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Fives Pillard 1
COMBUSTION IN ROTARY KILNS& PRECALCINERS
NEW TARGETS AND SOLUTIONS
Fives Driving Progress
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Fives Pillard 2
Brief overview of Fives Pillard, Marseilles, France...
J.C.P.
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3Fives Pillard
Kiln burner concepts of the 90's
BURNERS WITH AXIAL & RADIAL
CHANNELSADJUSTABLE AT SITE
The ROTAFLAM burner
FIXED BURNER HIGH IMPULSE
LIMITING MISTAKES OF OPERATORS
The traditional burner
versus
(+) Can be tuned to each kiln at site
(-) Difficult to adjustComplexHeavy
The two concepts have been applied for over 15 years,both have
shown their limits none is a clear winner.
NEW PATENTSDE 3933050C2 of Oct. 4, 1989EP 90.430017.5 of
Sept.14,1990
(+) Avoid mistakes ofoperators
(-) Damages on refractoriesHigh NOx emissionLimited
adjustmentsSticking on tips
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4Fives Pillard
New (priority) millennium targets
Target YearAssess burner operation in a kiln, using Fluent CFD
softwareCement kiln simulations1 1999
Develop the use of Alternative Solid Fuels (A.S.F.) in
EuropePowders (animal, biomass, urban) and "Fluff"
Decrease the running costs of European Cement PlantsBy
conversion to high % of A.S.F.
Put Clinker quality as a priority(+) The Sulphur cycle must be
improved
Address new Sustainable development requirementsReducing CO and
NOx emission AT STACK
2001-
2005Simplify burners use : the NOVAFLAM burnerImprove
precalciners / Urea Ammonia injection
2000-
2004
2 2002
3 2003
4
5
6 2005Control combustion in real time
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Target 1:
Assess burner operation in a kiln,using Fluent CFD software
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First cement kiln simulations (with Fluent CFD software)
The Fluent CFD tool allows to compare burner tip geometries
Stream lines around flames
Question : Are there big recirculation areas inside the kiln
?
Answer : NoExtract from competitor article
UNTRUE
High intensity flameLong lazy flame
Question : Can we evaluate the influenceof flame intensity on
theclinker bed ?
Answer : Yes
Bad air distribution(white cement)
Improved
Question : What is the influence of airdistribution ?
Answer : essentialMUST be optimized first
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Target 2:
Develop the use of A.S.F. in Europe
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A.S.F.: how to improve the combustion of fluff ?
First dispersor New dispersor (2005)
NEW PATENTSFR 9808254 of June 24, 1998EP 99.430010.1 of June 23,
1999
; A fast dispersion into the flameA new "fluff dispersor" has
been developed
Fluff being heterogeneous, its combustion requires:
Suction of secondary air Radiation on clinker
; An acceleration of the combustion, by SLOT EFFECT,
enabling
to Adapt the amount of Hot Secondary Air(H.S.A.) introduced in
the flame
And, - as a consequence- , to affect the flame temperature
Few H.S.A. in flame,SOFT FLAME
Fast/high H.S.A. in flame,HIGH INTENSITY FLAME
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Target 3:
Decrease the running cost of European Cement Plants by
conversion to high % of A.S.F.
