vrnvase FUL Mepnircencrur LIME MANUFACTURING. Gaseous fuel firing in lime kilns De ees acre mR Vara a AL eee LLY eee ie conta and oxidant in lime kilns ee ERE - ption, kiln inlet eeu MMe Se De agen venifitis an oversimplified st ee ers itis commonly sad that there are three 7 necessary for good combustion: fe temperature timeand turbulence Especially inexstingequipmentthere are often sie linitations such thatitienat possible toincrease the restience time. There are aso often materials operational temperature oremisions limits. Therefore, thefoaus of cambuston efficiency advances has been onimproving and bettie controling turbulence. n simple terms e bal improving and contoting the ming ate aati 7 between fuel and oxidant ese ree i cee From et stream tojet excitation ete (ver the yearsliferent ways to increase ate theturbulence have been tried and the most frequently employed conceptin ‘eden kiln burners uses the energy intoa larger chamber with certain the Gyro Therm chamber, which uses the contained inthe fuel and/orexidant steam geometric characteristics, would precess static pressueof the gasto create a gas tapromotethembing. Thisconceptis around the chamber longitudinal is. _jetthateitsthe burner at alarge ange to based on steady state constant tstreams Thistechnologyisthe key onceptofthe thelongitudinal axis. The et also changes Interferingwitheach otherandviththe patented FCTGyro-Therm, usedwhen direction ata high frequency. surrounding secondary aircreating the gaseous fuelisthemain fel ofthe burner, The gasiscvided int two streams: rnecessaryturbulence.Thisprincipleis __etheralone, with coalor fuel ol theprecessingjet and the centrebod et appliedinthedesignof mesteurentiiin _Gyro-Thermburnershave been applied (Figure 1). The precessng tis the majority Dbumers, including FCT's muttfue high-_tonumerousindustriessince 1995. of gas low andisinjectedat highspeed omentum Turbx Jet urer casestudyispresented foratimelil,in into theback ofthe chamber through a However othermethods donot use whichitwaspassibleto compare different small ofice, Due tothe audden expansion constant etstreams but pulsatingor ‘operational parameters with three diferent in chamber diameter and fuld behaviour variable ets known asjetexcation, burners: fuloil burner rignaly fitted siilarto the Coandacffect (tendency ofa which ake advantageot fluid dynamic tothe kln,aconventionalturbulent jet fluid tostay attached to aconvex surface), singularities to promote mixing 225 burner installed duringa conversion the gas stream tends to attach toone side Jetercitatioasamethod ofincreasing tonaturalgas,andtheGyro-Therm asan ofthe wall, creating low-pressure zone rmixingrateshasbeen investigated for more improvement for natural gas operation, on the opposite side ofthe chamber. This than four decades. Diferent methods Teurique propertosof the Gyro fect is desirable because induces ar Inchiding acoustic, uidicandmechanical, Therm burner have resulted ina from burner surroundings int the low. ofpromotingjet exitation have been ‘Smultaneous 2 percentincrease ink pressure zone inside the chamber, creating, tried, However,twas not unite 1950s production forte same ime quality, an niialpremixng between gas and ait thatanaxisymmetric, welldefined and specifi fue consumption fll by 10 per ‘tthe chamber ext there isa replicable solution was ound vathe studies cent and NO, emissions by44percent _constrctioninthe diameter that forces ffG Nathan, SJHillandRELuxton inthe when compared the conventional thenatural gasjetto the opposite side Departmentof Mechanical Engineeringat turbulent jet burner fringgas. ofthe burner while exiting the chamber The University of Adelaide, Australia ‘This creates another low-pressure zonein Their morkconclced that fluid Technology explained thecentreofthe Lame justin front ofthepassing at highspeed through a nozzle INTERNATIONAL CEMENT REVIEW OC 105¢k helps to capture ational airinthecentre ‘ofthe gascloud and aso siehtly deflects thegasjetbacktothe centre together with the deflection caused by secondary 2, avoiding an excessive lame diameter. The precessingjetisnot fied inone singe position because of the inherent instalitiesof the low which foree the jet tw occupy successive positionsinsie the chamber: Thiscreaes a gyroscopiclike rotation movement, a precession around thebumer longitudinal axis sce Figure 2). This behaviour isvery similar towhat ‘would happen nthe case ofa water hose beingrotated hell a metre from ts extremity, In this movement, the psition of thegasjet