GRECO KILN BURNERS FOR PETCOKE COMBUSTION

Transcription

1 GRECO KILN BURNERS FOR PETCOKE COMBUSTION Specific burner design for your kiln Loesche Round Table / India 2012

2 ABOUT GRECO Founded in 1966 Uni. Prof. Clemento Greco 90 th Conversion from fuel oil to petcoke Since more than 10 years around 300pc. installed burners Since 2010 part of the A TEC Group Worldwide Offices

3 WORLDWIDE OFFICES

4 COMPETENCE IN THE ROCK INDUSTRY Kiln Burners Calciner Burners Hot Gas Generators Fuel Systems NEW: Solid Alternative Fuel Handling System

5 COMBUSTION OF PETCOKE

6 DESIGN OF FLEXIFLAME PETCOKE Combustion of petcoke: Petcoke is harder to ignite as conventional coal (low volatile) Petcoke provides a higher flame radiation then coal Petcoke has a typicall high sulfur content Petcoke develops a higher NOx formation Usually petcoke changes the kiln profile Petcoke needs a special burner design

7 PETCOKE COMBUSTION The combustion of petcoke requires: Quick mixing of secondary air to the flame, to allow the complete combustion which is iniciated by primary air. Primary air jets need to accellerate the secondary air. Internal recirculations are controlling the ignition distance of the fuel

8 FLAME CONTROL

9 PETCOKE COMBUSTION Design criteria for kilnburners working with 100% petcoke:

10 PETCOKE COMBUSTION Design criteria for kiln working with 100% petcoke:

11 PETCOKE COMBUSTION Tendency of buid ups (clorine vs. sulfur) in hot meal Build ups out of control No build ups Build ups under control Source: VDZ Forschungszentrum Düsseldorf The additional sulfur input by petcoke requires a check of raw material mix

12 PETCOKE COMBUSTION High flame momentum has advantages in: Kiln operations becomes more stable & improved fuel efficiency Improved clinker reaktivity and shorter sintering zone Lowered volatility and recirculation of sulfur in kiln gases (control of surfur into the clinker) Tendency for ring formation is lower Clinker granulometry more uniform

13 FLEXIFLAME KILN BURNER

14 FLEXIFLAME KILN BURNER Design Philosophy: Each kiln burner will be designed individually according to the process of each kiln and its characteristics. That provides operation safety for the entire combustion and sintering process

15 REQUIREMENTS FOR KILN BURNERS Maximum use of solid alternative fuels Clinker quality Kiln operation Lowest possible NO x & CO emissions Wear resistance + low maintenance Compromise between different parameters Flexibility to operate with different fuels TAILOR MADE HIGH FLEXIBILITY

16 DESIGN OF FLEXIFLAME BURNERS FOR PETCOKE EXTERNAL AIR TANGENTIAL AIR (ROTATION) COAL/PETCOKE DISPERSION AIR (ROTATION) CENTRAL AIR (RECIRCULATION/COOLING SLUDGES / ANIMALMEAL IGNITOR MIXING AIR FOR ASF RDF / FLUFF DOUBLE SWIRL EFFECT

17 DESIGN OF FLEXIFLAME KILN BURNERS Coal / Petcoke RDF+mixing air MBM+mixing air Cooling Air Dispersion Air External Air Tangential Air

18 DESIGN OF FLEXIFLAME KILN BURNERS Conveying air ratio Conveying air flow Pulverized solid fuel (Coal / Petcoke) Animal meal and/or Sewage sludge Fluff / RDF Up to 5,0 kg of material per kg of air Up to 4,0 kg of material per kg of air Up to 2,5 kg of material per kg of air 2-3,5 % of stoichiometric air 1-3,5 % of stoichiometric air 1-3,5 % of stoichiometric air

19 DESIGN OF FLEXIFLAME KILN BURNERS HIGH EFFICIENT BURNER DESIGN Customized primary air pressure ( mbar) Less possible transport air flow for coal/petcoke Primary air with high pressure (high momentum) 6 12% of stoichiometric combustion air NO X emission control

20 DESIGN OF FLEXIFLAME KILN BURNERS SOLID ALTERNATIVE FUEL FIRING SAF solid alternative fuels with pneumatic mixing device SAF pipes in compound wear resistant material O2 READY design to improve the kiln performance Pulverized fuel inlet in hardened material outer pipe Pulverized fuel inlet with ceramic protection inner pipe No wear at SAF nozzles!

21 NEW FLEXIFLAME RS KILN BURNER New FLEXIFLAME RS kiln burner with advantages of: Easy flame setting and control Smaller burner diameter -30% steel burner weight Less internal air pressure drop Quicker and simpler burner tip service Shorter kiln burner lenght, easier in handling Maintaining of a high burner momentum

22 NEW FLEXIFLAME RS NEW FLEXIFLAME RS KILN BURNER New FLEXIFLAME RS kiln burner

23 NEW FLEXIFLAME RS NEW FLEXIFLAME RS KILN BURNER External Air Tangential Air with air control slide Petcoke/Coal Cooling air Dispersion Air with air control slide

24 NEW FLEXIFLAME RS NEW FLEXIFLAME RS KILN BURNER External Air Tangential Air with air control slide Petcoke/Coal Dispersion Air with air control slide Cooling air

25 BURNERS LANCES

26 BURNERS LANCES OC- JET nozzle for dirty alternative liquids Waste oil, Animal fat, Residues Range 1:8 Viscosity: up to 300cSt