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The ROTAFLAM Version 2 with SLOT EFFECT
allowed for a huge increase of A.S.F. use (%)
(A.S.F.) Alternative Solid FuelsEnd user Kiln (tpd)
% Heat release Type
HOLCIM HOVER, Germany DRY 3200 75 Fluff + Animal meal ROTAFLAM
V2
HEIDELBERGER LENGFURT, Germany DRY 2500 80 Fluff + Animal meal +
Solvents ROTAFLAM V2
HEIDELBERGER SCHELKLINGEN, Germany DRY 2500 75 Fluff+ Dry sewage
sludge ROTAFLAM V2
ROHRDORF, Germany SEMI WET 3000 80 Tetrapack, Plastic
ROTAFLAM
WITTEKIND, Germany DRY 2500 52 Bram ROTAFLAM V2
DYCKERHOFF, DEUNA, Germany DRY 3000 50 Fluff + Plastic
ROTAFLAM
HOLCIM ECLEPENS, Switzerland DRY 2000 30 Sawdust + Animal meal
ROTAFLAM V2
Burner
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The ROTAFLAM Version 2 with SLOT EFFECT
Focus on Holcim plant, Hver (G) : Clinker quality improved and
Fluff consumption increased
up to 75 %, i.e. 13 tons/hr
NEW PATENTSFR 0705305 of July 20, 2007EP 08.160478.7 of July 16,
2008
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Target 4:
Put Clinker quality as a PRIORITY
Fives
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Clinker quality & Sulphur cycle
The ROTAFLAM Version 2 with "SLOT EFFECT improves the clinker
quality and impedes the Sulphur cycle formation, thanks to:
No contact between flame and the clinker bed
Low diameter "cigar" shaped flame in the kiln axis
High intensity flame (DRY PROCESS), softer (WET)
End user Main fuel Kiln (tpd) Former burner New burner
Improvement
TIANRUI RUIZHOU, China High ash coal 6000 ROTAFLAM 14
Mpa,production increase by 3,5 %
HOLCIM, Sri Lanka Coal + sawdust 900 ROTAFLAM 30 Mpa
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Target 5:
Address New Sustainable development requirements
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Sustainable development : a struggle against pollutants
NEW PATENT: EP 04.290293.2 of Feb.4, 2004
CO and NOx reduction at stack needs FIRST to limit them AT KILN
INLET !
Patented concept: Low NOx Tips, joint development between
Italcementi & Fives Pillard(Grant awarded from the European
Community) :
0
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0 1 2 3 4 5 6 7
OXYGEN (%)
N
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m
g
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%
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4
6
%
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2
4
%
ORIGINAL
1ST LOW NOX
TIP
2ND LOW NOX TIP
NOx AT KILN INLET
DIFFERENTBURNER TIPS
First tests at ITALCEMENTI's SARCHE plant (It) (1997-2001),
confirmed in ITALCEMENTI's BRONI plant (It) (2002-2004) tests led
to developing special LOW NOx tips.
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Sustainable development : a struggle against pollutants
Low NOx tips have proven sizeable benefits
End User Kiln (tpd) Main fuel NOx at kiln inlet@ 10% O2 dry
Improvements (NOx reduction, capacity)ITALCEMENTI SALERNO, Italy
1400 Petcoke 1020 Increase production from 1300 to 1400 tpd. in a
narrow furnace
ITALCEMENTI BRONI, Italy 730 Petcoke 775 NOx reduction -46%
compared with previous ITC burner
ITALCEMENTI SARCHE, Italy 800 Petcoke 1020 NOx reduction -29%
compared with the Monochannel burner in narrow furnace -
ITALCEMENTI SCAFA, Italy 950 Petcoke 1063 NOx reduction -26%
compared to the previous ROTAFLAM
ITALCEMENTI CALUSCO, Italy 4000 Petcoke 510 Good performances -
fully satisfied (new plant)
CALCIA VILLIERS, France 1200 Coal 880 Kiln more stable and use
of a higher LSF meal with same NOx emission
CCB GAURIN, Belgium 1650 Petcoke 755 NOx reduction -30% compared
to the previous ROTAFLAM
HOLCIM MERONE, Italy 2300 Petcoke 730 NOx reduction -27 %
compared to the previous ROTAFLAM
ITALCEMENTI COLLEFERO, Italy 2300 Petcoke 920 NOx reduction -17%
compared to FLS and no hot spot
ITALCEMENTI VASSILIKO, Cyprus 6000 Coal Under com.
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Prediction software for NOx emissions at kiln inlet
Coal concentration
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0.5 1 1.5 2 2.5 3 3.5kg coal/Kg (Transport +Central) air
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0 0.05 0.1 0.15 0.2 0.25 0.3(m/m)
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Primary air amount
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6 8 10 12 14(%)
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Secondary air temperature
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O2 at kiln inlet
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1 2 3 4 5 6O2 (% dry basis)
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The Fives Pillard NOx ROTA software allows to separate the
influencing factors of NOx emission.The use of computerized multi
points measurements is mandatory.
