User Tips and Instructions

Note : The OFT (Optimum Flame Theory) burner spreadsheet based on the OFT theory
(from Tom Lowes report released in 1995 (Blue Circle)
The burner 's jet momentum needs to be adequate to entrain sufficient secondary air to
be able to mix the coal on a macro scale before
the plug flow zone in the kiln.

Only for an axial flame ( no swirl)

1
2 Inputs
3 Enter burner elevation , cell F5 and verify
4 Enter the type of burner, cell E14
5 Enter the burner inlet diameter (D1), cell K17 or K29
6 Enter the burner outlet (tip) diameter (D2), cell D18 or D30& D32
7 Enter production at which you are evaluating cell K43
8 Enter SHC , cell D54 (solid fuel flowrate)
9 enter back-end O2 %, cell K54
10 Enter kiln diameter, cell K50
11 Enter brick thickness in the burning zone, cell K52
12 Q50)
13 Enter burner inlet temperature, cell K20 or cell K32
14 Enter the actual primary air flow measured, cell K22 or K34

Check that other statistics and dimensions are correct

Back Pressure at the burner

If the iteration doesn't work , type "0" in cell D63 and after type"1"
You should be able to find out the back pressure needed at the burner with a subsonic
type of flow
and compare with the existing pressure measured, cell D87

Optimum flame theory

rows 96 to 105
This theory will predict an optimal momentum and an optimal velocity at the burner inlet
and at the burner tip
You can compare with your actual numbers, rows 103 to 105

the
inlet diameter ( no bluff body, no tip reduction), this momentum is calculated with the kiln
production rate (tph) , the kiln diameter and the gross fuel consumption (kcal/kg)

burner
momentum decreases below that specified number , reducing conditions begin to occur,
once less
than 85 % of the optimal momentum is reached. Cell D23 or D37

A shorter flame could be achieved by increasing primary air at constant velocity

OPTIMAL FLAME THEORY (Monotube burner)
Plant Westbury K1 Existing Legend
Date : 2/24/2004 Very High
Name Olivier BERNARD High
Language 2 Burner elevation: 100 m, ASL OK
English, type "1" 10210.45 mm WG Low
Comments

For standard pipe type "1", for bluff body type "2" 1

1. Standard Monotube Burner Pipe

438.15 D1 - Inlet ID, mm
D2 - exit ID, mm 361.95 17.25 Inlet ID, inches
exit ID, inches 14.25 33 Velocity m/s
area, mm2 102,893 125 Back pressure, mm WG
Velocity m/s 50.6 4.9 Back pressure, inches WG
Impulse N*m/GJ 0.96 13,921 Measured Flow, Nm3/h
% of Optimu 59% 85.0 Inlet temperature, deg C
Optimum velocity m/s 86.11 17.7% % Primary Air
MAP/MAS 1.02

2. Monotube with Bluff Body

438.15 D1 - Inlet ID, mm
D2 - exit ID, mm 438.2 17.25 Inlet ID, inches
exit ID, inches 17.25 33 Velocity m/s
D3 - Bluff body OD, mm 10.0 57 Back pressure, mm WG
Bluff body OD inches 0.39 2.2 Back pressure, inches WG
area, mm2 150,699 13,921 Measured Flow, Nm3/h
Velocity m/s 34.6 85.0 Inlet temperature, deg C
Impulse N*m/GJ 0.66 17.7% % Primary Air
% of Optimu 40%
Optimum velocity m/s 86.11
MAP/MAS 1.02

Production KK (tpd) 1080

Production KK (tph) 45
\
Total combustion air Nm3/kg kk 1.74 Fuel characteristics (dry basis)
0
% fuel in pre-calciner 0 Coal Coke

