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05-09: Fuel and Firing Systems
©FLSmidth A/S 2016, all rights reserved.
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
1
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
©FLSmidth A/S 2016, all rights reserved.
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
2
Filter
Crusher
Filter Analyzer
Limestone
Sand
Clay 1
2
Iron 3
Raw meal silo
4 Storage
Coal mill
4 3
2
1 Raw mill
Clinker Silo
Separator 2
Packers
3 Cement silo
Cement 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 and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
3
Typical In-Line Calciner system
Kiln burner
Calciner burner ©FLSmidth A/S 2016, all rights reserved.
4
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
4
Scope of lecture
The combustion process
©FLSmidth A/S 2016, all rights reserved.
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
5
Burning cement requires:
Fuel
Burner
Temperature
©FLSmidth A/S 2016, all rights reserved.
Combustion air
6
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
6
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
©FLSmidth A/S 2016, all rights reserved.
Hot
stoichiometric + Excess air
7
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
7
Kiln burner selection
•Flame formation & heat transfer
•Burner design
•Primary air momentum
©FLSmidth A/S 2016, all rights reserved.
8
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
8
Flame formation and heat transfer Important parameters: -
Fuel type/quality Combustion air Excess air Mixing rate Burner type
©FLSmidth A/S 2016, all rights reserved.
Temperature
9
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
9
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! ©FLSmidth A/S 2016, all rights reserved.
10
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
10
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
©FLSmidth A/S 2016, all rights reserved.
11
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
11
Burner design Parameters to be considered
Primary air momentum Primary air swirl Number of burner channels
©FLSmidth A/S 2016, all rights reserved.
12
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
12
Burning requires mixing of fuel and air Flame formation in a rotary kiln
Fuel and primary air
Internal recirculation zone
Swirl air Hot secondary air
©FLSmidth A/S 2016, all rights reserved.
13
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
External recirculation zone
Fuel & Firing Systems
13
Momentum is the deciding parameter for flame formation [N/MW] (Air mass flow rate) x (discharge velocity)/(heat release rate): .
m air c Q
N/MW 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 ©FLSmidth A/S 2016, all rights reserved.
14
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
14
Comparison of PA% versus momentum
Examples: Uniflow burner: Swirlax burner FCO, 120 mbar: Swirlax burner SCO, 160 mbar: Duoflex burner, 250 mbar: Centrax burner, 750 mbar:
20% 10,7% 9,4% 7,5% 4,3%
x x x x x
75 m/s = 1500 %m/s 140 m/s = 1500 %m/s 160 m/s = 1500 %m/s 200 m/s = 1500 %m/s 350 m/s = 1500 %m/s
Conversion: 1 N/MW y 300 %m/s
©FLSmidth A/S 2016, all rights reserved.
15
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
15
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
©FLSmidth A/S 2016, all rights reserved.
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
16
Scope of lecture
Fuel types
©FLSmidth A/S 2016, all rights reserved.
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
17
Fuel types • Primary/main fuels • Solid (Coal, Petcoke) • Liquid (Fuel oil) • Gaseous (Natural gas) • Secondary fuels • Solid, liquid or gaseous waste Dried paper sludge
Wood chips
Used oils
©FLSmidth A/S 2016, all rights reserved.
Rice husk
RDF
Plastics
18
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
18
Main fuels used in cement production
©FLSmidth A/S 2016, all rights reserved.
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
19
Alternative fuel substitution
©FLSmidth A/S 2016, all rights reserved.
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
20
Fuel types comparison
•No preconditioning Advantages
•Low cost
•No storage
•High radiation
•Low S content •Low momentum required
3500
Disadvantages
•No ash white cement •Usually back-up fuel Liquids
Coal/petcoke 5.000
6.000
7.000
8.000
9.000
•Need for grinding
•Expensive
•Storage
•High H content
•Large volumes
•Low radiation
•Needs high momentum
•High ignition temperature – explosion risk
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21
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
10.000
kcal/kg
Alternative fuels
•Easy to ignite
•Expensive •Needs preconditioning •Needs storage •High S content
Fuel & Firing Systems
21
Solid fuels typical data
% volatile
Net. kcal/kg
Air kg/kg
Lignite
40-50
4820
7,1
Bitum. coal
10-40
6310
9,2
5
6900
9,9
11
8300
11,5
Antracite
Petcoke
©FLSmidth A/S 2016, all rights reserved.
