GRECO KILN BURNERS FOR

„PETCOKE COMBUSTION“
Specific burner design for your kiln

Loesche Round Table / India  2012
 ABOUT GRECO

Founded in 1966 – Uni. Prof. Clemento Greco

90th – Conversion from fuel oil to petcoke

Since more than 10 years around 300pc. installed burners

Since 2010 part of the A TEC Group

Worldwide Offices

2011 2
 WORLDWIDE OFFICES

2011 3
 COMPETENCE IN THE
ROCK INDUSTRY

Kiln Burners Calciner Burners Hot Gas Generators Fuel Systems

NEW: Solid Alternative Fuel Handling System

2011 4
 COMBUSTION OF
PETCOKE

2011 5
 DESIGN OF FLEXIFLAME
PETCOKE

Combustion of petcoke:

Petcoke is harder to ignite as conventional coal (low volatile)

Petcoke provides a higher flame radiation then coal
Petcoke has a typicall high sulfur content
Petcoke develops a higher NOx formation
Usually petcoke changes the kiln profile
Petcoke needs a special burner design

2011 6
 PETCOKE COMBUSTION

The combustion of petcoke requires:

Quick mixing of secondary air to the flame, to allow the complete

combustion which is iniciated by primary air.
Primary air jets need to accellerate the secondary air.
Internal recirculations are controlling the ignition distance of the fuel

2011 7
 FLAME CONTROL

2011 8
 PETCOKE COMBUSTION

Design criteria for kilnburners working with 100% petcoke:

2011 9
 PETCOKE COMBUSTION

Design criteria for kiln working with 100% petcoke:

2011 10
 PETCOKE COMBUSTION

Tendency of buid ups (clorine vs. sulfur) in hot meal

Build ups – out of control

Build‐ups  Source:
under control VDZ Forschungszentrum
Düsseldorf

No build‐ups 

The additional sulfur input by petcoke requires a check of raw material mix.

2011 11
 PETCOKE COMBUSTION

High flame momentum has advantages in:

Kiln operations becomes more stable & improved fuel efficiency

Improved clinker reaktivity and shorter sintering zone
Lowered volatility and recirculation of sulfur in kiln gases (control of
surfur into the clinker)
Tendency for ring formation is lower
Clinker granulometry more uniform

2011 12
 FLEXIFLAME™
KILN BURNER

2011 13
 FLEXIFLAME KILN BURNER

Design Philosophy:
Each kiln burner will be designed individually according to the process of
each kiln and its characteristics. That provides operation safety for the
entire combustion and sintering process.

2011 14
 REQUIREMENTS FOR
KILN BURNERS

Maximum use of solid alternative fuels

Clinker quality
Kiln operation
Lowest possible NOx & CO emissions
Wear resistance + low maintenance
– Compromise between different parameters

– Flexibility to operate with different fuels

• TAILOR MADE
• HIGH FLEXIBILITY
2011 15
 DESIGN OF FLEXIFLAME
BURNERS FOR PETCOKE

EXTERNAL AIR
TANGENTIAL AIR (ROTATION)
COAL/PETCOKE
DISPERSION AIR (ROTATION)
CENTRAL AIR
(RECIRCULATION/COOLING
SLUDGES / ANIMALMEAL
IGNITOR
MIXING AIR FOR ASF
RDF / FLUFF

DOUBLE SWIRL EFFECT

2011 16
 DESIGN OF FLEXIFLAME
KILN BURNERS

Coal / Petcoke

RDF+mixing air

External Air
MBM+mixing air
Tangential
Air
Cooling Air Dispersion Air

2011 17
 DESIGN OF FLEXIFLAME
KILN BURNERS

Conveying air ratio Conveying air flow

Pulverized solid fuel Up to 5,0 kg of material 2-3,5 % of stoichiometric air

(Coal / Petcoke) per kg of air
Animal meal and/or Up to 4,0 kg of material
1-3,5 % of stoichiometric air
Sewage sludge per kg of air
Up to 2,5 kg of material
Fluff / RDF 1-3,5 % of stoichiometric air
per kg of air

2011 18
 DESIGN OF FLEXIFLAME KILN
BURNERS

HIGH EFFICIENT BURNER DESIGN

Customized primary air pressure (250 – 500 mbar)

