Reducing Kiln Introduction Stcetley Dolomite operates two dolomite lime plants with three kilns between them in Northern England. Here, the company produces three grades of lime {or use in the steel and refractory industries. Asa result of recent global market _qressures the comigany has needed to cut the cost of production. A number of initiatives have been identified, but the one that showed the greatest potential for savings was to reduce fuel costs in the kiln. There were multiple ways that this could be achieved, but a decision was made to concentrate on reducing fuel consumption levels and maximising the use of alternative fuels, A review of the kilns indicated that the Theislington Works kiln 3 would have the greatest potential for fuel reduction because of its unusually high primary ait requirements, The bumer designed and supplied tothe plant some yearsearler ‘would not allow proper kiln operation at lower amounts of primary ai. The ‘burner was firing coal and could accommodate up to 40% of the required heat input as wastesolvent, Statutory regulations prevented more than a 40% addition of waste solvents, so another alternative fuel (tyre crumb) was sourced, This provided the incentive to improve on the existing burner and improve efficiency ‘with a better burner design. Oxygen was being used as the atomising medium forthe waste solvent for a number of reasons, so it was determined that any redluction in the amount of oxygen used would also be welcomed, given its high price ‘Alteran extensive search for a suitable bumer supplier, FCT Combustion ‘was selected because ofits strong, technical ability andl capacity to model the kiln ‘under all ofthe firing conditions. This article discusses some ofthe expertise used toachieve significant cost savings. Kiln assessment For meaningful modelling, accurate data is needed, so an experienced engineer ‘went to the site in order to collect information vital to the bumer design. Apart from measuring fan flows, air temperatures and fuel data, a number of specialised ae) ‘meastirements were taken. These included secondary air temperature and kiln Managing Director, inlet gas concentrations, both of which are critical for analysing the performance ae ‘of combustion inthe kiln. Long,term data was collected from plant logs too, to Sel assist in determining typical values and as a reference for assessing performance and Grant England, eee ie ares ae aon for pels Combustion Engineer, nurposes,and plant engineers and operators were consulted about thei ae We ee id ce é FCT Combustion Pty Ltd, experiences with the operation ofthe ki Celta a RNR aL Modelling FCT uses a number of modelling techniques when assessing a kiln DO eg ‘combustion system. Each of them helps to build up a picture of the improved efficiency.shortened refractory lite and po ct quality results based on data collected from the site. Additionally, the ‘aerodynamics can be observed in realtime by following small beads placed inthe water Flow Water-bead modelling was ist used to investigate the aerodynamics ofthe coole throat and kiln hood. in this technique, the seconclary aris represented by water and neutrally buoyant polystyrene beads are added and illuminated with thin light sheet to enable the flow in that area tobe visualised (Figure 1), Te was found that the flow of secondary air in the cooler throat and kiln hood was relatively uniform, with ile ono swirl. However, a the hot air from the cooler bends to enter the kiln, it continues in a downivard motion around the burner: The downward direction can cause the flame to be deflected conto the bed, often with detrimental effects to product quali process and includes various mathematic techniques, as well as__and refractory life In this case the downward motion could be physical modelling, The physical modelling technique focuses adequately addressed using clever design and repositioning of ton the clominant processes that determine how well the fuels the burner within the kiln and air mix and, hence, how effectively combustion occurs ‘Acid-alkali modelling was used! to simulate the combustion in the process. The technique has been proven through its process in the kiln. With this technique, dilute acid is used successful use in hundreds of applications over 25 years and is, torepresent air andl alkali is used to represent the fuel. The a primary tool for validating the burmer design, acid and alkali flows and concentrations are based on site The physical modelling involved the construction of @ measurements to reflect the actual flows of fuel, primary and 38:1 laboratory scale acrylic model ofthe kiln and cooler secondary air By adding a pH indicator, phenolphthalein, Dilute acid and alkali solutions are introduced into the model tunburnt fuel appears pink. This highlights the fame shape and through specially-sized nozzles to represent the air and fuel how well the fuel mixing occurs. Gambarotta Gschwendt. bulk solid mechanical “TIREX. Receiver from truck 94 years of reliable experience ‘and feeder for several bulk materialsflame from the optin oncentrating neat in the burning zone. Simulated flame from the original bumer is ely lang and inefficient. hort and cer Modelling ofthe original burner showed that the flame zone, where itis needed. The centred flame will increase was excessively long, me at it was impinging on the refractory life bottom ofthe kiln (Figure 2a). This indicated that the fuel and 1 insight into the impact ofthe icient combustion. flame that the plant engineers or operators could not have burnt fuel was appreciated by other means. Typically, operators use atrial and | leaving the kiln. With the flame & impinging on the ‘error approach that will often jeopardise product quality and | kiln walls the effects were low ity and shorter production, refractory lf. The new, optimised flame nin Figure 2b implementation operating under the same cond same fuel rate During a routine maintenance shutdown, a number of and kiln oxygen, at 1.4%, The flame is now centred in improvements w youn the kiln system, andl the the kiln and is sig a direct result installation of the new burner provided an opportunity to | of the new burner improving the mixing of the fuel and frve up precious burner deck spac and recluce some safety | air, ineroasir adjusting, concerns. This was acheived by replacing the original floor- the insertion slightly. As a resu profile of the ‘mounted trolley with an overhead one. The primary air fan flame is shorter, and more hea he burning ‘was replaced with one of higher pressure to reduce the volume The complete range of handling technologies. in our work shop Clinker pan conveyor Noe V \GAMBAROTTA 1919 .AGSCHWENDT 38123 TRENTO, ITALY - Viale Verova, 200, “Tel, 439 0461 920403 - Fax +39 0461 933391 www gambarotta.it nbarotta@gambarottait= ‘The new Turbufet bummer is rated for 60 MW, either fring, Es San eS entirely pulverised coal or with a combination of altemative gn fuels. The burner included FCT’ proprietary lofting ar channel ie to assist the dispersion of tye crumb into the lame at more ° Salvent than 3tph. Figure 3 shows how the use of coal has reduced Ey A ‘There have been a number of significant improvements Soe ra in kiln operation since the installation ofthe new bumer. An alternative fuel substitution of 70% has been achieved, the Setar ate specific heat consumption has dropped by 12%, primary use by. 44586 and pure oxygen use has dropped by 10%. These effects are summarised in Figure 4 Itis also expected that there will be Figure 4. Savi after the installation of the an improvement in refractory life, but it will take until the end new burner (of this campaign to confirm this. Savings Conclusion ‘o. ‘The installation ofa fully optimised, mult-fuel bumer in the oo Steetley Thrislington dolomite kiln has resulted in significant ichieved for the company. The burner is now firing up to 70% alternative fuel, as well as improving ne financial savings bei overall fuel consumption and fan power savings. Ata time when there are significant marketing pressures its vitally etre et important to improve efficiency and drive down operating cena secret sala costs. This kiln has demonstrated the potential savings of this consumption oxygen use process, and as a sult, kiln 2 at the Whitwell plant will also be upgraded in 2013, a Legacy + Safety and Commitment ning expertise can safely and efficiently Cea When ac ila en ae ea Nee eae teuere als reused as well, saving you material and money. Poca ce ‘© Over 500 projects in the cement industry alone Deu RRR MMe Ma Aged sl =r econ ler etigeyse ere) ens or to request a quote, visit www.molemaster.com/cement MOLE-MASTER SERVICES CORPORATION aoe