22
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
22
Solid fuels typical data
Lignite
Bitum. coal
Total Hygro moisture scopic % water % 40-50 10-25
Ash %
C %
H %
S %
(N+O) %
5-25
56
4
1
19
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
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
23
Coal dust - proper fineness is essential Coal to calciner never coarser than to kiln
Typ. Value, Petcoke: As fine as possible
©FLSmidth A/S 2016, all rights reserved.
24
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
24
About petcoke firing Advantages
Disadvantages
Normally low cost per kcal
Low volatile content
Consistent analysis •Low ash content •High calorific value •Raw mix as for oil firing => easy shift
High sulphur content Build ups
More chemically stable than coal •Less tendency of spontaneous combustion •low explosion tendency in the mill
Slow combustion High momentum required High excess air amount recommended (15-20%)
Low wear
Blending with coal often necessary
Burner requirement
Finer grinding - 5 % on 90 microns– upgrade of mill system ©FLSmidth A/S 2016, all rights reserved.
25
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
25
Liquid fuels Typical data
Fuel type
Necessary temp.
Net. kcal/kg
Air kg/kg
Gas oil
0 °C
10200
14,4
60 °C
9900
14,2
120 °C
9750
14
Light fuel oil
Heavy fuel oil
©FLSmidth A/S 2016, all rights reserved.
26
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
26
Gaseous fuels Typical data
% CH4
Net. kcal/Nm3
Air kg/Nm3
(Methane)
Dutch (Groningen)
81,7
7580
10,91
Saharan
86,5
9750
13,96
North Sea (Typical)
91,8
8760
12,6
97,6
8400
14,04
27
Fuel & Firing Systems
Russian
©FLSmidth A/S 2016, all rights reserved.
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
27
Alternative fuels Typical data
Rubber
% C
Net. kcal/kg
Air kg/kg
66,8
7090
9,66
~Equivalent to 1 kg coal Wood
Rice husk
Paper
47,2
4360
5,68
38,5
3230
4,65
43,4
3730
5,06
Can only be used with high calorific value fuels ©FLSmidth A/S 2016, all rights reserved.
28
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
28
Fuel characteristics influencing flame formation
Ignition temperature
Theoretical flame temperature °C
°C Coal (Smouldering temp.)
450-600
2150
(200-300)
Oil
300-550
2120
Gas
600-700
2050
©FLSmidth A/S 2016, all rights reserved.
29
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
29
Scope of lecture
Main burner equipment Kiln burner Oil and gas firing equipment
©FLSmidth A/S 2016, all rights reserved.
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
30
Main burner evolvement Single Channel
Multi channel
Low Primary
Swirl & High momentum
Brand names
Uniflow
Swirlax, Rotaflam
Centrax, PyroJet
Duoflex, Novaflam, JETFLEX
Max air nozzle velocity m/s
70-80
120-140
>300
210-260
Fuel possibilities
One
Multiple
Multiple
Multiple
Advantages
Simple Low cost
•PA% 10-12 •Flame adjustment possible
PA% 4
•PA% 8-10 (up to 15) •High fuel concentration in flame core •Suitable for alternative fuels
Disadvantages
•PA% 20-25 •Flame shape adjustment difficult
•Complicated •Risk of divergent flame
Not suitable for alternative fuels
High initial cost
©FLSmidth A/S 2016, all rights reserved.
31
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
31
Installation overview
1) 2) 3) 4) 5) 6) 7)
Kiln hood Burner seal Trolley Ignition gas burner Flexible connections Primary air ducting Valve trains
©FLSmidth A/S 2016, all rights reserved.
8) Flame safety/Burner management 9) Coal dosing system 10)Emergency air fan 11)Primary air fan 12)Burner sets for oil and/or gas The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
32
Main kiln burner – Duoflex type
©FLSmidth A/S 2016, all rights reserved.
33
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Fuel & Firing Systems
33
Front end view - Duoflex
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34
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Fuel & Firing Systems
34
Front end of burner - Duoflex Radial air channel
Axial air channel
Coal meal channel ©FLSmidth A/S 2016, all rights reserved.
Central air duct 35
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Oil burner lance Fuel & Firing Systems
35
Burner tip
2-nozzle burner, type B (FLS Duoflex)
>210 m/s ~30 m/s
©FLSmidth A/S 2016, all rights reserved.
