Fuel Types and Firing Systems

Fuel types and firing systems
Kiln Process and Operation course
© FLSmidth 2014, all rights reserved. Fuel and Firering

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© FLSmidth 2014, all rights reserved. Fuel and Firering 2

Typical In-Line Calciner system
Kiln burner
Calciner burner
Burning cement
requires:
 Fuel
 Combustion air
 Burner

What is the focus today for
burner systems?
 High flexibility towards different fuels

 Must be able to burn
 coal,
 coke,
 fuel oil,
 natural gas,
 Alternative fuels and mixtures hereof
 Usage of alternative fuels can cut your fuel bill by half or
more

burner systems?
 Increased production or lower fuel

consumption
 Short burning zone results in lower kiln exit temperature
 Lower average kiln shell temperature
 2-4% increase of production is normal when changing to a
modern burner
 Lowering of primary air consumption

burner systems?

consumption
 Repeatability - easy change of burner

settings
 Reduces cost of operational personnel
 Minimizing the ”down time” between changing productions

burner systems?

consumption
 Repeatability - easy change of burner

settings
 Stable kiln operation

 Good burnout
 Improved coating profile
 Long refractory life

Scope of lecture
 Fuel types
 Kiln burner selection
 Oil and gas burners
 Practical hints, troubleshooting
 Calciner burners

Fuel types
 Primary fuels (Fossil)

 Solid (Coal, pet coke)
 Liquid (Fuel oil)
 Gaseous (Natural gas)
 Secondary fuels (Non-fossil “Waste”)

 Solid,
 liquid or
 gaseous waste

Fuel types comparison
•No preconditioning •Easy to burn

Advantages
•No storage •High S content
•Low or •Low cost
negative cost •Low S content
•High radiation
•Non-fossil •Low momentum
required
Liquids
Alt. Fuels Coal/pet coke
kcal/kg
3500 5.000 6.000 7.000 8.000 9.000 10.000
•Handling •Need for grinding •Expensive

•Expensive
•Larger gas •Storage •High H content
volume •Needs preconditioning
•Large volumes •Low radiation
Disadvantages •Storage
•Needs high momentum •Risk of explosion
•High S content

Solid fuels
Typical coal data
% Net. Air
volatile kcal/kg kg/kg
Lignite 40-50 4800 7,1
Bitum. coal 10-40 6300 9,2
Antracite 5 6900 9,9
Petcoke 11 8300 11,5

Solid fuel combustion path
 Volatile amount high

 Fast conversion
 Fuel fineness low (meaning high percent left on 90 res.)
 Volatile amount low
 Slow conversion (Calciner design)
 Fuel fineness high (meaning little percent left on 80 res.)

Liquid fuels …..Typical data
Necessary Net. Air

temp. kcal/kg kg/kg
Gas oil 0 °C 10,200 14,4
Light fuel oil 60 °C 9,900 14,2
Heavy fuel oil 120 °C 9,800 14

Liquid fuels
 Composition of the fuel varies with the origin

 Influence on combustion
 C/H ratio
 Possible high S content
 Influence on kiln operation
 Important parameter: Viscosity
 °E (degree Engler)
 2°E preferred for optimum flow-ability and atomization

Gaseous fuels
Typical natural gas data
% Net. Air
CH4 kcal/Nm3 kg/Nm3
Dutch 82 7600 10,9
(Groningen)
Saharan 87 9800 14,0
North Sea 92 8800 12,6

(Typical)

Gaseous fuels
 Constant chemical composition

 Low sulfur content
 Ignition temperature higher than coal and oil
 Precaution must be taken for calciner start interlock
 Usually taken higher gas volume into account when
designing

Combustion
Theoretical air requirement
 Is Lmin sufficient??
Lmin [Nm3 air/kg fuel] =
1,8641  C  5,5531   2  0,692  S  0,6997   2

0 ,21

Excess air …With reference to Lmin
LTot    LMin
1
Excess air  
79 O2
1 
21 100  CO2  O2
Normally FLSmidth designs the kiln burner system
for
λ = 1,15 (~15% excess air)
Scope of lecture
 Fuel types

Kiln burner selection
 Flame formation & heat transfer
 Burner considerations
 Burner design
 Primary air momentum

Flame formation and heat transfer
Important parameters:
 Fuel type/quality
 Combustion air
 Temperature
 Excess air
 Mixing rate
 Flame momentum %×m/s
 Burner type

Flame formation …Ignition temperature
Fuel parameters
Ignition Theoretical
temperature flame temperature
°C
°C
Coal 450-600 2150
(Smouldering temp.) (200-300)
Oil 300-550 2120

Gas 600-700 2050

Flame formation
Heat radiation
Q      (Tflame  Tlining ) 4 4
εcoal  up to 1,0
εoil  0,7 - 0,9
εgas  0,7 - 0,9
Stefan-Boltzmanns Constant:
  5 ,6697  10 W  m K 8 2 4
Remember: 90% of the heat input to the charge

comes from radiation!
Burner considerations
1. Must be able to burn

1. coal,
2. coke,
3. fuel oil,
4. natural gas,
5. waste fuels and
6. mixtures hereof
2. A short, narrow, strongly radiant flame
3. Dense, stable coating on the refractory in the burning
zone of the kiln
4. Must use as little primary air as possible typically 10-
12%

