Flames and Fuel Preparation

Flames
 Provide Heat For Clinkerisation

Also Optimize :

QUALITY

PRODUCTION

ENERGY CONSUMPTION

BRICK LIFE

KILN DOWNTIME
 FLAMES & FUEL PREPARATION
Problem Areas for a poor Flame
• REDUCING CONDITIONS NEED TO BE AVOIDED
OR:-
– Decreased 28 day concrete strength
– Decreased workability/setting time
– Increased fuel consumption
– Increased volatile recirculation/loss
– Decreased Output
– Modified concrete strength growth curve
– Decreased refractory life
– Increased grinding energy
– Increased pollutant emission
 Combustion of Coal (1)
Eg: Carbon

C + O2 CO2

12lb 32lb 44lb

O2 required per lb of coal = (32/12) X %C in coal/100

CO2 produced per lb coal = (44/12) X %C in coal/100

 TYPICAL FUEL ANALYSIS

• ULTIMATE • PROXIMATE
Carbon 75.9
Hydrogen 4.8 Volatile Matter 30.9
Nitrogen 1.5 Fixed Carbon 55.2
Sulphur 1.5 Ash 9.46
Oxygen 1.5 Moisture 4.44
Ash 9.9 TOTAL
100.0 TOTAL 100.0
What do we need
Fuel
Oxygen
Mixing
Ignition source
Acceptable PSD
‘Dried Fuel’
 Typical Gas Flow Pattern in the Burning Zone

Ignition Secondary Air External Recirculation Plug Flow

Region Entrainment Region Region
Region
A- Ignition Distance
B- Position by which all Secondary Air is Entrained into the Jet Boundary
C- Mid Point between B and D, “Eye” of Recirculation Bubble
D- Position by which all Secondary Air is Mixed into the Jet Axis
E- Impingement Point of Non-Swirl Primary Air Jet on Kiln Shell [N.B. Not Flame]
F- End of “Effective” Flame
 FLAME LENGTH
Mixing Distance
Ignition Distance
End of Flame Recirculating Combustion Products
Flame Front

Secondary Air

Secondary Air

COAL FLAME IN A CEMENT KILN

 Exit Gas Temperature 220ºC

Extra Fuel Consumed above that for Complete Combustion with

140

Effec
Theoretical Air Quantity (e.g.. O2 & CO = 0%) Kcal/kg clinker
Slurry Moisture 39%

t of I
120

ncom
100

plete
80

Com
bu
60

stion
40

A ir
20
x c ess
ct of E
Effe
0
2 % CO 1 0 %02
1 2 3 4 5

Effect of Incomplete Combustion and Excess Air on the Fuel

Consumption of a Wet Process Kiln
 Figura 17.2
% Carbon Monoxide at 1% Back-End Oxygen as a
Function of % Primary Air and Primary Air Velocity
Barnstone No.2 Kiln

% Carbon Monoxide
at 1 % Back-End 1.0
Oxygen

PRIMARY AIR VELOCITY (m/S)

0.5

30
50
80
150 100
0
0 5 10 15 20 25 30

% PRIMARY AIR
 “MOMENTUM”

FUEL +
PRIMARY AIR

SECONDARY AIR
Good Flame Shape is Determined by :
“ MOMENTUM”
= Mass x Velocity
Low Primary Air = High Velocity
10 % 120 - 140 m/sec

Typical Primary Air = Medium Velocity

25 % 60 - 70 m/sec
 “ADEQUATE” MOMENTUM

• O.F.T. DEVELOPED IN EARLY 80’S

• MOST MULTICHANNEL BURNERS COMING INTO
LINE
• G = 2.7* ((Mc.Fc)/ (1000*D))**2
– G = NEWTONS, Kg.m/sec²
– Mc = TPH CLINKER
– Fc = KCal/Kg - GROSS
– D = INNER BRICK KILN DIAMETER - m
 FLAMES & FUEL PREPARATION
S - Size: A - Axis: D - Dry

• Size
– +90u 50% of Volatiles
– 100% Petcoke +200u < 0.1%
• Axis
– Centrally along axis of kiln
• Dry
– 1-1.5% Moisture as fired for black coal
 FLAMES & FUEL PREPARATION
A - Air: M- Momentum
• Air
– Back End Oxygen Appropriate for Fuel - 2% Coal, 3.5%
100% petcoke
– Increased SO2 emission or build ups occur if insufficient
oxygen
• Momentum
– Appropriate Momentum
– Poor mixing of air into volatiles and insufficient air before PFZ
if momentum low
 Flames and Fuel Preparation
Basic Requirements
• SADAM
– Size
– Axial
– Dryness
– Air
– Momentum
 Schematic -Combustion in a Flame

Radiation
from Recirculation
Shell
Primary Air + Fuel
Secondary
Air
Radiation Mixing
from
Hot Secondary Air Clinker

Ignition Secondary Air Mixing Last Remaining

Length and Combustion Tar and
Carbon Particles
Burn Out
 Schematic - FLS Swirlax Burner Nozzle

Axial air
Coal
Swirl or radial air
FLS Swirlax Burner
 What if we increase?
ignition Flame length

excess air Reduce reduce/lengthen

primary air reduce then lengthen

Primary air temp shorten shorten

Fuel psd lengthen lengthen

Secondary air temp shorten shorten ?