36
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
36
Solutions for waste co-firing
©FLSmidth A/S 2016, all rights reserved.
37
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
37
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
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38
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
38
Pressure atomizing - TFSM High liquid pressure is required
Oil burner head
Liquid fuel inlet No particles allowed Tangential slot openings, adjustable
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39
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Fuel & Firing Systems
39
Air atomizing - OBA Air or steam supply is required
Mixing chamber
Liquid fuel Liquid fuel
Nozzle holes
Burner head
©FLSmidth A/S 2016, all rights reserved.
Atomising air
40
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Particles allowed Atomising air
Fuel & Firing Systems
40
Oil valve train – safe control of flow and function
Flow measuring unit with mass flow meter ©FLSmidth A/S 2016, all rights reserved.
Shut-off unit with double block function 41
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
41
Gas burner systems
•Burner lances •Valve train
©FLSmidth A/S 2016, all rights reserved.
42
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
42
Fuel gas burner lance – Oil/Gas Shown with oil burner mounted Gas nozzle in closed position
Oil burner regulator
Gas nozzle in open position
Gas inlet pressure from gas station 0-3 bar.
©FLSmidth A/S 2016, all rights reserved.
43
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
43
Gas firing Velocity and flow, relative to pressure 450
3,50
400 3,00 350
Velocity Velocity, m/s
300
Flow
250
2,00
200
1,50
Flow, Nm3/h mm2
2,50
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
©FLSmidth A/S 2016, all rights reserved.
44
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
44
Gas reduction station
Place in vented room and close to burner ©FLSmidth A/S 2016, all rights reserved.
45
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
45
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).
©FLSmidth A/S 2016, all rights reserved.
46
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
46
©FLSmidth A/S 2016, all rights reserved.
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
47
Scope of lecture
Calciner burner and coal firing equipment
©FLSmidth A/S 2016, all rights reserved.
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
48
In-Line Calciner – high fuel input area
Calciner
burner
©FLSmidth A/S 2016, all rights reserved.
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
50
Coal injection – How and where
Velocity: 45 m/s Inclination: 300 ~150 mm above spreader box ©FLSmidth A/S 2016, all rights reserved.
51
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
51
ILC LOW NOx CALCINER Gas
©FLSmidth A/S 2016, all rights reserved.
“Raw meal”
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
52
Fuel & Firing Systems
Oil firing Equipment Calciner (OEC)
1. 2. 3. 4. 5. 6.
Oil valve train Shut-off unit Distribution unit Cooling air fan Connection unit Oil burner CBO
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The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
53
Cloud of distributed oil mixed with air and material Material
Hot kiln gasses
©FLSmidth A/S 2016, all rights reserved.
Fuel oil Cooling air
54
Atomizing air
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
54
Gas firing Equipment Calciner GEC
©FLSmidth A/S 2016, all rights reserved.
55
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
55
Burner equipment GEC for gas firing in calciner
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The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
56
Calciner Gas Burners ILC
RISER DUCT
CALCINER BURNER CBG (4 OR 6 REQUIRED BASED ON CAPACITY) ©FLSmidth A/S 2016, all rights reserved.
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
57
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 formation is required
©FLSmidth A/S 2016, all rights reserved.
59
Burner installation and function identical to main kiln burner
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
59
Start burners
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60
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
60
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
©FLSmidth A/S 2016, all rights reserved.
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
62
A coal feeding system The Pfister feeder DRW
©FLSmidth A/S 2016, all rights reserved.
63
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
63
Scope of lecture
Installation and operation
©FLSmidth A/S 2016, all rights reserved.
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
64
Installation and operation
Initial installation Flame shaping Liquid fuel problems Burner snowman (“rhino” formation)
©FLSmidth A/S 2016, all rights reserved.
65
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
65
Initial installation
FLS recommendation: • X app. 0,5 m
• Burner tip in kiln center • Burner parallel to kiln axis
©FLSmidth A/S 2016, all rights reserved.
66
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
66
Flame shaping – Plume is necessary
©FLSmidth A/S 2016, all rights reserved.
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
67
Instruments to use for flame shaping (Example: Duoflex)
• •
Air nozzle – opening Swirl air Axial air
Radial air damper
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
©FLSmidth A/S 2016, all rights reserved.
68
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
68
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
©FLSmidth A/S 2016, all rights reserved.