Burner design
Parameters to be considered
 Primary air momentum
 Primary air swirl
 Number of burner channels
 Burner design type

Secondary air flow model

Flame formation
Fuel and
primary air
Swirl air Internal External

Hot recirculation recirculation
secondary air zone zone

Kiln burners
 Single channel burners

 Multi channel burners
 Type A (Swirl air inside coal channel)
 Type B (Swirl air outside coal channel)

Single channel burner
(Uniflow)
Advantages: Disadvantages:
•Simple design •High primary air consumption
•Low cost •Flame shape adjustment not possible

Multi-channel burner
Type A - Axial outside Swirl inside..
Coal in the middle
•Low primary air consumption •Complicated design
•Flame adjustment possible •High cost
•Risk of divergent flame

Multi channel burner
3-nozzle burner,
type A … Coal in the middle (FLS Swirlax)

Multi-channel burner
Type B --- Swirl and Axial … Coal inside
•Low primary air consumption •Complicated design
•Flame adjustment possible •High cost
•High fuel concentration in
flame core •Risk of divergent flame

Multi channel burner
2-nozzle burner,
type B (FLS Duoflex)… Coal inside

Kiln burners
Primary air momentum
(Air mass flow rate) x (discharge velocity)/(heat release rate):
m air  c
N/MW
Q
or:
(% of Lmin) x (discharge velocity):
Lp  c %m/s 
Kiln burners: Primary air momentum
(1 N/MW = 300 %×m/s
 Uniflow burner: 20% × 75 m/s = 1500 %m/s

 Swirlax burner FCO,
120 mbar: 10,7% × 140 m/s = 1500 %m/s
 Swirlax burner SCO,
160 mbar: 9,4% × 160 m/s = 1500 %m/s
 Duoflex burner, 250 mbar: 7,5% × 200 m/s = 1500 %m/s
 Centrax burner, 750 mbar: 4,3% × 350 m/s = 1500 %m/s

Kiln burners
Primary air and flame momentum
Primary air velocity for 1500 %m/s
400
Centrax
300
Discharge velocity m/s
Duoflex & Swirlax SCO (250 mbar)
200 Swirlax SCO (160 mbar)
Swirlax FCO
100
Uniflow
0
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
Primary air, % of Lmin

Duoflex kiln burner

Duoflex kiln burner
Front end view
Primary air nozzle,

Ignition gas burner Axial + Radial
Coal meal nozzle
Fuel oil nozzle

Duoflex kiln burner-Front end
Radial air channel

Axial air channel
Coal meal channel Central air duct Oil burner lance

Duoflex kiln burner
Burner tip … Nozzle opening adjustable

Duoflex kiln burners
For waste co-firing

Flame adjustment and flame shapes
(Example: Duoflex)
 Primary air fan damper,

 opening increases air amount and pressure. Gives a shorter, stronger
flame.
 Air nozzle opening,
 opening increases the area, increases air amount, decreases air
pressure.
 Radial air damper,
 opening increases swirl effect, increases mixing, decreases the
ignition time and ignition distance from burner nozzle (shorter
plume).
 Axial air damper (normally keep 70-100% open at all time)
 opening increases air amount
 Oil and gas nozzle:
 Depending on the design of the oil and gas nozzles, these items have
an influence on the flame shape.

Scope of lecture
 Fuel types

Liquid fuel atomisers
 2 systems:
 Atomisation by pressure
 Atomisation by air

Liquid fuel atomizers
Pressure atomizing
Oil burner head
Liquid fuel inlet

Tangential slot openings,
adjustable
Liquid fuel atomizers
Compressed Air atomizing
Mixing chamber
Liquid fuel
Nozzle holes Atomising air

Burner head
Liquid fuel
Valve train
Flow measuring unit and shut-off unit
Flow measuring unit with mass flow meter Shut-off unit with double block function

Liquid fuel preparation

Gas burner systems
 Burner lances
 Valve train

Gas burner lance
shown with oil burner lance mounted
Gas nozzle in closed position
Gas inlet pressure from gas

station 0-1,5 bar.
Gas nozzle in open position
Oil burner regulator

Duoflex burner
(1) Burner (5) Flexible connections (9) Coal feed system*

(2) Closing plate (6) Primary air piping (10) Emergency air fan
(3) Burner suspension (7) Valve train (11) Primary air fan
(4) Ignition gas burner (8) Local control panel (12) Oil/gas burner sets
Duoflex burner
Elevation
adjustment
Axial air
adjustment
Servomotor
for oil flow
control Gas nozzle Air nozzle Central air Swirl air
adjustment adjustment adjustment adjustment

Gas firing
Velocity and flow, relative to pressure
450 3,50
400
3,00
350
Velocity 2,50
300
Flow, Nm3/h mm2

Velocity, m/s
250 Flow 2,00
200 1,50
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

Fuel gas reduction station
Gas reduction station and shut-off unit

Scope of lecture
 Fuel types

Kiln burner operation
Practical hints, …trouble shooting
 Burner position
 Flame shape
 Liquid fuel problems
 Burner snowman (“rhino” formation)

Kiln burner position
Initial adjustment
FLS recommendation:
•X y 0,5 m
•Burner tip in kiln center
FLS recommendation:
•Kiln axis same as burner
axis
Flame shape
Short and round >< Long and lazy

Liquid fuel problems
Oil burner back spill



Practical hints
How to avoid oil back spill
 Check the oil lance for leaks or damages.

