Combustion in Cement Process

Douglas GoncalvesEngenheiro de Projetos, FCT Combustion Americas

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FCT Group

C o m p a n y f a c t s• Founded 35 years ago• Large experience in Cement, as well

as Lime and Minerals • Worldwide presence• More than 300 references in Cement

Australia

Middle East

TurkeyEurope

USA - FL

Brazil

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FCT Group

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FCT Group

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FCT Group

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FCT Group

Flexibi l i ty for al l fuels in al l ki lns

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Kiln Burner

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Kiln Burners – 2 Cases

Turbu-Flex Gyro-Therm

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Kiln Burners

Turbu-Flex

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Turbu-Flex - Impact of axial air hole arrangement on secondary air entrainment

?

• ½ the number of holes• Same axial hole area (mm²)• Same high momentum

• Group holes – Large gaps• Same axial hole area (mm²)• Same high momentum

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Axial Air Swirl AirCoal

M

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Turbu-Flex - Primary air axial hole arrangementImpact on flame radiation for coal

1. Peak Radiation (kW/m²)

2. Area under curve = Net radiation (kW) to clinker 5 kiln diameters from discharge.

36 Even

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Turbu-Flex - Primary air axial hole arrangementImpact on flame radiation for coal

1. Peak Radiation (kW/m²)

2. Area under curve = Net radiation (kW) to clinker 5 kiln diameters from discharge.

36 Even

18 Even

½ number holes

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Turbu-Flex - Primary air axial hole arrangementImpact on flame radiation for coal

1. Peak Radiation (kW/m²)

2. Area under curve = Net radiation (kW) to clinker 5 kiln diameters from discharge.

36 Even

18 Even

18 Gaps

½ number holes

Large gaps

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Turbu-Flex - Primary air axial hole arrangementFor new Turbu-FlexTM Burner

Take 2 extremes burner

arrangements and merge into

1 burner

Take 2 extremes burner

arrangements and merge into

1 burner

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Turbu-Flex - Primary air axial hole arrangementFor new Turbu-FlexTM Burner

With separate air supply to

large and small holes

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Turbu-FlexTM BurnerAxial Primary Air Flow Pattern

2 Extreme modes of operation

AF Boost Mode18 High Pressure

Holes

Standard Mode36 Medium

Pressure Holes

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Turbu-FlexTM BurnerSecondary Air Entrainment

• Looking at the burner tip.• Viewing secondary air path lines.• Lines coloured by velocity .

Standard Mode

36 Medium Pressure

Holes

AF Boost Mode

18 High Pressure

Holes

Secondary air entrainment

rate much higher

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Turbu-FlexTM BurnerImpact on flame radiation for coal

Standard ModeStandard Mode

AF Boost Mode

Peak radiation and total

radiation in first 5 kiln diameters increased

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Turbu-FlexTM BurnerImpact on flame radiation for coal and RDF

Standard Mode

With 50% RDF there is a reduction in flame radiation close to the burner

Standard Mode

AF Boost Mode

With AF Boost mode there is significant recovery in flame radiation close to the burner

Turbu-FlexTM BurnerSummary of Benefits

Standard ModeAF Boost Mode

• High AF substitution• Low fuel consumption

One Burner – Two Modes

• Good heat flux/radiation profile for coal and petcoke

• Low NOx

Flexibility to switch

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First Turbu-FlexTM Burner in Operation

First Turbu-FlexTM Burner in operation in Europe firing 80% RDF, remainder Petcoke and Liquid AF.

RDF

Pipe

Petcoke

Channel

Groups x 3 Large Holes

Groups x 3 Small Holes

Swirl

Primary

Air

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2 more Turbu-FlexTM supplied in Europe

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Kiln Burners

Gyro-Therm

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Gas firing problems

-40

-20

0

20

40

60

80

100

120

0 5 10 15 20 25 30 35 40 45

Distance from Burner Nozzle (m)

Wa

ll H

ea

t F

lux

(kW

/m^

2)

Oil

Gas: TDJF

Gas: Gyro-Therm

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Kiln Burners – Gyro-Therm

F e a t u r e s• Gaseous fuels as main fuel -

Precessing Jet Technology• Simple operation• Highly flexible flame shape• No moveable parts• Multi-fuel capability

B e n e f i t s• Optimized heat flux profile• Low Nox emissions – naturally staged

combustion• Radiant flame• Virtually no primary air

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GyroTherm Burner

1 0 0 % P r e c e s s i n g J e t

8 5 % P r e c e s s i n g J e t1 5 % C e n t r e B o d y J e t

7 0 % P r e c e s s i n g J e t3 0 % C e n t r e B o d y J e t

• 100% PJ gives a very wide flame with distinct

volumes of gas mixing very slowly with air in the

near field.

• 85% PJ gives a narrower flame still with distinct

volumes of gas mixing slowly with air in the near

field.

• 70% PJ gives a much narrower flame with

predominantly a continuous jet of gas mixing more

vigorously in the near field.

• 0-30% CBJ

is sufficient

to control

the flame

shape.

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Kiln Burners – Gyro-Therm

Turbulent Jet gas burner Gyro-Therm burner

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GyroTherm Burner

• E x a m p l e o f b e n e f i t s i n C e m e n t C l i n k e r R o t a r y K i l n s

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GyroTherm Burner

• E x a m p l e o f b e n e f i t s i n C e m e n t C l i n k e r R o t a r y K i l n s

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Australia

Middle East

TurkeyEurope

USA - FL

Brazil

Thank You!

Douglas Goncalvesdouglas.goncalves@fctinternational.com