Kiln shell diameter 4.40 m % 100% 0%

Heat consumption to the main burner Flow Heat value Therm energy brick thickness 0.2 m % volatiles 25 1
kg/h Kcal/kg Gcal/h Kiln ID (BZ) 4 m
COAL 10000 6300 63.00 Back end O2 % 1.5
1400 kcal/kg CK %C 55 1
5862 MJ/T %S 1 1
%H 9 1
%O 1 1
Thermal load (kcal/h/m2) 6123 Nm3/kg fuel 7.28 0.35
Notes and Comments
> valid for dry air LHV (BTU/lb) 11340 0
Burner Design > does not account for energy transferred LHV(Kcal/kg) 6300 0
Iteration Reset 1 to ground fuel carried LHV(kJ/kg) 26377 1
Pipe Dimensions Standard Bluff Nm3/cal
Burner inlet ID (D1) mm 438.15 438.15 ACN
Burner exit ID (D2) mm 361.95 438.2 Nm3/T CK
Bluff body OD (D3) mm 10.0
inlet area mm2 150,777 150,777
outlet area mm2 102,893 150,699
ratio outlet/inlet % 0.68 1.00
Gas/Air Calculations Std Bluff
atmospheric pressure @ elev mmWG 10,210
Normal density kg/m3 1.293
R J/kg K 287.00
k Cp/Cv 1.40
Measured primary air flow Nm3/h 13,921 13,921
Inlet Air temperature Celcius 85.0 85.0
Barrel air density kg/m3 1.00 0.99
Exit air density kg/m3 0.99 0.99
Barrel air flow Am3/h 18,033 18,152
Exit air flow Am3/h 18,194 18,228
Barrel Inlet Velocity m/s 33.2 33.4
Tip Exit Velocity m/s 50.6 34.6
Barrel Inlet Mach Number 0.09 0.09
Tip Exit Mach Number 0.13 0.09
Calculated req'd back pressu mmWG 125 57
Back Pressure mmWG 125 57
inches WG 4.92 2.23
Pa 1224.61 556.01
psig 0.18 0.08
Add Impulse and velocity guidelines

0.96883127
Optimum Flame Theory and Impulse Calculations 7.03694444
Std. Bluff 5
Primary Air Mass flow kg/s 5.00 5.00
Axial Impulsion (air only) N 253.2 173.2
Impulse N.h/Gcal 4.02 2.75
N.h/GJ 0.96 0.66
Total Impulse (air+fuel) N 393.8 269.4
Actual tip velocity m/s 50.6 34.6

Optimum Momentum (G opt) N 669.8 669.8

Optimum tip velocity m/s 86.1 86.1
Ratio momemtun (actual/opt) 0.59 0.40

2.03694444
7333
Energy Balance
Energy gas inlet kJ/s 1776.90
Kinetic energy fuel inlet kJ/s 1.53
Energy gas exit kJ/s 1770.59
Kinetic energy fuel exit kJ/s 3.56
IN minus OUT 4.28
0.24%

MAP/MAS determination

Kiln production,tpd 1080 0.5 1.0 1.5 2.0 2.5 3.0 m

Kiln diam.,m 4.40 primary Nm3/h 13,921 1000 1300 1500 1600 1650 1700 DegC
Coating thickness,m 0.2 m/s 8.4 10.4 11.7 12.4 12.7 13.0
primary% 17.75 Moment,N 195 241 271 286 294 302
kcal/kg CK 1400

Coal kcal/kg 6300

0 Spe.Impuls 3.09 3.82 4.30 4.55 4.67 4.79

Back end O2% 1.5
Approx. Sec air, Nm3/h 64,525 248 N Sec.air
combus air Nm3/cal 1.156 253 N Axial component of burner
Gcal/h through main burner 63.0 Difference 5N
 614841745.xls
SWIRL AND MOMENTUM DETERMINATION
Original: CLV / S.THIERS Apr-95 PLANT : BATH
Update: CTS / W.Oliveira Sep-99 Date : 9/24/2022
(Inputs are in bold characters) Name : W. Oliveira
COMMENTS :
Modifications on Bath's burner - Increase the axial hole dimension (from 25 to 28.3) and reduce the swirl angle (from 35 to 20
degree).
Goal is to increase the turbulence at the tip, and then reducing the buildups.