 Oil temperature should be high enough giving a
viscosity of max. 17 cSt.
 For pressure atomizers: Check that there is sufficient
pressure
 For air atomizers: Check that there is sufficient
atomizing fluid flow.
 Check balance Compressed air  liquid
 The nozzle tip should be clear of the burner front.
 If necessary move it up to 15 mm outside burner front.
 Increase central air.
 Reduce swirl air.

Burner snowman “Rhino” formation

“Rhino” formation Impact on flame:
Flame lifts up and touches “naked” lining
•Flame will lift due to ”bluff body” effect

•This may lead to increased kiln shell
temperature
•Removal by burner retraction?

Burner snowman
Air blaster for “Rhino” removal

Scope of lecture
 Fuel types
 Calciner burners

Calciner burners
 ILC calciner
 Down draught calciner

ILC - In-Line Calciner
Kiln burner
Calciner burners
ILC Calciner
Calciner burners

Burner equipment OEC
for oil firing in calciner

Calciner burner CBO
for oil firing in calciner
Atomising air
Cooling air Oil

Calciner Gas Burners
ILC
RISER DUCT
CALCINER BURNER CBG

(4 OR 6 REQUIRED BASED ON CAPACITY)

Calciner burner CBG
Wear resistant design

Fuel types and firing systems
End of Lecture
Kiln Process and Operation course
© FLSmidth 2014, all rights reserved. Fuel and Firering

Fuel Types and Firing Systems

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Formati disponibili

Fuel types and firing systems

Kiln Process and Operation course

© FLSmidth 2014, all rights reserved. Fuel and Firering

© FLSmidth 2014, all rights reserved. Fuel and Firering 2

© FLSmidth 2014, all rights reserved. Fuel and Firering 4

 High flexibility towards different fuels

© FLSmidth 2014, all rights reserved. Fuel and Firering 5

 High flexibility towards different fuels

 Increased production or lower fuel

© FLSmidth 2014, all rights reserved. Fuel and Firering 6

 High flexibility towards different fuels

 Increased production or lower fuel

 Repeatability - easy change of burner

© FLSmidth 2014, all rights reserved. Fuel and Firering 7

 High flexibility towards different fuels

 Increased production or lower fuel

 Repeatability - easy change of burner

 Stable kiln operation

© FLSmidth 2014, all rights reserved. Fuel and Firering 8

 Kiln burner selection

 Oil and gas burners

 Practical hints, troubleshooting

© FLSmidth 2014, all rights reserved. Fuel and Firering 9

 Primary fuels (Fossil)

 Secondary fuels (Non-fossil “Waste”)

© FLSmidth 2014, all rights reserved. Fuel and Firering 10

•No preconditioning •Easy to burn

•Handling •Need for grinding •Expensive

© FLSmidth 2014, all rights reserved. Fuel and Firering 11

Lignite 40-50 4800 7,1

Bitum. coal 10-40 6300 9,2

Antracite 5 6900 9,9

Petcoke 11 8300 11,5

© FLSmidth 2014, all rights reserved. Fuel and Firering 12

 Volatile amount high

© FLSmidth 2014, all rights reserved. Fuel and Firering 14

Necessary Net. Air

Gas oil 0 °C 10,200 14,4

Light fuel oil 60 °C 9,900 14,2

Heavy fuel oil 120 °C 9,800 14

© FLSmidth 2014, all rights reserved. Fuel and Firering 16

 Composition of the fuel varies with the origin

© FLSmidth 2014, all rights reserved. Fuel and Firering 17

Saharan 87 9800 14,0

North Sea 92 8800 12,6

© FLSmidth 2014, all rights reserved. Fuel and Firering 20

 Constant chemical composition

© FLSmidth 2014, all rights reserved. Fuel and Firering 21

Lmin [Nm3 air/kg fuel] =

1,8641  C  5,5531   2  0,692  S  0,6997   2

© FLSmidth 2014, all rights reserved. Fuel and Firering 23

 Kiln burner selection

© FLSmidth 2014, all rights reserved. Fuel and Firering 25

 Flame formation & heat transfer

 Primary air momentum

© FLSmidth 2014, all rights reserved. Fuel and Firering 26

© FLSmidth 2014, all rights reserved. Fuel and Firering 27

Oil 300-550 2120

© FLSmidth 2014, all rights reserved. Fuel and Firering 28

Remember: 90% of the heat input to the charge

1. Must be able to burn

© FLSmidth 2014, all rights reserved. Fuel and Firering 30

 Primary air momentum

 Primary air swirl