R O T A F L A M ® PRESENTATION

2002

PILLARD R O T A F L A M ®
Rotary Kiln Burner
Development and actual Design
ROTAFLAM®

The flexible combustion tool for rotary kilns

(protected by patent)
History

PILLARD burner type VR

First multi channel burner
developed over 30 years ago.

Over 600 burners have been

operated successfully.
Initial requirements
for new burner development

Significant reduction of NOx emission

Energy saving

Most efficient adaption of heat transfer to the product

ROTAFLAM® / VR burner design

Axial air channel VR burner:

Coal channel Static pressure 120 mbarg
Pressure at tip Pu 85 mbarg
Radial air channel Flow Q 10 – 12 % of total
Specific kinetic energy:
Q x Pu = 10 x 850 = 850

ROTAFLAM:
Static pressure 160 mbarg
Pressure at tip Pu 150 mbarg
Axial air channel Flow Q 6% of total
Specific kinetic energy:
Radial air channel Q x Pu = 6 x 150 = 900

Coal channel

Flame stabilizer
 ROTAFLAM® characteristics

Axial ring

Axial air slots

Radial air swirler

Coal duct

Flame stabilizer
ROTAFLAM®
main targets of development

Concentration of fuel along burner axis by
arrangement inside swirl air duct, in order
to avoid that fuel particles leave the main
flame contour and burn in the hot secon-
dary air atmosphere under superstoichio-
metric conditions
Flame stabilization without using the swirl
air component, thus reduction of total
primary air input for flame shaping and
decrease of oxygen concentration in the
primary combustion zone
More equal heat distribution avoiding
temperature peaks to decrease NO
formation and reduce thermal stress
on kiln lining
Variations of the primary air flows for
flame adjustment by changing
burner tip geometry during operation

Improved burner tip aerodynamics Early fuel ignition and stable flame even
allowing flame shaping with a minimum of in cold kiln
primary air input and maximum outlet
velocity
ROTAFLAM® type O
(single oil operation)
ROTAFLAM® type GO
(gas and oil operation)
ROTAFLAM® type KO
(coal and oil operation)
ROTAFLAM® type KGO
(coal, gas and oil operation)
ROTAFLAM® adjusting device

Mechanical adjusting device

Hydraulic adjusting device

ROTAFLAM® type KGO
Burner tip variation by longitudinal
adjustment




















Reset
Flame shaping by air flow variation

Axial Radial

START STOP
100% 100%
ROTAFLAM® small scale test

Flame adjustment by air flow variation

with a small ROTAFLAM® test burner
showing short hot flame, long flame and wide soft flame

Click on picture to start and stop the video

Flame shape adjustment by variation
of fuel flow distribution

PILLARD MYS atomizer gun for rotary kiln burners

Atomizer system MYS
Flame shaping by variation of oil
differential pressure

Primary Secondary

START STOP

40 bar 39 bar
13 years of continuous improvement

Increasing flexibility to satisfy more critical process requirements

NOx reduction and low primary air consumption are no longer the cement producer´s
main requirements.
Stable kiln conditions and energy saving by substitution of „primary“ fuels by low
cost „secondary“ or alternative fuels without affecting the kiln operation have
become new main targets.
Revision of the former basic design criteria was essential:

ROTAFLAM - 1. Generation ROTAFLAM - New generation

Designed for max. 6% of primary air Designed for 8% of primary air
Fan capacity max. 7% of primary air Fan capacity 10% of primary air
Static pressure 160 mbar Static pressure 250 mbar
13 years of continuous improvement

Extended burner operation with low cost liquid (waste) fuels

Waste oil
Solvents
Residues from oil industry
Contaminated water

Complete individual fuel supply system is required.

Varying chemical properties and content of solid impurties have
to be considered for the design of equipment to prevent from
incredible wear and the risk of interruption of kiln operation
due to plugging of atomizer system.
13 years of continuous improvement

Liquid waste atomization

Fuel pressure: 8-12 bar

Atomizing air: 6- 8 bar
Max. particle size: 6 mm
13 years of continuous improvement

Liquid waste atomization

Flame stabilizer and central air circuit

allow installation of additional fuel
feeding systems
13 years of continuous improvement

Extended burner operation with low cost solid (waste) fuels

Petroleum coke
Bark powder
Wood powder
Municipal waste (depending on degree of preparation)
Tyres (depending on degree of preparation)
Agricultural derived fuels
Plastics
Paper
Animal powder
13 years of continuous improvement

Examples of solid (waste) fuels

Click on picture to start and stop the video

New development

The PILLARD solid (waste) fuel swirler unit

(protected by patent)
Portion of primary air
(pressure 250 mbar)

Swirler
nozzles Solid waste
with transport air
The PILLARD solid waste swirler unit

Test arrangement : First sequence without swirl air

Click on picture to start and stop the video

The PILLARD solid waste swirler unit

Test arrangement : Second sequence with swirl air

Click on picture to start and stop the video

ROTAFLAM®

Three ROTAFLAM® burners KO-S ready for shipment

Click on picture to start and stop the video

ROTAFLAM® burner KO-S 125 MW
for Rohrdorf Zement Plant
Coal: 15.000 kg / h Actually 10.000 kg / h of Tetrapak
Heavy fuel oil: 11.000 kg / h primary fuel substitution rate: 60%
Plastics (Tetrapak): 12.000 kg / h

+20/-45

+10/-30

+10/-50

+20/-50
ROTAFLAM® burner KO-S 93 MW
for HOLCIM Untervaz Zement Plant
Coal: 9.855 kg / h Waste oil: 6.750 kg / h
Heavy fuel oil: 6.300 kg / h Animal powder: 3.000 kg / h
Plastics (Tetrapak): 3.500 kg / h Distillation residuals: 1.500 kg / h
Contaminated water: 500 kg / h

Liquid wastes Solid wastes

Flame stabilizer
Heavy fuel oil
ROTAFLAM® burner KGO 98 MW
for Mérida Yucatan – Plant Cementos Maya Kiln 5
Petcoke: 10.000 kg / h
Heavy fuel oil: 9.050 kg / h
Natural gas: 9.970 Nm³/ h

Installation of the burner Start-up flame

ROTAFLAM® burner KGO 35 MW
for Plant Monterrey Kiln 5
Petcoke: 3.700 kg / h
Heavy fuel oil: 3.300 kg / h
Natural gas: 3.600 Nm³/ h
 ROTAFLAM®
The most flexible combustion tool for rotary kilns

More than 500

ROTAFLAM® burners
since 1989
testify success