goes around thecomplete Circumference 20.50 times/s In cntest, {his would mean 10-15 complete tus per eyeblink, creating a perfectly even dispersion ofthe gas. No precession can beseeninthe lameltsf, which seems to be stationary. An animation about the ‘operation principieof Gyro-Therm 35 well a8 avideo ofits flame canbe foundat \wevActinternationat.com. The second stream of gas isinjected througha central erficeinthefrontof the Gyro-Therm chamber. Adjusting ‘ales atthe back ofthe bumer changes theproportion of gas between thetwo channels and allows for exellent fame control. When amore cenial jets chosen, theflame will become longer and simmer ‘Aste precessingt faction increased, theflame becomes shorter and wider The precessingmovementis continuously engulfingand eenewing two mainair pockets: one inside the Gyo Therm chamber ane one justin font ofthe burner (see Figute3) ‘The air availabe the pocketsis not sufcient fr complete gas combustion “Thisforcesthe gas to crackinto carbon Figure normal turbulent peerans Siete matet er eee tit FUL Mepnircencrur ‘The central feature ofthistechnelogyis bi urner. This second low pressure zone Copyright Tradeship Publications Led 2016 cy oe particlesbetore completebur out. The catbon particles gnerated inthe process increase the lame's emissivity, rising heat transfer by radiation fromthe Ramete the product The gasflame generated bythe GGyro-Therms interme of heat ux profile, ‘mace similar to fel ol or coal Rame than to the comment long and low radiant gas flames (see Figured}, The moreradlativelame fromthe Gyro-Therm brings a series of advantages wien compared to anormal gas lame Theimproved heat transfer fromthe LIME MANUFACTURING [id flame tothe productresuitsin ower kiln inlet temperatures, allowing fora higher production rate Reducing the kiln inlet temperature also leadsto lower thermal losses, decreasing specific energy ‘consumption. This improved even furtherby the higher production rates allowed, Due toa betterhest flux profile, theproduct characterises canbe also Improved, ‘The carbon parteles, important for theimproved heat transfer, subsequently bur out completely when reaching more 6yr0 Therm lame with ighradation and a tenants >» T= ¥FUL Mepnircencrur eae LIME MANUFACTURING 2CTORER 2000 INTERNATIONAL CEMENT REVIEW es Perea secondary ai ‘Asa further benefit, the improved radiation of heat out ofthe ameresutsin a decrease inthe flame peak temperature No, formation istherefore much reduce Further NO, reduction is achieved due to thepresenceofthe carbon pattcesin theeary stages of combustion. The NO, reduction benefits ares strongcompared toother gasbumers that Gyro-Thermis {quoted by US Environmental Protection ‘Agency as best practice technology for NO, reduction andimproving combustion with gaseous fuel (se boxstory. ‘Autanged around the central precessing Jet chamber are further burner channels, dependingon other fuels used, Asma amountof primary iris also injected when Energy efficiency improvement and cost- saving opportunities for cement making ‘recent technology thathas been demonstrated in severallocations the Gyro Thea technology thatimproves gas flame quolty while reducing NO, emissions. ‘Originally developed a the University of Adelaide (Australi), the Gyro-Therm technology con be applied togas bumes oF as/eoal dua fuel. The Gyro-Therm burner uses patented ‘preessing et" technology. The nazzle design produces {as etleaving the burer ina gyroscope-tke precessing motion. Fis stiring ‘ction produces rapid large scale mixing inutich pockets oir are engulfed thin the fuel envelope without using high velocity gas orarets. The combustion tokesplacein pockets within the fuel envelope under fulrich conltions. This ‘reotes highly lumincus flame, ensuringgoodrediatve heat transfer ‘Ademonstiation project tan Adelaide Eight plant found overage fuel sovingsbeteenfve and 0 percent aswell asan increase in autputof19per cent (CADDETT, 19971 second demonstration project the ash Grove platin the US (Durkee, Oregon fun fut savings between 2,7 per cent ands percent vith increases output between 59 percent (CADET, 1988 Vidergar and Ropson, 1857, ‘Reed tat nonmerin( a enka a Available and emerging technologies for rediicina areanharice mas amicsinns fram the burnerhas other fuelcapablties, ‘The main function af thiairis for cling the burner while operating with gs (1:3 per cent stichiometic a), to provide a channel for housingof ancillaries such as anignition system and amedetection, and also to provide