Influencing factors:0
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1 000
1 200
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NOx calculatedNOx Measured
Specific heat per m3 Material flow density
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0,0 2,5 5,0 7,5 10,0 12,5 15,0 17,5 20,0Refuse @ 90 mm
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Coal fineness
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0 10 20 30 40Volatiles %
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Volatiles
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Burner swirl
The 800 mg/Nm3@10%O2 target at kiln inlet is achievable !
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Target 6:
Simplify burner use : the NOVAFLAM burner
Improve Precalciners / Urea Ammonia injection
Control combustion in real time
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19Fives Pillard
The NOVAFLAM burner : a simplified use
From the ROTAFLAM to the NOVAFLAM burner
ROTAFLAM NOVAFLAMROTAFLAM Version2Burners with axial & swirl
channels adjustable at site
Tailor-made" engineered designAllows much more simple
adjustmentsAddition of "slot effect"
Main features :
S.A.S. (single air supply) as standard
D.A.S. (double air supply) only for special applications,for
example : LOW NOx application
burner tips engineered according to process data
NEW PATENTSEP 06.778673.1 of June 26,2006EP 07.290663.9 of May
23, 2007FR0852836 of April 28, 2008FR2009/050593 of April 07,
2009
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The NOVAFLAM burner : Input data for engineering
Process data (incl. kiln geometry); Dry or wet process, and L of
kiln; Burner heat release without safety margin; LSF of raw
material, sulphur content; Secondary air temperature, type of
cooler, position of tip in kiln; List of fuels, concentration in
conveying lines, % of each, volatiles, granulometry, sulphur
content; Carriage: Can the burner be in the kiln axis ?
Running data; Past experience with the kiln (difficulties,
rings, other); Priority targets (Increase prod ? Improve clinker
quality ? Sulphur cycle problems ? Decrease NOx ?
Increase A.S.F. %?)
Absolutely avoid a burner oversizing
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The NOVAFLAM burner : technical design choices
primary air outletInfluence of increasing SWIRL
Flame OK
primary air outletMax velocity for 250 mb fan pressure
Max velocity # 100 m/sUnacce
ptable
primary air outletInfluence of increasing SWIRL
Flame OK Flame OK
primary air outletMax velocity for 250 mb fan pressure
Max velocity # 250 m/s
SINGLE or DOUBLE primary air outlet ?
SINGLE
DOUBLE
SINGLE
DOUBLE Adopted!
LOW SWIRL
LOW SWIRL
HIGH SWIRL
HIGH SWIRL
Unacce
ptable
Adopted!
A DOUBLE primary air outlet is mandatory
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The NOVAFLAM burner : references
ASFEnd user Main fuel Kiln (tpd) % Heat release TypeKOHAT
CEMENT, Pakistan GAS / COAL DRY 6700 0 - Successfully commissioned
by customer , satisfiedGHARIBWAL CEMENT, Pakistan GAS / COAL DRY
6700 0 - Successfully commissioned by customer , satisfied
HEBEI, Kuishan, China COAL DRY 5500 0 - Very satisfied, high
clinker quality & production
YANBU, Saudi Arabia HEAVY FUEL OIL DRY 11000 0 - Not yet
startedFUCHUAN, China HIGH ASH COAL / OIL DRY 5500 0 - Not yet
startedCHIFENG YUANHANG, China HIGH ASH COAL / OIL DRY 2900 0 -
StartedXIBEI CHANGYE, China HIGH ASH COAL / OIL DRY 4500 0 - Not
