Combustion in Cement Process -...
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Combustion in Cement Process Douglas Goncalves Engenheiro de Projetos, FCT Combustion Americas
Transcript of Combustion in Cement Process -...
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
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• 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