Less possible transport air flow for coal/petcoke
Primary air with high pressure (high momentum)
• 6 – 12% of stoichiometric combustion air
• NOX emission control

2011 19
 DESIGN OF FLEXIFLAME
KILN BURNERS

SOLID ALTERNATIVE FUEL FIRING

SAF – solid alternative fuels

with pneumatic mixing device
SAF pipes in compound wear resistant
material
„O2 – READY“ design to improve the
kiln performance
Pulverized fuel inlet in hardened
material– outer pipe
Pulverized fuel inlet with ceramic
protection – inner pipe
No wear at SAF nozzles !

2011 20
 NEW FLEXIFLAME RS
KILN BURNER

New FLEXIFLAME RS® kiln burner with advantages of:

Easy flame setting and control

Smaller burner diameter
-30% steel burner weight
Less internal air pressure drop
Quicker and simpler burner tip service
Shorter kiln burner lenght, easier in handling
Maintaining of a high burner momentum

2011 21
 NEW FLEXIFLAME RS
KILN BURNER

New FLEXIFLAME RS® kiln burner

2011 22
 NEW FLEXIFLAME RS
KILN BURNER

External Air

Tangential Air
with air control slide

Petcoke/Coal

Cooling air

Dispersion Air
with air control slide

2011 23
 NEW FLEXIFLAME RS
KILN BURNER

External Air

Tangential Air
with air control slide

Petcoke/Coal

Dispersion Air
with air control slide

Cooling air

2011 24
 BURNERS LANCES

2011 25
 BURNERS LANCES

„OC- JET“ nozzle – for dirty alternative liquids

Waste oil, Animal fat, Residues…

Range 1:8
Viscosity: up to 300cSt
2011 26
 BURNERS LANCES

2011 27
 HANSON – KETTON / UK

Nominal thermal power: 66 MW

Burner operational range: 80 – 105 % of nominal thermal power.
Multi-fuel burner firing coal, gas-oil, solvent and solid alternative fuels.
Nominal fuel flows:
Coal: 12,000 kg/h.
Liquid fuel: 6,000 l/h.
Solvents: 7,000 l/h.
Solid alternative fuel #1: 7,000 kg/h.
Solid alternative fuel #2: 7,000 kg/h.
2011 28
 AALBORG CEMENT /
DENMARK

Thermal power: 73,4 Gcal/h.

- Coal+Petcoke: 10.300 kg/h -> 100% of burner thermal power

- Fuel oil: 7.340 kg/h -> 100% of burner thermal power
- Glycerin: 4.000 kg/h -> 22% of burner thermal power
- MBM: 3.000 kg/h -> 16% of burner thermal power
- RDF: 6.000 kg/h -> 33% of burner thermal power
- Optional waste fuel: 4.000 kg/h ->16% of burner thermal power

2011 29
 CBR – ANTOING / BELGIUM

Thermal power: 50 MW (43,1 Gcal/h).

•Petcoke: 6.015 kg/h.

•Coal: 7.515 kg/h.
•Light fuel oil: 1,775 kg/h.
•Animal meal: 5.000 kg/h
•Dry sewage sludge or Resofuel: 2.500 kg/h
•Fluffs: 3.000 kg/h.
2011 30
 HANSON – RIBBLESDALE / UK

Thermal power (considering future capacity):

44,4 MW (38,25 Gcal/h)

Nominal fuel flows:

Coal: 6.660 kg/h
Kerosene / gas oil: 3.485 kg/h
Cemfuel: 6.000 – 7.000 kg/h
Animal meal: 5.000 – 7.000 kg/h
2011 31
 CBR HARMIGNIES / BELGIUM

Thermal power: 62 MW
•Petcoke
•Heavy fuel oil
•Solvents
•Plastics & RDF
•Animal meal

2011 32
 CEMENTOS ALFA / SPAIN

Thermal burner power: 52 MW

•Petcoke
•Heavy fuel oil
•Waste oil
•Plastics & RDF
•Dry Sewage Sludge
2011 33
 ENCI MAASTRICHT /
NETHERLAND

Thermal burner power: 128 MW

•Petcoke, sludge, anode dust
•Natural gas
•Glycol
•Animal meal
•Paper sludge
2011 34
 WOPFING CEMENT
AUSTRIA

Thermal burner power: 45 MW

•Petcoke
•Natural Gas
•RDF
•Animal Meal
•Waste Oil

2011 35
 BURNER TROLLEYS

Adjustable around the front suspension support in all directions to

align the burner well to the kiln requirements.