yet startedLUOYANG TONGLI, China HIGH ASH COAL / OIL DRY 5500 0 -
StartedXING KUANG CEMENT, China HIGH ASH COAL / OIL DRY 5500 0 -
Not yet startedZAOZHUANG JINQAO, China HIGH ASH COAL / OIL DRY 6000
0 - Not yet startedDANGOTE CEMENT LINES 1 & 2, Nigeria
HFO/GAS/COAL DRY 6000 0 - Not yet startedLARESTAN CEMENT, Iran
HFO/GAS DRY 3300 0 - Not yet startedBAOARE CEMENT, Chad HFO DRY 800
0 - Not yet startedMCE CEMENT, Ethiopia HFO/GAS/COAL DRY 3000 0 -
Not yet startedWUAN XINFENG CEMENT, China HIGH ASH COAL / OIL DRY
6000 0 - Not yet startedXUZHOU LONGHAN CEMENT, China HIGH ASH COAL
/ OIL DRY 5500 0 - Not yet startedFURONG JUNLIAN CEMENT, China HIGH
ASH COAL / OIL DRY 5500 0 - Not yet startedQUINLIANSHAN MINE
CEMENT, China HIGH ASH COAL / OIL DRY 2500 0 - Not yet startedTPI
POLENE KILNS 1,2 & 3, Thailand COAL / FLUFF (RDF) / OIL DRY
10000 0 - Not yet startedEL NAHDA CEMENT CO., Egypt HFO/GAS DRY
7000 0 - Not yet startedCAMCE KANT LINES 1 TO 5, Kyrkystan
HFO/GAS/COAL DRY 720 0 - Not yet startedCAMCE KANT LINES 6 & 7,
Kyrkystan HFO/GAS/COAL DRY 504 0 - Not yet startedHENAN YONGAN
CEMENT, Chine HIGH ASH COAL / OIL DRY 5800 0 - Not yet
startedQUINLIANSHAN YONGDENG CEMENT, Chine HIGH ASH COAL / OIL DRY
5500 0 - Not yet startedZAOZHUANG WOFENG, Chine HIGH ASH COAL / OIL
DRY 5800 0 - Not yet startedQUYANG JINYU CEMENT, Chine HIGH ASH
COAL / OIL DRY 5800 0 - Not yet startedNANJING HOPE, Ethiopia HFO
DRY 1700 0 - Not yet started
HOLCIM LUMBRES, France PETCOKE WET 800 30 Sawdust+ Animal meal
Commissioned by customer, satisfied, sawdust flow x 2HOLCIM DANNES,
France PETCOKE SEMI DRY 1200 50 Sawdust+ Animal meal Very
satisfied, 70 % more sawdust (5 t/hr)SHANDONG DONGHUA, China COAL
DRY 5500 0 - Very satisfied, high clinker quality &
productionBEIJING LIMA, China COAL DRY 5000 0 - Very satisfied,
high clinker quality with low LHV coal
GUANGZHOU, China COAL DRY 4000 20 Plastic chips Commissioning
scheduled on June 2009SHANDONG QUANXING, China COAL DRY 3200 0 -
Commissioning scheduled on June 2009AHLIA CEMENT, Lybia HFO/GAS DRY
3000 0 - Not yet startedCBMI AL BADIA, Syria COAL/PETCOKE DRY 5500
0 - Not yet startedVICAT KAZAKHSTAN, Kazakhstan COAL DRY 3000 0 -
Not yet startedHOLCIM, OBOURG PLANT, Belgium PETCOKE WET 3000 50
Schiste / Sludge / Sawdust Commissioning scheduled on July2009
User feedback
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23Fives Pillard
The NOVAFLAM burner : references
; Simplicity of adjustment confirmed.
; Intense flame, low with low primary air pressure (< 250
mbar), confirmed.
HOLCIM LUMBRES opinion: "Replacing the previous burner by the
NOVAFLAM has allowed us to increase the % total kiln energy amount
from impregnated sawdust from 11% in 2007 to 20% in
2008Furthermore, the NOVAFLAM is very simple to use
HOLCIM DANNES opinion: "The total substitution rate has
increased by 70%... The flame is strong and intense even with
pressure from 160 to 180 mbar the operators highly appreciate the
burner flexibility and the simplicity of the adjustments"
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24Fives Pillard
The NOVAFLAM burner : a shorter Return on Investment
RUNNING COSTS INSTALLATION COSTS
KILN PRODUCTION EXISTING CARRIAGE
Stability increased
Production increased (typically 2-4%)
A low quality coal can be used
Recovered
USE OF HIGH A.S.F. % EXISTING P.A. FAN
Cancelling fuel costs Recovered
Huge savings! Minimized!