27 BURNERS LANCES

28 HANSON KETTON / UK Nominal thermal power: 66 MW Burner operational range: % of nominal thermal power. Multi-fuel burner firing coal, gas-oil, solvent and solid alternative fuels. Nominal fuel flows: Coal: 12,000 kg/h. Liquid fuel: 6,000 l/h. Solvents: 7,000 l/h. Solid alternative fuel #1: 7,000 kg/h. Solid alternative fuel #2: 7,000 kg/h

29 AALBORG CEMENT / DENMARK Thermal power: 73,4 Gcal/h. - Coal+Petcoke: kg/h -> 100% of burner thermal power - Fuel oil: kg/h -> 100% of burner thermal power - Glycerin: kg/h -> 22% of burner thermal power - MBM: kg/h -> 16% of burner thermal power - RDF: kg/h -> 33% of burner thermal power - Optional waste fuel: kg/h ->16% of burner thermal power

30 CBR ANTOING / BELGIUM Thermal power: 50 MW (43,1 Gcal/h). Petcoke: kg/h. Coal: kg/h. Light fuel oil: 1,775 kg/h. Animal meal: kg/h Dry sewage sludge or Resofuel: kg/h Fluffs: kg/h

31 HANSON RIBBLESDALE / UK Thermal power (considering future capacity): 44,4 MW (38,25 Gcal/h) Nominal fuel flows: Coal: kg/h Kerosene / gas oil: kg/h Cemfuel: kg/h Animal meal: kg/h

32 CBR HARMIGNIES / BELGIUM Thermal power: 62 MW Petcoke Heavy fuel oil Solvents Plastics & RDF Animal meal

33 CEMENTOS ALFA / SPAIN Thermal burner power: 52 MW Petcoke Heavy fuel oil Waste oil Plastics & RDF Dry Sewage Sludge

34 ENCI MAASTRICHT / NETHERLAND Thermal burner power: 128 MW Petcoke, sludge, anode dust Natural gas Glycol Animal meal Paper sludge

35 WOPFING CEMENT AUSTRIA Thermal burner power: 45 MW Petcoke Natural Gas RDF Animal Meal Waste Oil

36 BURNER TROLLEYS Adjustable around the front suspension support in all directions to align the burner well to the kiln requirements

37 BURNER TROLLEYS Adjustable around the front suspension support in all directions to align the burner well to the kiln requirements

38 FLEXICAL CALCINER BURNERS

39 DESIGN OF FLEXICAL PRECALCINER BURNERS For all traditional fuels as well as RDF and waste liquids

40 SPRCIAL DRYER BURNERS

41 DESIGN OF FLEXICAL DRYER BURNERS For all traditional fuels as well as RDF and waste liquids

42 DESIGN OF FLEXICAL DRYER BURNERS Thermal Power: 1 50 MW Easy controllable flame Safe and robust burner design Low maintanance necessary Stable flame with refractory mouth

43 DESIGN OF FLEXICAL DRYER BURNERS Flexical Burner: Coal &Fuel Oil burner on a rotary dryer for calcination of raw materials or chemicals

44 FLEXIGEN HOT GAS GENERATORS for solid fuels as Petcoke /Coal

45 VERTICAL DESIGN / SOLID FUELS

46 SPECIFIC DESIGN OF AIRFLOW

47 SPECIFIC DESIGN OF AIRFLOW

48 SECONDARY AIR FAN

49 SECONDARY AIR & COOLING AIR INLET Secondary air inlet: Provides oxygen to the flame. Cooling air inlet: Controls the refractory lining temperature. Automatic mode, to keep the temperature bellow 1000 C (ash melting point) Both flows are adjusted by pneumatic valves

50 DILUTION AIR INLET The dilution air is used to adjust the outlet gases temperature Its main inlet is located just before (above) the outlet of the HGG

51 FLAME ADJUSTMENTS The flame shape can be adjusted by changing the axial and tangential air ratios There are two butterfly valves used for these adjustments: - External air channel - Tangential air channel

52 SPECIFIC DESIGN OF AIRFLOW HGG COMBUSTION CHAMBER ROOF VIEW FLAME SENSOR IGNITOR BURNER SPY-HOLE SECONDARY AIR COOLING AIR FLAME SENSOR

53 VALVE TRAINS FOR LIQUID & GASEOUS FUELS

54 FUEL PROCESSING Oil Valve Trains & Gas Valve Trains design according DIN EN Oil Pump stations HFO Preheater stations BMS (Simatic, Alain Bradely )

55 FUEL PROCESSING Fuel supply system for liquide alternative fuels - Used oil - Animal fat - Any liquid fuel residue - Solvents - Glycerine

56 FUEL PROCESSING 40 ft standard container 40m³ double shellstorage tank in one unit Easy to manipulate and flexible in use Execution according to valid TÜV and ATEX standards

57 SOLID ALTERNATIVE FUELS HANDLING SYSTEMS

58 RDF PREPARATION SYSTEM

59 CONTACT US If you have any questions or need any assistance, please do not hesitate to contact your GRECO team: GRECO Combustion Systems Europe

60 THANK YOU FOR YOUR ATTENTION / GRECO Combustion Systems Europe GmbH Kasernstraße Krems/Donau. Austria [email protected] A TEC GRECO Projetos e Equipamentos Ltda. Av. Brigadeiro Faria Lima 1912 Cj B São Paulo. Brasil [email protected]