WELCOME

TO

BURNER TECHNICAL SESSION

09-11-17
 AGENDA

FLAME MOMENTUM

FLAME SHAPING

09-11-17
 BURNER GENERAL ARRANGEMENT

(1) Fire hood (7) Valve train

(2) Burner seal (8) Flame safety/control panel
(3) Trolley (9) Coal transport system
(4) Ignition gas burner (10) Emergency air fan w/motor
(5) Flexible connector sets (11) Primary air fan w/motor
(6) Primary air ducting (12) Burner set for oil or gas

09-11-17
 BURNER DESIGN CONCEPT

Primary air inlet

Burner trolley

Burner pipe with

refractory

Valve for radial air Valve for axial air

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 BURNER FRONT END
Radial air channel
Axial air channel

Coal meal channel Central air duct Oil burner lance

09-11-17
 INPUT DESIGN DATA

Ambient pressure (mm Hg)

Ambient temperature (C)
Kiln production rate (tpd)
Firing in kiln (kcal/kg.cl)
Fuel Net Calorific value (kcal/kg)
Design coefficient coal (1.25)
Coal conveying air amount (m/min)
Fuel flow rate (kg/h)
Kiln hood width (kiln w.p.h to door front)
Pyro PD

09-11-17
 CONSTANTS USED IN DESIGN

Axial air temperature: 80C

Radial air temperature: 50C
Coal transport air temperature: 70C
Central duct air temperature: 50C
Coal discharge velocity: 30 m/s
Coal discharge velocity deviation: 2 m/s
Max. radial air velocity: 30 m/s
Max. axial air duct velocity: 35 m/s
Central duct nozzle hole velocity: 20 m/s
Refractory thickness: 80mm
Refractory density: 2800 kg/m

09-11-17
CALCULATION

Burner capacity, Qmax (Mcal/h)

= (Design coefficient x Firing in kiln x kiln production)/24

Burner capacity (MW)

= (Qmax (Mcal/h) x 4.1868)/3600

Maximum fuel capacity (kg/h)

= (((Kiln production x 1000/24) x Firing in kiln) / Fuel NCV) x Design

coefficient

09-11-17
CALCULATION
Theoretical air amount, Lmin (Kg/s)

= Burner capacity, Qmax (Mcal/s) x kg.air/Mcal

(Where 1.39 kg.air/Mcal > 4500 fuel NCV and 1.43 kg.air/Mcal < 4500
fuel NCV)

Primary air fan volume (m/s)

= 10% of Theoretical air amount, Lmin / Ambient air density

Absorbed power (kW)

= Pr. Air flow (m/sec) x Pressure (mmWG)/102*efficiency

09-11-17
FLAME MOMENTUM

09-11-17
 FLAME MOMENTUM

The best way of expressing the efficiency of a burner is by the

momentum (primary air percentage multiplied by discharge
velocity) expressed as %m/s or as n/mw (1 N/MW 296
%m/s).

The higher momentum means that a stronger, wider and shorter

flame can be generated.

09-11-17
PRIMARY AIR SPLIT UP - SCHEMATIC

09-11-17
PRIMARY AIR MOMENTUM

Input data:
Ambient pressure: pamb mbar
Ambient temperature: tamb C
Stoichiometric combustion airflow: Lmin kg/s
Primary airflow, measured: mpr kg/s
Primary air pressure at nozzle: pN mbar
Primary air temperature: tpr C
Isentropic exponent for air: 1,4
Gas constant for air: R 286,89 J/kgK

09-11-17
 PRIMARY AIR MOMENTUM

m
pr
Primary air percentage: L = 100[%]
p L
min
k -1

2k p amb
R (t pr + 273,15) 1 -
k
c pr = [m / s ]
Nozzle velocity: k -1 p amb + p N

Primary air momentum: G pr = L p c pr [% m / s ]

09-11-17
 AIRFLOW CALCULATION

Input data:-

Nozzle area: AN [mm2]

Nozzle coefficient (for 100% axial air, lower with

swirl air) : kN 0,95

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 AIRFLOW CALCULATION

2 k +1
p amb k p amb k
Flow function: y = -
( p amb + p N ) ( p amb + p N )

Primary air flow:

2k 1
m pr = 10 - 4 AN k N y ( p amb + p N ) [kg / s ]
k - 1 R (t pr + 273,15)

09-11-17
 PRIMARY AIR MOMENTUM (EXAMPLE)

Input data:
Kiln production: 3949 tpd
Ambient pressure: 953 mbar
Ambient temperature: 43 C
Stoichiometric combustion air flow, Lmin: 20.21 kg/s
Axial air damper: 100% open
Radial air damper: 20% open
Nozzle coefficient: 0,95
Primary air pressure at nozzle: 197 mbar
Primary air temperature: 80 C
Air nozzle opening: 35 mm
Nozzle area: 7281 mm2
Primary air, measured: 134.5 m3/min 2,13 kg/s

09-11-17
 PRIMARY AIR PERCENTAGE (EXAMPLE)

2 1, 4 1
953 1, 4 953 1, 4
0,199
953 197 953 197

2 1,4 1
m pr 10 4 7281 0,95 0,199 953 197

132
, kg / s

1,4 1 286,89 80 273,15

1,32
Lp 100 6,53%
20,21
09-11-17
 PRIMARY AIR MOMENTUM (EXAMPLE)

Velocity:

1, 4 1


2 1,4 953
286,8980 273,15 1 193 m / s
1, 4
c pr
1,4 1 953 197

Primary air momentum:

G 6, 53 1931260 % m/s

09-11-17
FLAME MOMENTUM EFFECT

Burner momentum is insufficient to effectively mix the fuel with the

secondary air, the heat consumption could be increases.

Burner momentum is insufficient and it can give a lazy flame and a

bad burn out of the fuel, which can lead to fuel particles in the charge

The flame momentum below the recommended range will result in

too long a flame, high kiln shell temperature above the burning zone
and in the kiln back end as unstable kiln operation with a too long
and cold burning zone thereby permitting undesirable clinker crystal
growth.

A higher momentum can reduce the CO.

09-11-17
 NOZZLE MOVEMENT
Minimum 0 Position Maximum Position

Adjustments made
using hand wheel

Nozzle Flush Nozzle Retracted

09-11-17
PRIMARY AIR MOMENTUM
(Nozzle max. open)

09-11-17
PRIMARY AIR MOMENTUM
(Nozzle min. open)

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PRIMARY AIR MOMENTUM

Fuel gas ~1200 %m/s

Fuel oil ~1200-1500 %m/s

Medium volatiles coal ~1500-1700 %m/s

Anthracite or petcoke ~1600-2100 %m/s

Secondary fuels, up to ~2400 %m/s

Flame Momentum is a practical number in which the flame shape will be optimum for the
particular fuel.

09-11-17
FLAME SHAPING

09-11-17
RADIAL AIR ADJUSTMENT

Open - more swirl action gives a recirculation zone resulting in

shorter, wider and steadier flame

Close - less swirl action, long and relatively thin flame.

Increase in radial air will results in a hot zone close to the

burner.

For nominal operation, radial air damper will be set between

10 - 30 % open.

Excessive radial air might influence in coating loss close to the

burner.

09-11-17
RADIAL AIR EFFECT

Fuel and
primary air

Swirl air Internal External

Hot recirculation recirculation
secondary air zone zone

09-11-17
AXIAL AIR ADJUSTMENT

Open - increases axial flow, relatively thinner and steadier

flame.

Close - decreases axial flow, softer and less intense flame.

Closing the axial air will make the flame softer / low
momentum and might result in the flame impingement on to
the coating.

For nominal operation, axial air damper will be set 80 - 100

%open.

During startup, if there are fumes of un-burnt fuel (black and

co formation) then it signifies either lack of axial air or the
combustion air.

09-11-17
AIR NOZZLE ADJUSTMENT

Open - rotating the spindle anti-clockwise will increases the

nozzle area.

If the primary air fan damper control is in auto mode (static

pressure), an increase in nozzle area will open the fan damper
to maintain the static pressure thereby increasing the flame
momentum.

Close - decreases in nozzle area will have a reverse effect of

the above.

For nominal operation, nozzle position will be set between 45 -

65 % open.

09-11-17
THANKS FOR YOUR ATTENTION!

QUESTIONS?

09-11-17