2011 36
 BURNER TROLLEYS

Adjustable around the front suspension support in all

directions to align the burner well to the kiln
requirements

2011 37
 FLEXICAL™
CALCINER
BURNERS

2011 38
 DESIGN OF FLEXICAL
PRECALCINER BURNERS

For all traditional fuels as well as RDF and waste liquids

2011 39
 SPRCIAL
DRYER BURNERS

2011 40
 DESIGN OF FLEXICAL
DRYER BURNERS

For all traditional fuels as well as RDF and waste liquids

2011 41
 DESIGN OF FLEXICAL
DRYER BURNERS

• Thermal Power:  1‐ 50 MW
• Easy controllable flame
• Safe and robust burner design
• Low maintanance necessary
• Stable flame with refractory 
mouth 
2011 42
 DESIGN OF FLEXICAL
DRYER BURNERS

Flexical Burner:
Coal &Fuel Oil burner on a rotary  
dryer  for  calcination  of    raw 
materials or chemicals.

2011 43
 FLEXIGEN™
HOT GAS
GENERATORS
for solid fuels as Petcoke /Coal…

2011 44
 VERTICAL DESIGN / SOLID
FUELS

2011 45
 SPECIFIC DESIGN OF
AIRFLOW

2011 46
 SPECIFIC DESIGN OF
AIRFLOW

2011 47
 SECONDARY AIR FAN

2011 48
 SECONDARY AIR & COOLING
AIR INLET

Secondary air inlet:

 Provides oxygen to the
flame.

Cooling air inlet:

 Controls the refractory
lining temperature.

 Automatic mode, to keep

the temperature bellow
1000 °C (ash melting
point)

 Both flows are adjusted

by pneumatic valves.
2011 49
 DILUTION AIR INLET

The dilution air is used

to adjust the outlet gases
temperature

Its main inlet is located

just before (above) the
outlet of the HGG

2011 50
 FLAME ADJUSTMENTS

The flame shape can be

adjusted by changing the
axial and tangential air
ratios

There are two butterfly

valves used for these
adjustments:

- External air channel

- Tangential air channel

2011 51
 SPECIFIC DESIGN OF
AIRFLOW

HGG COMBUSTION CHAMBER ROOF VIEW

FLAME SENSOR

IGNITOR

BURNER

SPY-HOLE

SECONDARY
AIR

COOLING
AIR

FLAME SENSOR
2011 52
 VALVE TRAINS FOR
LIQUID & GASEOUS
FUELS

2011 53
 FUEL PROCESSING

Oil Valve Trains & Gas Valve Trains

design according DIN EN 746 – 2
Oil Pump stations
HFO Preheater stations
BMS (Simatic, Alain Bradely…)

2011 54
 FUEL PROCESSING

Fuel supply system for liquide alternative fuels

- Used oil - Animal fat - Any liquid fuel residue

- Solvents - Glycerine
2011 55
 FUEL PROCESSING

40 ft standard container

40m³ double shellstorage tank in one unit

Easy to manipulate and flexible in use

Execution according to valid TÜV and ATEX standards

2011 56
 SOLID ALTERNATIVE
FUELS
HANDLING SYSTEMS

2011 57
 RDF PREPARATION SYSTEM

2011 58
 CONTACT US

If you have any questions or need any assistance, please

do not hesitate to contact your GRECO team:

GRECO Combustion Systems

Europe
+43 2732 75680
info-europe@atec-greco.com
info@atec-greco.com

2011 59
THANK YOU FOR YOUR ATTENTION

www.grecotec.com / www.atec-ltd.com

GRECO Combustion Systems Europe GmbH A TEC GRECO Projetos e Equipamentos Ltda.
Kasernstraße 16-18 . 3500 Krems/Donau . Austria Av. Brigadeiro Faria Lima 1912 Cj B. 01451-000 São Paulo . Brasil
info-europe@atec-greco.com info@atec-greco.com