Combustion training in Cement Kilns

Guess what it is?

2 m

Coating in the preheater

4

Cl in ho otmeal [ % ]

strong coating
2

acceptable coating ti low coating

0 0 1 2 3 SO 3 in hotmeal [ % ] 4 5 6

Factors influencing SO3 in hotmeal

Input to the kiln Raw meal (limestone, kaolin, sand, iron scale) Fuels (oil, petcoke, olive residues) Volitalisation Temperature profile of kiln (Burning zone) Burner (shape of the flame) Fuel preparation Combustion condition (CO) Indirect factors Raw mix (homogenity, burnability)

Input to the kiln I t t th kil

Input to the kiln

Actual raw mix + 100% oil 14.1 14 1 g/kg clinker
90% oil 10% olive residues 13.7 g/kg clinker 50% oil % 40% petcoke 10% olive residues 19.8 /k li k 19 8 g/kg clinker

Volitalisation V lit li ti

volatile circuits at kiln

K2SO4: Tmelting =1069C Tboiling=1689C Na2SO4: N Tmelting =884C Eutectic: Tmelting =823C

Mechanism of volitalisation
Volitalisation reaction of CaSO4

CaSO4 CaO + SO2 + 1 O2 2

Law of mass action (Goldberg and Waage)

[CaO ]* [SO2 ]* [O2 ] k= [CaSO4 ]

Constant (fuel, raw mix input)

keys to control volitalisation

Key 1: Oxygen
2000 1800 1600 1400 1200 1000 800 600 400 200 0 0.0 0.5 1.0 1.5 2.0 2.5 Oxygen %

Increase O2! Limits: Fan capacity Heat consumption Temperature kiln inlet Above 900degC: 2 CO + 1 O2 => 2 CO2 Decrease CO!

SO2 ppm 2

Local reducing condition

Fuel burns locally with lack of O2 -> CO formation Alignment of the burner Shape of flame Fuel flow uniformity Fuel preparation

Key 2: Temperature
100 80 balance 60 40 20 0 700 SO3 (in clinker) SO2 (in gas)

800

900

1000 temperature degC

1100

1200

1300

Decrease burning zone temperature! Limit: Free lime

Keys 1&2: Oxygen and Temperature

1 volitalisation n 0.8 0.6 0.4 0.2 0 0 1 2 O2 % 3 4 5
1000degC 1200degC 1400degC

Key 3: time
Which profile causes more evaporation? p p temperature profile

Maintain short burning zone! Kiln speed Calcination degree Flame shape

20% more evaporation time

Flame / combustion theory

fuel

oxygen

temperature
Increase oxygen! Increase secondary air temperature! Mix it properly!

Kiln burner
Air gun

Axial air Rotational air 2 longitudinal expansion joints

Jacket tubes

Coal transfer

Central air (flame catcher)

Axial, Axial radial & central air

Axial air Higher pressure ~ higher impulsion Higher impulsion => hot secondary air sucked in quicker => faster combustion => shorter flame Radial air Higher pressure ~ higher swirl Higher swirl => flame gets wider (dont touch (don t refractory or clinker bed!) Central air Higher pressure => more cooling of bluff body, but less dp => flame farer away from burner tip

Burner settings
Axial air

Momentum Swirl Flame length Diameter

Rotational air

Momentum Swirl Flame length Diameter

Momentum Swirl Flame length Diameter

(1) Results are a function of the relative importance of the two actions (2) Central air as low as needed for cooling bluff body

Fuel burner nozzle

2 pressure regulating valves Primary valve adjust the output Secondary valve adjust primary / secondary ratio => divergence

secondary circuit Primary circuit

Orifice plate Orificeplate Secondary circuit primary

circuit
Primary atomizer secondary

atomizer Secondary primary atomizer atomizer

Fuel burner nozzle

12000 10000 8000 fuel flow 6000 4000 2000 0 20 25 30 pressure main valve (bar) 52 sec open 52 sec closed 64 sec open 64 sec closed 78 sec open 78 sec closed 35 40

Adjust flow with primary valve or change of orifice set! j p y g Adjust flame shape with secondary valve!

Fuel preparation
Fuel flow uniformity ( 1%) Fuel preparation Atomizing of oil (target: 17cSt t burner) 17 St at b )
100 90 80 70 60 50 40 30 20 10 0
80
7

Fineness of Petcoke (target: R200m=0%, (t t 0% R90m<0.5%VM)

6 burning time s 5 4 3 2 1 0

vi iscosity cSt

HVO fuel #6

900 degC 1500 degC

90 10 0 11 0 12 0 13 0 14 0 15 0 16 0 17 0 18 0 19 0 20 0

0. 05

0. 15

0. 25

0. 1

0. 2

fuel temperature degC

Coal particle size mm

Maintain oil temperature and petcoke fineness targets!

0. 3

Burner position
Centered in and parallel to kiln axis, maybe a little offset to kiln top side Moving of burner tip between 0m and 1m inside kiln Less deeper inside (closer to nose ring) =>
Shorter Sh t cooling zone => h tt clinker i cooler => li > hotter li k in l > hotter secondary air temperature => shorter flame higher risk for nose ring (temperature) more risk for snowman upwards deformed flame => less evaporation

Indirect f t I di t factors

Indirect factors
Kiln feed uniformity Settings of kiln operation according to worse material (e.g. high LSF) => overheating of good material Burnability Low b L burnability ( bilit (e.g. hi h rejects) needs hi h b i high j t ) d high burning zone temperature Stability of cooler operation Variations of cooler operation => variation of secondary air temperature => variation of burning zone t temperature t

Monitoring combustion
Free lime (ratio fuel / feed) Kiln inlet Kil i l t gas analyzer l O2 (oxydizing atmosphere) CO (reducing atmosphere) NOx (flame / secondary air temperature) SO2 (burning zone temperature) ( g p ) Temperature measurements Kiln inlet (burning zone length) Tertiar air (flame length) Shell scanner, kiln amps (burning zone length) Colour of clinker (burning zone temperature) White steam from cooler (burning zone temperature)

In order to minimize volitalisation volitalisation

Increase O2 Decrease CO Increase flame / secondary air temperature Decrease burning zone temperature Decrease burning zone length Maintain fuel preparation targets Reduce raw mix f fineness Increase free lime Control the flame shape