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
69
Oil burner back spill can happen
©FLSmidth A/S 2016, all rights reserved.
71
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
71
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.
©FLSmidth A/S 2016, all rights reserved.
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
72
“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
©FLSmidth A/S 2016, all rights reserved.
73
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
73
Air blaster solutions for “Rhino” removal
©FLSmidth A/S 2016, all rights reserved.
74
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
74
Scope of lecture
Burner upgrades
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The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
75
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
©FLSmidth A/S 2016, all rights reserved.
Test of new fuel
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
76
Plan for the future pays off Go for flexible upgradeable solutions Plan for future fuels
©FLSmidth A/S 2016, all rights reserved.
77
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
77
Burner suppliers
©FLSmidth A/S 2016, all rights reserved.
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
78
Different solutions exists
©FLSmidth A/S 2016, all rights reserved.
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
79
Scope of lecture
Trends for future / R&D work
©FLSmidth A/S 2016, all rights reserved.
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
81
Maximum AF substitution is often limited to 30-50%. This is about to change.
AF not suspended sufficiently in flame core is commonly seen
©FLSmidth A/S 2016, all rights reserved.
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
82
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 A/S 2016, all rights reserved.
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
84
FLSmidth JETFLEX® burner
To be launch 2016
©FLSmidth A/S 2016, all rights reserved.
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
85
FLSmidth JETFLEX® kiln burner JETFLEX FLSMIDTH kiln burner meeting tomorrows fuel requirements
©FLSmidth A/S 2016, all rights reserved.
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
86
Maximum flame adjustment made possible Annular configura tion with center back and center out (normal)
Nozzle adjustmen t and tensioning
©FLSmidth A/S 2016, all rights reserved.
Individua l nozzle adjustme nt
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
87
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 4
5
5
6
x b
b
Coal dosing
Coal dosing
3
3
1
a
a
2
©FLSmidth A/S 2016, all rights reserved.
1
2
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
88
Thanks for your attention
©FLSmidth A/S 2016, all rights reserved.
91
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Fuel & Firing Systems
91
©FLSmidth A/S 2016, all rights reserved.
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
1
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
©FLSmidth A/S 2016, all rights reserved.
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
2
Filter
Crusher
Filter Analyzer
Limestone
Sand
Clay 1
2
Iron 3
Raw meal silo
4 Storage
Coal mill
4 3
2
1 Raw mill
Clinker Silo
Separator 2
Packers
3 Cement silo
Cement 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 and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
3
Typical In-Line Calciner system
Kiln burner
Calciner burner ©FLSmidth A/S 2016, all rights reserved.
4
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
4
Scope of lecture
The combustion process
©FLSmidth A/S 2016, all rights reserved.
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
5
Burning cement requires:
Fuel
Burner
Temperature
©FLSmidth A/S 2016, all rights reserved.
Combustion air
6
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
6
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
©FLSmidth A/S 2016, all rights reserved.
Hot
stoichiometric + Excess air
7
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
7
Kiln burner selection
•Flame formation & heat transfer
•Burner design
•Primary air momentum
©FLSmidth A/S 2016, all rights reserved.
8
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
8
Flame formation and heat transfer Important parameters: -
Fuel type/quality Combustion air Excess air Mixing rate Burner type
©FLSmidth A/S 2016, all rights reserved.
Temperature
9
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
9
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! ©FLSmidth A/S 2016, all rights reserved.
10
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Fuel & Firing Systems
10
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
©FLSmidth A/S 2016, all rights reserved.
11
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
11
Burner design Parameters to be considered
Primary air momentum Primary air swirl Number of burner channels
©FLSmidth A/S 2016, all rights reserved.
12
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
12
Burning requires mixing of fuel and air Flame formation in a rotary kiln
Fuel and primary air
Internal recirculation zone
Swirl air Hot secondary air
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13
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
External recirculation zone
Fuel & Firing Systems
13
Momentum is the deciding parameter for flame formation [N/MW] (Air mass flow rate) x (discharge velocity)/(heat release rate): .
m air c Q
N/MW 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 ©FLSmidth A/S 2016, all rights reserved.