TIP CROSS SECTION AREAS Diameters : % cross section reduction Dext : 609.6
(mm) thk : 17.475
AXIAL AIR 545.3 2900 mmWG
Holes 1, Vanes 2 : 1 226 m/s 488.7 72.6% 24 m/s 7806 Nm3/h
12580 mm2 Dext : 457.2
428.7 thk : 14.275
TRANSPORT AIR 0 m/s 327.9 0 m/s Dext : 323.9
0 mm2 thk : 9.5
298.9 2500 mmWG
SWIRL AIR 203 m/s 267.5 62.5% 24 m/s 2957 Nm3/h
4915 mm2 Dext : 219
thk : 8.2

DETAILS OF THE TIP Swirler Number slots groove width radial gap radius
angle (o) of vanes width(mm) (mm) vanes(mm) raccord.
Swirl 20 20 15.697 14.750 0.5 1
Axial (if vanes) -

Axial (if holes) Number of holes : 20 Diameter : 28.30

GENERAL DATA
Kiln TYPE : LD PRODUCTION (T CK /d) : 2950.00

NP : no preca, AT : air through, AS : air seperat. Specific heat consumpt.kJ/kg CK : 3590.00

FUEL ANALYSIS, AS FIRED (DRY BASIS) Swirl Air: F=Fan; B=Blower B

%C #REF! %O #REF! Percent of heat at back-end : 0.00

%S #REF! NCA
%H #REF! Nm3/kg fuel #REF! Shell internal diameter (m) : 5.80

Total combust. air (Nm3/hr) : #VALUE!

SPECIFIC HEAT CONSUMPTION Throughput L.H.V. Therm.power
AT THE BLAST PIPE kg/h KJ/kg GJ/h
COKE/COAL 40/60 #VALUE! #REF! #VALUE!
0.00
0.00
0.00 Recalculated SHC :

Total (GJ/h) : #VALUE! #VALUE! kJ/kg CK

GAS FLOW MEASUREMENTS Axial Swirl Transport

Static pressure in the tip 2900 2500 -
Temperature in the pipe (deg C) 100 70 100
Theoretical flow rate (Nm3/h) 7806 2957 - Fuel to air ratio:
Bias coefficient : 1.00 1.00
Accepted flowrate (Nm3/h) 7806 2957 4200 #VALUE! kg/m3

Axial / Swirl distribution 73% 27%

RESULTS
FLOW VELOCITIES Axial Swirl Transport Is Swirl
Nature of flow subsonic subsonic velocity N.h/GJ
Release tip velocity (m/s) 226 203 0 ### 0.08