Hood inleak lengthen
 OXIDES OF NITROGEN

Industrial Combustion results in, NO2 and NO

1.- THERMAL NOX

2.- FUEL NOX

 FLAMES
NOx FORMATION

The Principal Reactions For Thermal NOx Formation are:

N2 + 0 NO + N E = 75 KCal/mol (13)
N + 02 NO + O E = 6 KCal/mol (14)
H + 02 OH + O E = 16.5 KCal/mol (15)
O2 20 E = 59 KCal/mol (16)

The Principal Reactions For Fuel NOx Formation are:

HNC + O NH + CO (17)
NH + O2 NO + HO (18)
 Schematic -Combustion in a Flame

Radiation
from Recirculation
Shell
Primary Air + Fuel
Secondary
Air
Radiation Mixing
from
Hot Secondary Air Clinker

Ignition Secondary Air Mixing Last Remaining

Length and Combustion Tar and
Carbon Particles
Burn Out
 NOx vs COMBUSTION AIR MIXED PRIOR TO IGNITION

KILN PARAMETER ANTICIPATED CHANGE IN NOx READING

NEGATIVE ZERO POSITIVE

1.- INCREASE IN BURNING ZONE TEMPERATURE L ARGE POSITIVE CHANGE

2.- INCREASE IN KILN AMPS LARGE POSITIVE CHANGE

3.- INCREASE IN COAL FEED RATE LARGE POSITIVE CHANGE

4.- INCREASE IN KILN EXIT O2 BY INCREASING MODERATE POSITIVE CHANGE

FAN SPEED AT CONSTANT COAL FEED

5.- INREASE IN SECONDARY AIR SMALL POSITIVE CHANGE

TEMPERATURE

6.- INCREASE IN KILN EXIT O2 BY DECREASING SMALL NEGATIVE CHANGE

COAL FEED AT CONSTANT FAN SPEED

7.- PRESENCE OF CO ABOVE 0.1% LARGE NEGATIVE CHANGE

 Stage 4 SO3 Hope Works vs
NOx and O2
5
4.5
4
% SO3 Stage 4

3.5
3
2.5
2
1.5 2,500 PPM CO at
1 1.4% BEO2
0.5
0
1000 1100 1200 1300 1400 1500
NOx ppm
2.5% 02 500 ppm CO
1.8% 02 500 ppm CO
 FLAMES
NOx REDUCTION

• Lower Burning Zone Temperature, ie.Higher Free Lime,Lower

L.S.F.,Lower Combinability Temperature.
• Lower Flame Temperature, ie. Flue Dust Injection,Water
Addition, Liquid Recycled Fuels, Higher Excess Air.
• Flame Front Nearer the Burner, ie. Bluff Body, Finer
Grind,Higher Volatile Coal.
• Lower Primary Air, ie. Indirect Firing.
• Optimum Distribution of Primary Air, ie. Customised
Multichannel Burner.
• Staged Combustion, ie. Modifying Precalciner Design to Ensure
that the Coal Volatiles Combust Sub Stoichiometric,via Two Stage
Combustion Principles that are applied in Boiler NOx Reduction
Technologies.
• Post Flame Reduction with NH3 or CH.
 S O 2 vs B E O 2 vs T im e - N o rth fleet

900 5

800 4.5

700 4
3.5
600
3
B E S O 2 ppm

500

% BEO 2
2.5
400
2
300
1.5
200 1
100 0.5
0 0
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
B E S O 2 ppm % BEO 2 T im e H rs
 Flames and Fuel Preparation
SO2 Cycles
• High burning zone temperature increases cycles of K20
and SO3
• CO or C in burning zone reduces K2SO4
• CO or C above 1050C reduces CaSO4
• Above 1420C even in presence of Oxygen CaSO4
breaks down
• Stage 4 sulphate > 3 % indicates cycling of sulphates
Calciner Firing
 NOx COMBUSTION AIR MIXED PRIOR TO IGNITION

PPM NOx
3,000

2,500

2,000

1,500

1,000

500

0
0 20 40 60 80 100 120
% TOTAL AIR MIXED WITH COAL -PRIOR TO IGNITION

HIGH VOLATILE MEDIUM VOLATILE

 TYPICAL NOx vs FREE LIME

NOx ppm LSF 96

3,000
LSF 98
2,500
LSF 100
2,000

1,500

1,000
COMBINABILITY
500 TEMPERATURE

0
0.25 0.5 1.0 1.5 2.0 2.5
% FREE LIME