14
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
14
Comparison of PA% versus momentum
Examples: Uniflow burner: Swirlax burner FCO, 120 mbar: Swirlax burner SCO, 160 mbar: Duoflex burner, 250 mbar: Centrax burner, 750 mbar:
20% 10,7% 9,4% 7,5% 4,3%
x x x x x
75 m/s = 1500 %m/s 140 m/s = 1500 %m/s 160 m/s = 1500 %m/s 200 m/s = 1500 %m/s 350 m/s = 1500 %m/s
Conversion: 1 N/MW y 300 %m/s
©FLSmidth A/S 2016, all rights reserved.
15
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
15
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
©FLSmidth A/S 2016, all rights reserved.
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
16
Scope of lecture
Fuel types
©FLSmidth A/S 2016, all rights reserved.
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
17
Fuel types • Primary/main fuels • Solid (Coal, Petcoke) • Liquid (Fuel oil) • Gaseous (Natural gas) • Secondary fuels • Solid, liquid or gaseous waste Dried paper sludge
Wood chips
Used oils
©FLSmidth A/S 2016, all rights reserved.
Rice husk
RDF
Plastics
18
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
18
Main fuels used in cement production
©FLSmidth A/S 2016, all rights reserved.
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
19
Alternative fuel substitution
©FLSmidth A/S 2016, all rights reserved.
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
20
Fuel types comparison
•No preconditioning Advantages
•Low cost
•No storage
•High radiation
•Low S content •Low momentum required
3500
Disadvantages
•No ash white cement •Usually back-up fuel Liquids
Coal/petcoke 5.000
6.000
7.000
8.000
9.000
•Need for grinding
•Expensive
•Storage
•High H content
•Large volumes
•Low radiation
•Needs high momentum
•High ignition temperature – explosion risk
©FLSmidth A/S 2016, all rights reserved.
21
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
10.000
kcal/kg
Alternative fuels
•Easy to ignite
•Expensive •Needs preconditioning •Needs storage •High S content
Fuel & Firing Systems
21
Solid fuels typical data
% volatile
Net. kcal/kg
Air kg/kg
Lignite
40-50
4820
7,1
Bitum. coal
10-40
6310
9,2
5
6900
9,9
11
8300
11,5
Antracite
Petcoke
©FLSmidth A/S 2016, all rights reserved.
22
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
22
Solid fuels typical data
Lignite
Bitum. coal
Total Hygro moisture scopic % water % 40-50 10-25
Ash %
C %
H %
S %
(N+O) %
5-25
56
4
1
19
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
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
23
Coal dust - proper fineness is essential Coal to calciner never coarser than to kiln
Typ. Value, Petcoke: As fine as possible
©FLSmidth A/S 2016, all rights reserved.
24
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
24
About petcoke firing Advantages
Disadvantages
Normally low cost per kcal
Low volatile content
Consistent analysis •Low ash content •High calorific value •Raw mix as for oil firing => easy shift
High sulphur content Build ups
More chemically stable than coal •Less tendency of spontaneous combustion •low explosion tendency in the mill
Slow combustion High momentum required High excess air amount recommended (15-20%)
Low wear
Blending with coal often necessary
Burner requirement
Finer grinding - 5 % on 90 microns– upgrade of mill system ©FLSmidth A/S 2016, all rights reserved.
25
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
25
Liquid fuels Typical data
Fuel type
Necessary temp.
Net. kcal/kg
Air kg/kg
Gas oil
0 °C
10200
14,4
60 °C
9900
14,2
120 °C
9750
14
Light fuel oil
Heavy fuel oil
©FLSmidth A/S 2016, all rights reserved.
26
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
26
Gaseous fuels Typical data
% CH4
Net. kcal/Nm3
Air kg/Nm3
(Methane)
Dutch (Groningen)
81,7
7580
10,91
Saharan
86,5
9750
13,96
North Sea (Typical)
91,8
8760
12,6
97,6
8400
14,04
27
Fuel & Firing Systems
Russian
©FLSmidth A/S 2016, all rights reserved.
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
27
Alternative fuels Typical data
Rubber
% C
Net. kcal/kg
Air kg/kg
66,8
7090
9,66
~Equivalent to 1 kg coal Wood
Rice husk
Paper
47,2
4360
5,68
38,5
3230
4,65
43,4
3730
5,06
Can only be used with high calorific value fuels ©FLSmidth A/S 2016, all rights reserved.
28
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
28
Fuel characteristics influencing flame formation
Ignition temperature
Theoretical flame temperature °C
°C Coal (Smouldering temp.)
