Cement Kiln Flame Formation

1. The Pyro-jet burner takes advantage of two types of primary air

injection – jet air and swirl air. The first of these certainly lives up to its
name. Jet air is injected from axial nozzles at the speed of sound,
creating a suction effect that facilitates efficient mixing of secondary air
and fuel.
 Cement Kiln Flame Formation

In contrast, swirl air is injected at a much lower velocity and creates an

area of low pressure in front of the burner. This promotes recirculation
of burning particles around newly-injected fuel, thus ensuring quick
ignition. The axial rotation of the swirl air also helps to stabilize and
optimize the shape of the flame
Cement Kiln Flame Formation
The IFRF has shown that the best use of swirl is to apply it to generate a
swirl induced internal reverse flow zone which brings back hot gases
and heats up the fuel as the root of the flame. To produce such an
internal reverse flow zone a minimum of 30 degree vane angle is
needed. This swirl itself would expand the flame shape too fast and
cause flame impingement, so the swirl needs to be able to be contained
by a powerful axial flow to get the benefit of the reverse flow zone and
not the impingent downsides. Hence a burner that combines swirl and
axial in the same outlet nozzles cannot use its swirl effectively. In the
same way a burner that has swirl and axial in two separate channels but
cannot independently control both the axial and swirl flows, also cannot
use the swirl effectively. A swirl angle less than 30 degrees has little
value as it does not generate a swirl induced reverse flow zone.
 Cement Kiln Flame Formation
For high levels of alternative fuels, a retractable adjustable swirl system is
available for better distribution of fuel in the flame. This improves
combustion conditions, without the need for additional primary air, and
eases some of the main problems encountered during co-combustion of
alternative fuels.
advanced burning technologies are: thermal savings:3 – 5 kcal/kg clinker,
electrical savings: 0 – 0.5 kWh/t clinker and CO2 reduction: 2 – 4 kg/t
ceme
Swirling flow creates an internal recirculation zone (IRZ), drawing hot flue gas back to the burner inlet. • PF is injected into the IRZ where it is rapidly heated and devolatilises. • Interaction of PF injection and IRZ is important to achieve stable flame. • Volatiles burn,
consume PA, and release heat in the near-burner region. • Char particles spread out to periphery of the IRZ. • SA, then TA gradually mixes in with IRZ, and supports combustion of char particles. • Radiant heat from adjacent flames further supports combustion.
Burner Design Parameters
The burner momentum (Ia, N/MW) describes how well the hot secondary air, at about 1000 ℃,
is mixed with the cold (ambient) primary air. The primary air is added to the process at high pressure and
velocity (150 – 250 m/s). There is a difference between radial and axial momentum but when momentum
is mentioned it normally refers to the total momentum. The most useful and easiest definition for the
momentum includes the product of primary air mass flow (ma, kg/s) and velocity (va, m/s) at the burner
tip, divided by the thermal energy input (H, MW).
Ia = ma . va / H
The thermal energy (H) input from burner for kiln capacity of 3000 – 12000 t/d ranges
between 63 – 250 MW (5.4 – 21.5x107 kcal/h). The lower and upper limits may vary substantially
depending upon the burner design and efficiency. A typical 1200 t/d rotary kiln, burning mineral coal,
required burner momentum of 6 N/MW, which was increased to 10 N/MW, to burn plastic pellets [3].
The momentum formula is useful and makes it possible to compare different burners. Higher
momentum is not always better; it is necessary to find optimum momentum. Keeping the burning zone in
the right temperature range and maintaining the flame position is crucial and requires a high burner
momentum, adapted to the conditions in the kiln system. High burner momentum has several
advantages [3] :
• Stable kiln operation and improved fuel efficiency
• Short burning zone and improved clinker reactivity
• Consistent clinker granulometry leads to efficient cooler operation
• Low volatility and recirculation of Sulphur leading to overall improvement of the kiln condition.
• Decreased tendency to form build-ups and rings
• Increased kiln capacity due to better operation.
Burner Refractory calculation

Below the calculations used to predict the result of the measures taken:
π* r2 * h = volume of a cylinder of a certain diameter and height
Density refractory casting:
= 2650 kg/m3
Volume of the burner with the 70 mm casting:
π *3.8*0.32 = 1,0744m3

Volume of the burner with the 55 mm casting:

π *3.8*0.2852 = 0.9697 m3
The difference in volume consists of refractory casting:
= 2650k
The lost weight is (1.0744 – 0.9697) m3 * 2650 kg/m3 = 277.6 kg With modification, the new weight is 3250
– 277.6 = 2972.4 kg .
The lifting equipment is capable of lifting 3000 kg so the modification will have the effect wished for.