Payback time of 8 months for the 2 HOLCIM French plants
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25Fives Pillard
The NOVAFLAM burner : a lower Carbon assessment
CO2 emission ELECTRIC CONSUMPTION
Concentration can be increasedElectric Consumption: less15%
Pressure can be reducedFlow reducedElectric Consumption: less
30/40%
Consumed electricityReduced!
SPECIFIC CONSUMPTION SOLID FUELCONVEYING LINES
Reduced (average 3 %)CO2
USE of higher BIOMASS FUEL % PRIMARY AIR FAN
CO2
CO2Reduced!
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Fives Pillard 26
Now, what about
Improving Precalciners
Control combustion in real time
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27Fives Pillard
Improving Precalciners / Urea Ammonia injection
The Fluent studies on PRECALCINERS focused on:
NEW PATENTSEP 06.291903.0 of Dec. 11, 2006FR 06.05355 of June
15, 2006
NOVAFLAM and NEUTRINOX are complementary
; Temperature profiles and recirculation zones; Influence of
(preca) burners positioning
They allow to choose the best Urea/Ammonia injection points to
meet NOx limits AT STACK
Control valve set
Re-circulation zones
Levels of injection
Temperature profile
Special atomizer
The NEUTRINOX SNCR system includes : A control valve set Two
levels of injectors Special atomizers
End user NOx at stackmg @10% O2, dryNOx reduction
%Efficiency
% Client's feedback
ITALCEMENTI Salerno, Italy 700 73 83 3 years of operation, easy
maintenance, high reliability
ITALCEMENTI Colleferro line 5, Italy 800 72 46 2 years of
operation, easy maintenance, ammonia tests pending
ITALCEMENTI Colleferro line 6, Italy 1080 60 56 2 years of
operation, easy maintenance, ammonia tests pending
ITALCEMENTI Vibo Valentia, Italy 790 50 30 2 years of operation
, modifications for 10% increase efficiency
HOLCIM Hon Chong, VI 750 50 25 2 years of satisfactory
operation
ITALCEMENTI Vassiliko, Cyprus Target 800 Guaranteed 50 - To be
commissioned Dec 2009
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28Fives Pillard
SITE ASSISTANCE SERVICES
Real-time combustion controls
Decreasing NOx emission needs an increase of P.C
concentration.It is servo-controlled by the line pressure drop.
NEW PATENTEP 00.401340.5 of May 16,2000
Enables to control via INTERNET:
Fives Pillard improved a well-known probe and offers it with
,for SO2, NOx, CO, O2 analyzers
: Our specialists operate worldwide.
coal/petcoke dosing systems :STAPILDOS
Burner Management System :ROTASAFE
sampling probes at kiln inlet :ROTASAMPLER
: 200 m: 8 kg/Nm3: +/- 1,5 %
Max length of conveying lineMax coal/petcoke
concentrationStability of coal/petcoke flow
; Flow rates of each fuel (incl. A.S.F.); Burner adjustments
& combustion measurements
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29Fives Pillard
Combustion in rotary kilns & precalciners: conclusions
The NOVAFLAM burner is simple to adjust
The NOVAFLAM burner allows: a very high % of Alternative Solid
Fuels minimum electric consumption recovering the existing carriage
and primary air fan
The NOVAFLAM LOW-NOx, in association with the NEUTRINOX system,
allows to meet emission limits AT STACK
The Fives Pillard group wants to develop a SPIRIT OF PARTNERSHIP
with your Group aiming at proposing the best adequate solutions on
a case by case basis.
We invite you to come and visit us in Marseilles, where all
detailed questions will be answered!
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With our warm thanks!All the Fives Pillard Management