450-600
2150
(200-300)
Oil
300-550
2120
Gas
600-700
2050
©FLSmidth A/S 2016, all rights reserved.
29
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
29
Scope of lecture
Main burner equipment Kiln burner Oil and gas firing equipment
©FLSmidth A/S 2016, all rights reserved.
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
30
Main burner evolvement Single Channel
Multi channel
Low Primary
Swirl & High momentum
Brand names
Uniflow
Swirlax, Rotaflam
Centrax, PyroJet
Duoflex, Novaflam, JETFLEX
Max air nozzle velocity m/s
70-80
120-140
>300
210-260
Fuel possibilities
One
Multiple
Multiple
Multiple
Advantages
Simple Low cost
•PA% 10-12 •Flame adjustment possible
PA% 4
•PA% 8-10 (up to 15) •High fuel concentration in flame core •Suitable for alternative fuels
Disadvantages
•PA% 20-25 •Flame shape adjustment difficult
•Complicated •Risk of divergent flame
Not suitable for alternative fuels
High initial cost
©FLSmidth A/S 2016, all rights reserved.
31
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
31
Installation overview
1) 2) 3) 4) 5) 6) 7)
Kiln hood Burner seal Trolley Ignition gas burner Flexible connections Primary air ducting Valve trains
©FLSmidth A/S 2016, all rights reserved.
8) Flame safety/Burner management 9) Coal dosing system 10)Emergency air fan 11)Primary air fan 12)Burner sets for oil and/or gas The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
32
Main kiln burner – Duoflex type
©FLSmidth A/S 2016, all rights reserved.
33
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
33
Front end view - Duoflex
©FLSmidth A/S 2016, all rights reserved.
34
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
34
Front end of burner - Duoflex Radial air channel
Axial air channel
Coal meal channel ©FLSmidth A/S 2016, all rights reserved.
Central air duct 35
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Oil burner lance Fuel & Firing Systems
35
Burner tip
2-nozzle burner, type B (FLS Duoflex)
>210 m/s ~30 m/s
©FLSmidth A/S 2016, all rights reserved.
36
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
36
Solutions for waste co-firing
©FLSmidth A/S 2016, all rights reserved.
37
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
37
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
©FLSmidth A/S 2016, all rights reserved.
38
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
38
Pressure atomizing - TFSM High liquid pressure is required
Oil burner head
Liquid fuel inlet No particles allowed Tangential slot openings, adjustable
©FLSmidth A/S 2016, all rights reserved.
39
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Fuel & Firing Systems
39
Air atomizing - OBA Air or steam supply is required
Mixing chamber
Liquid fuel Liquid fuel
Nozzle holes
Burner head
©FLSmidth A/S 2016, all rights reserved.
Atomising air
40
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Particles allowed Atomising air
Fuel & Firing Systems
40
Oil valve train – safe control of flow and function
Flow measuring unit with mass flow meter ©FLSmidth A/S 2016, all rights reserved.
Shut-off unit with double block function 41
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
41
Gas burner systems
•Burner lances •Valve train
©FLSmidth A/S 2016, all rights reserved.
42
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
42
Fuel gas burner lance – Oil/Gas Shown with oil burner mounted Gas nozzle in closed position
Oil burner regulator
Gas nozzle in open position
Gas inlet pressure from gas station 0-3 bar.
©FLSmidth A/S 2016, all rights reserved.
43
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
43
Gas firing Velocity and flow, relative to pressure 450
3,50
400 3,00 350
Velocity Velocity, m/s
300
Flow
250
2,00
200
1,50
Flow, Nm3/h mm2
2,50
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
©FLSmidth A/S 2016, all rights reserved.
44
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
44
Gas reduction station
Place in vented room and close to burner ©FLSmidth A/S 2016, all rights reserved.
45
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
45
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).
©FLSmidth A/S 2016, all rights reserved.
46
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
46
©FLSmidth A/S 2016, all rights reserved.
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
47
Scope of lecture
Calciner burner and coal firing equipment
©FLSmidth A/S 2016, all rights reserved.
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
48
In-Line Calciner – high fuel input area
Calciner
burner
©FLSmidth A/S 2016, all rights reserved.
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
50
Coal injection – How and where
Velocity: 45 m/s Inclination: 300 ~150 mm above spreader box ©FLSmidth A/S 2016, all rights reserved.
51
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
51
ILC LOW NOx CALCINER Gas
©FLSmidth A/S 2016, all rights reserved.