additional lameshape control with other fuels than gas 35 per cantstoichiometi ai, Case study: Australian time kitn ‘The_fistGyro-Therm was supplied in 1995, and over 50 urits have been delivered ‘ince tw diferentindusties. Anilustrative case vasa Gyre-Therm bumer installed Jinan Austraban ime kiln to replace uistng burners. Thsisaninteresting ase tobe presented because italows the comparison of several Kn operational parameters during three diferent stages: + Stage :fueloil operation usingthe cxiginal fuel oll bumer supplied vith the kin + Stage 2:aferaconversion tonal {35 usingacommonturbulent}et burner + Stage 3:afterthe installation of a Gyro ‘Therm burme firing natural gas tis very important not to underestimate the inherent changesin a process when convertingto natural gas firing, For example, theamaurt of exhaust {gases inthe hin forthesameamount of energy ishigher with natural gasthan with to simply because natural gasPUL reprincrnicror Freuvenly yr Sern wuse yus ergo Hut the Portland cement industry A proprietary system called yro-Therm has beendemonstroted t several cement plont to improve combustion and reduce fuel usage. The system is applicable ‘to gastred and gascoal-fied ks ondrepotedty rest i102710 percent reduction in fuel usage endlupto 10 percent increase in outputof the kiln Average costs ofthe system based on demonstration projects isUSS0.8fannual ton cement capacity Moreland Glitshy, 208), nd paybook time isestimotedto be les than ‘ne year. (FTC, 2009) year \senvonmenttmtcnangingy aber 8 VTERNATIONAL CEMENT REVIEW OCTOSER 2015, turbulent jet wit aGyro-Therm, bth ring natural gas. The data presented represents averages overashemonth period during, thethrce diferent stages presented Production ate reviously. was possible to observe an change (%) Increasein production rate of 2 percent simultaneously with areduction of speci energy consumption of 1opercentandkin | 100% a backend temperature of seven percent NO, emissionsin stages? (natural a s-common turbulent et bummer) and 3 (natural g3s~ Gyro-Therm) were measured | % continuously ati backend in ppm and ‘normalised at 1Spercentonygentovel(as | “5% a3 ‘how in Figure 7). The datapoints that Uieat thezeroNO, ppmlevelare thosefor | 200 ‘an air purge cycleon the instrument and Indicate that the zero calibration ofthe oe insrumentremained godthreughoutthe | ‘measurements ‘AverageN0, at kiln back end wth a ‘common turbulent jet burner fring natural 9513s 337ppm at15 percent 0 or bas proportionally morehydrogen ints compestion. This cannot beadéressed bbyany burner and canimpact negatively, reducing production rates custo limitations on the kiln exhaust fan Other changes, suchas fame emissivity, heat ux profile and NO, formation, are burner spect and there the Gyro-Therm has proven superior. Figure 6 provider a good reference forpettormance improvement that cn bbe achieved when replacinga common LIME MANUFACTURING Ez Specificenerey linback end ‘consumption temperature change (s) change ether brn 072mg Nev" at 10 per cent 0). The same ‘measurement with 3 Gyro-Therm burner fiingnatual gas averaged S24ppm at 1.5 per cent, (or sa4mg/tm’ at 10 percent (J,representing arection of 4 per cent, The NO, reduction s ever greater when considering the NO, emissions (in “7 'Bpm or mg/m’ pertonre of product, as theproductionrate increased by 12 per oe ‘ont with a Gyro-Therm installation, sh tats fs eae Conclusions She se re oe Conversions to natural gas present issues Inherent to natural gas composition, but there ae also other challenges thatcan y WO, (ppmI@ ISO, be addressed by burner design. Using theunique and patented technology of re {Gyro-Therm FCTisableto overcome those bummer specific issues, increasing production ates, reducing specific energy ‘consumption, kiln back end temperature ‘Stage 2: natural gas -turbulentjet burnervunvano PUL reprincrnicror ‘and NO, emissions fora profitable and fervironmentalfiendly operation. i "YALL, npg Line Padi ah yo ours AL Suan URTONRE 198) ‘an serynmetc le se Gerrt t ACEICY fat ottteanceneaeg Teepe sus nbn Enon fam be orond Gana aty regret cet ArandRacaton Oct "NORREL En GALT C208 Ey ereencyimpoemantandtat surg (pparanedtr Coma ng Solo Sr® Gane nenyond Poe nape (pees Onan were ely Nara ‘Stage 3:natural gas - Gyro-Therm burner ‘Usain, Erdtonmetl erry Tetons isin pone ne USEPA se é fe i & ‘Copyright Tradeship Publications Ltd 2016 [OCTOBER 2010 INTERNATIONAL CEMENT REVIEW ofa Like this slideshow? Why not share! 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