear or deposits

Replacement of the nozzles For dismantling push the bolts of the nozzle wrench in the corresponding holes located on the nozzle and unscrew the nozzle. When the nozzle is loose, take it off by unscrewing the last few turns by hand.
Unscrew with nozzle wrench Unitherm Cemcon Firing Systems
Take off nozzle by hand

Replacement of the baffle plate To replace the baffle plate the innermost nozzle must be screwed off first, because the baffle plate is clamped between this innermost nozzle and inside located bolts. When the innermost nozzle is dismantled, take out the baffle plate by hand
innermost nozzle is dismantled Unitherm Cemcon Firing Systems
take out the baffle plate
References
M.A.S.-burners have been successfully operating in a lot of cement plants over the world

Unitherm MAS-SW Gas Burner Staff-Training (Compatibility Mode)

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M.A.S.

Unitherm Cemcon Firing Systems

Unitherm Cemcon Firing Systems

2. Correct burning conditions

M.A.S. -Rotary Kiln Burner

Coal dust inlet Central air damper

M.A.S. -Gas Rotary Kiln Burner

M.A.S.- main air

Unitherm Cemcon Firing Systems

3 Stages of clinker burning optimisation with M.A.S. burner

Unitherm Cemcon Firing Systems

1st Stage: Control of flame shape

Unitherm Cemcon Firing Systems

1st Stage: Control of flame shape

Unitherm Cemcon Firing Systems

1st Stage: Control of flame shape

Unitherm Cemcon Firing Systems

Jets flow pattern

Ring channel flow

The mixing zone for jets flow is shorter proportionally n

1st Stage: Control of flame shape

narrow, long flame

Unitherm Cemcon Firing Systems

1st Stage: Control of flame shape

Unitherm Cemcon Firing Systems

2nd Stage: Control of combustion intensity

M.A.S. air damper

M.A.S. air pressure

Unitherm Cemcon Firing Systems

2nd Stage: Control of combustion intensity

medium pressure 30-50 mbar

low pressure < 10-20 mbar soft, long flame

kiln length Unitherm Cemcon Firing Systems

3rd Stage: Control of flame core temperature

Central air pressure

Central air damper

3rd Stage: Control of flame core temperature

Unitherm Cemcon Firing Systems

3rd Stage: Control of flame core temperature

Contours of temperature [k]

Unitherm Cemcon Firing Systems

3rd Stage: Control of flame core temperature

Flame root temperature

central air pressure, mbar Unitherm Cemcon Firing Systems

3 Stages of clinker burning optimisation with M.A.S. burner

40-50 100 130 110 -140 100 -140

20-30 40 150 40 150 40 150

120 160 150 200 120 180

40 150 40 150 40 150

Unitherm Cemcon Firing Systems

3 Stages of clinker burning optimisation with M.A.S. burner

10-30 70 70 100 70 100

10-20 40 150 40 150 40 150

100 120 140 150 100 120

40 150 40 150 40 150

Unitherm Cemcon Firing Systems

3 Stages of clinker burning optimisation with M.A.S. burner

Setting on scale 3-5 67 67 68

Natural gas Light fuel oil Heavy fuel oil

50-60 40 150 40 150 40 150

58 40 150 68 68 40 150 40 150

Unitherm Cemcon Firing Systems