“Raw meal”
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
52
Fuel & Firing Systems
Oil firing Equipment Calciner (OEC)
1. 2. 3. 4. 5. 6.
Oil valve train Shut-off unit Distribution unit Cooling air fan Connection unit Oil burner CBO
©FLSmidth A/S 2016, all rights reserved.
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
53
Cloud of distributed oil mixed with air and material Material
Hot kiln gasses
©FLSmidth A/S 2016, all rights reserved.
Fuel oil Cooling air
54
Atomizing air
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
54
Gas firing Equipment Calciner GEC
©FLSmidth A/S 2016, all rights reserved.
55
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
55
Burner equipment GEC for gas firing in calciner
©FLSmidth A/S 2016, all rights reserved.
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
56
Calciner Gas Burners ILC
RISER DUCT
CALCINER BURNER CBG (4 OR 6 REQUIRED BASED ON CAPACITY) ©FLSmidth A/S 2016, all rights reserved.
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
57
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 formation is required
©FLSmidth A/S 2016, all rights reserved.
59
Burner installation and function identical to main kiln burner
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
59
Start burners
©FLSmidth A/S 2016, all rights reserved.
60
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
60
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
©FLSmidth A/S 2016, all rights reserved.
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
62
A coal feeding system The Pfister feeder DRW
©FLSmidth A/S 2016, all rights reserved.
63
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
63
Scope of lecture
Installation and operation
©FLSmidth A/S 2016, all rights reserved.
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
64
Installation and operation
Initial installation Flame shaping Liquid fuel problems Burner snowman (“rhino” formation)
©FLSmidth A/S 2016, all rights reserved.
65
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
65
Initial installation
FLS recommendation: • X app. 0,5 m
• Burner tip in kiln center • Burner parallel to kiln axis
©FLSmidth A/S 2016, all rights reserved.
66
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
66
Flame shaping – Plume is necessary
©FLSmidth A/S 2016, all rights reserved.
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
67
Instruments to use for flame shaping (Example: Duoflex)
• •
Air nozzle – opening Swirl air Axial air
Radial air damper
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
©FLSmidth A/S 2016, all rights reserved.
68
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
68
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
©FLSmidth A/S 2016, all rights reserved.
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
69
Oil burner back spill can happen
©FLSmidth A/S 2016, all rights reserved.
71
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
71
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.
©FLSmidth A/S 2016, all rights reserved.
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
72
“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
©FLSmidth A/S 2016, all rights reserved.
73
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Fuel & Firing Systems
73
Air blaster solutions for “Rhino” removal
©FLSmidth A/S 2016, all rights reserved.
74
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
74
Scope of lecture
Burner upgrades
©FLSmidth A/S 2016, all rights reserved.
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
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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
©FLSmidth A/S 2016, all rights reserved.
Test of new fuel
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
76
Plan for the future pays off Go for flexible upgradeable solutions Plan for future fuels
©FLSmidth A/S 2016, all rights reserved.
77
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
77
Burner suppliers
©FLSmidth A/S 2016, all rights reserved.
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
78
Different solutions exists
©FLSmidth A/S 2016, all rights reserved.
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
79
Scope of lecture
Trends for future / R&D work
©FLSmidth A/S 2016, all rights reserved.
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
81
Maximum AF substitution is often limited to 30-50%. This is about to change.
AF not suspended sufficiently in flame core is commonly seen
©FLSmidth A/S 2016, all rights reserved.
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
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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 A/S 2016, all rights reserved.
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
84
FLSmidth JETFLEX® burner
To be launch 2016
©FLSmidth A/S 2016, all rights reserved.
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
85
FLSmidth JETFLEX® kiln burner JETFLEX FLSMIDTH kiln burner meeting tomorrows fuel requirements
©FLSmidth A/S 2016, all rights reserved.
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
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Maximum flame adjustment made possible Annular configura tion with center back and center out (normal)
Nozzle adjustmen t and tensioning
©FLSmidth A/S 2016, all rights reserved.
Individua l nozzle adjustme nt
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
87
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 4
5
5
6
x b
b
Coal dosing
Coal dosing
3
3
1
a
a
2
©FLSmidth A/S 2016, all rights reserved.
1
2
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
88
Thanks for your attention
©FLSmidth A/S 2016, all rights reserved.
91
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
Fuel & Firing Systems
91
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