Primary air rate, axial : #VALUE! Targets: Fuel-Oil 1.2 0.15

swirl : #VALUE! Coal 1.5 0.15
transport : #VALUE! Coke 1.8 0.15
Axial + Transport: #VALUE!
Primary air rate #VALUE! THERMAL LOAD (MW/m2) : #VALUE!
Pipe
Size O.D. 5 10 20 30 40 STD 60 80 XH
in 6.625 0.109 0.134 0.280 0.280 0.432 0.432
6 mm 168.275 2.769 3.404 7.112 7.112 10.973 10.973
lbs/ft 7.585 9.289 18.970 18.970 28.570 28.570
in 7.625 0.301 0.500
7 mm 193.675 7.645 12.700
lbs/ft 23.570 38.050
in 8.625 0.109 0.148 0.250 0.277 0.322 0.322 0.406 0.500 0.500
8 mm 219.075 2.769 3.759 6.350 7.036 8.179 8.179 10.312 12.700 12.700
lbs/ft 9.914 22.360 22.360 24.700 28.550 28.550 35.640 43.490 43.490
in 9.625 0.342 0.500
9 mm 244.475 8.687 12.700
lbs/ft 33.900 48.720
in 10.750 0.134 0.165 0.250 0.307 0.365 0.365 0.500 0.593 0.500
10 mm 273.050 3.404 4.191 6.350 7.798 9.271 9.271 12.700 15.062 12.700
lbs/ft 15.190 18.700 28.040 34.240 54.740 54.740 54.740 64.330 54.740
in 11.750 0.375 0.500
11 mm 298.450 9.525 12.700
lbs/ft 45.550 60.070
in 12.750 0.165 0.180 0.250 0.330 0.406 0.375 0.562 0.687 0.500
12 mm 323.850 4.191 4.572 6.350 8.382 10.312 9.525 14.275 17.450 12.700
lbs/ft 22.180 24.200 43.770 43.770 53.530 49.560 73.160 88.510 65.420
I.D. mm ### ### 311.150 307.086 303.225 304.800 295.300 288.950 298.450
in 14.000 0.250 0.312 0.375 0.437 0.375 0.593 0.750 0.500
14 mm 355.600 6.350 7.925 9.525 11.100 9.525 15.062 19.050 12.700
lbs/ft 36.710 45.680 54.570 63.370 54.470 84.910 106.100 72.090
I.D. mm ### 339.750 336.550 333.400 336.550 325.476 317.500 330.200
in 15.000 0.250 0.312 0.375 0.375 0.500
15 mm 381.000 6.350 7.925 9.525 0.000 9.525 0.000 0.000 12.700
lbs/ft 36.710 45.680 54.570 63.370 54.470 84.910 106.100 72.090
I.D. mm ### 365.150 361.950 381.000 361.950 381.000 381.000 355.600
in 16.000 0.250 0.312 0.375 0.500 0.375 0.656 0.843 0.500
16 mm 406.400 6.350 7.925 9.525 12.700 9.525 16.662 21.412 12.700
lbs/ft 42.050 52.360 62.580 82.770 62.580 107.500 136.500 82.770
I.D. mm ### 390.550 387.350 381.000 387.350 373.075 363.576 381.000
in 18.000 0.250 0.312 0.437 0.562 0.375 0.750 0.937 0.500
18 mm 457.200 6.350 7.925 11.100 14.275 9.525 19.050 23.800 12.700
lbs/ft 47.390 59.030 82.060 104.800 70.590 138.200 170.800 93.450
I.D. mm ### 441.350 435.000 428.650 438.150 419.100 409.600 431.800
in 20.000 0.250 0.375 0.500 0.593 0.375 0.812 1.031 0.500
20 mm 508.000 6.350 9.525 12.700 15.062 9.525 20.625 26.187 12.700
lbs/ft 52.730 78.600 104.100 122.900 78.600 166.400 208.900 104.100
in 22.000 0.250 0.375 0.500 0.375 0.875 1.125 0.500
22 mm 558.800 6.350 9.525 12.700 9.525 22.225 28.575 12.700
lbs/ft 58.070 86.610 114.800 86.610 197.400 250.800 114.800
in 24.000 0.250 0.375 0.562 0.687 0.375 0.968 1.218 0.500
24 mm 609.600 6.350 9.525 14.275 17.450 9.525 24.587 30.937 12.700
lbs/ft 63.410 94.620 140.800 171.200 94.620 238.100 296.400 125.200
in 26.000 0.312 0.500 0.375 0.500
26 mm 660.400 7.925 12.700 9.525 12.700
lbs/ft 85.600 136.200 102.600 136.200
 100 120 140 160 XXH
0.562 0.718 0.864
14.275 18.237 21.946
36.390 45.300 53.160
0.875
22.225
63.080
0.593 0.718 0.812 0.906 0.875
15.062 18.237 20.625 23.012 22.225
50.870 60.630 67.760 74.690 72.420

0.718 0.843 1.000 1.125

18.237 21.412 25.400 28.575
76.930 89.200 104.100 115.700

0.843 1.000 1.125 1.312

21.412 25.400 28.575 33.325
125.500 125.500 139.700 160.300
281.026 273.050 266.700 257.200
0.937 1.093 1.250 1.406
23.800 27.762 31.750 35.712
130.700 130.700 170.200 189.100
308.000 300.076 292.100 284.175

0.000 0.000 0.000 0.000

130.700 130.700 170.200 189.100
381.000 381.000 381.000 381.000
1.031 1.218 1.437 1.593
26.187 30.937 36.500 40.462
164.800 192.300 223.500 245.100
354.025 344.526 333.400 325.476
1.156 1.375 1.562 1.718
29.362 34.925 39.675 43.637
208.000 244.100 274.200 308.500
398.475 387.350 377.850 369.926
1.280 1.500 1.750 1.968
32.512 38.100 44.450 49.987
256.100 256.100 341.100 379.000
1.375 1.625 1.875 2.125
34.925 41.275 47.625 53.975
302.900 353.600 403.000 451.100
1.531 1.812 2.062 2.343
38.887 46.025 52.375 59.512
367.400 429.400 483.100 541.900