GRECO KILN BURNERS FOR PETCOKE COMBUSTION Specific burner design for your kiln Loesche Round Table / India 2012
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 2011 2
WORLDWIDE OFFICES 2011 3
COMPETENCE IN THE ROCK INDUSTRY Kiln Burners Calciner Burners Hot Gas Generators Fuel Systems NEW: Solid Alternative Fuel Handling System 2011 4
COMBUSTION OF PETCOKE 2011 5
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 2011 6
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 2011 7
FLAME CONTROL 2011 8
PETCOKE COMBUSTION Design criteria for kilnburners working with 100% petcoke: 2011 9
PETCOKE COMBUSTION Design criteria for kiln working with 100% petcoke: 2011 10
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. 2011 11
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 2011 12
FLEXIFLAME KILN BURNER 2011 13
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. 2011 14
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 2011 15
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 2011 16
DESIGN OF FLEXIFLAME KILN BURNERS Coal / Petcoke RDF+mixing air MBM+mixing air Cooling Air Dispersion Air External Air Tangential Air 2011 17
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 2011 18
DESIGN OF FLEXIFLAME KILN BURNERS HIGH EFFICIENT BURNER DESIGN Customized primary air pressure (250 500 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 2011 19
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! 2011 20
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 2011 21
NEW FLEXIFLAME RS NEW FLEXIFLAME RS KILN BURNER New FLEXIFLAME RS kiln burner 2011 22
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 2011 23
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 2011 24
BURNERS LANCES 2011 25
BURNERS LANCES OC- JET nozzle for dirty alternative liquids Waste oil, Animal fat, Residues Range 1:8 Viscosity: up to 300cSt 2011 26
BURNERS LANCES 2011 27
HANSON KETTON / UK Nominal thermal power: 66 MW Burner operational range: 80 105 % 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. 2011 28
AALBORG CEMENT / DENMARK Thermal power: 73,4 Gcal/h. - Coal+Petcoke: 10.300 kg/h -> 100% of burner thermal power - Fuel oil: 7.340 kg/h -> 100% of burner thermal power - Glycerin: 4.000 kg/h -> 22% of burner thermal power - MBM: 3.000 kg/h -> 16% of burner thermal power - RDF: 6.000 kg/h -> 33% of burner thermal power - Optional waste fuel: 4.000 kg/h ->16% of burner thermal power 2011 29
CBR ANTOING / BELGIUM Thermal power: 50 MW (43,1 Gcal/h). Petcoke: 6.015 kg/h. Coal: 7.515 kg/h. Light fuel oil: 1,775 kg/h. Animal meal: 5.000 kg/h Dry sewage sludge or Resofuel: 2.500 kg/h Fluffs: 3.000 kg/h. 2011 30
HANSON RIBBLESDALE / UK Thermal power (considering future capacity): 44,4 MW (38,25 Gcal/h) Nominal fuel flows: Coal: 6.660 kg/h Kerosene / gas oil: 3.485 kg/h Cemfuel: 6.000 7.000 kg/h Animal meal: 5.000 7.000 kg/h 2011 31
CBR HARMIGNIES / BELGIUM Thermal power: 62 MW Petcoke Heavy fuel oil Solvents Plastics & RDF Animal meal 2011 32
CEMENTOS ALFA / SPAIN Thermal burner power: 52 MW Petcoke Heavy fuel oil Waste oil Plastics & RDF Dry Sewage Sludge 2011 33
ENCI MAASTRICHT / NETHERLAND Thermal burner power: 128 MW Petcoke, sludge, anode dust Natural gas Glycol Animal meal Paper sludge 2011 34
WOPFING CEMENT AUSTRIA Thermal burner power: 45 MW Petcoke Natural Gas RDF Animal Meal Waste Oil 2011 35
BURNER TROLLEYS Adjustable around the front suspension support in all directions to align the burner well to the kiln requirements. 2011 36
BURNER TROLLEYS Adjustable around the front suspension support in all directions to align the burner well to the kiln requirements 2011 37
FLEXICAL CALCINER BURNERS 2011 38
DESIGN OF FLEXICAL PRECALCINER BURNERS For all traditional fuels as well as RDF and waste liquids 2011 39
SPRCIAL DRYER BURNERS 2011 40
DESIGN OF FLEXICAL DRYER BURNERS For all traditional fuels as well as RDF and waste liquids 2011 41
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 2011 42
DESIGN OF FLEXICAL DRYER BURNERS Flexical Burner: Coal &Fuel Oil burner on a rotary dryer for calcination of raw materials or chemicals. 2011 43
FLEXIGEN HOT GAS GENERATORS for solid fuels as Petcoke /Coal 2011 44
VERTICAL DESIGN / SOLID FUELS 2011 45
SPECIFIC DESIGN OF AIRFLOW 2011 46
SPECIFIC DESIGN OF AIRFLOW 2011 47
SECONDARY AIR FAN 2011 48
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. 2011 49
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 2011 50
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 2011 51
SPECIFIC DESIGN OF AIRFLOW HGG COMBUSTION CHAMBER ROOF VIEW FLAME SENSOR IGNITOR BURNER SPY-HOLE SECONDARY AIR COOLING AIR FLAME SENSOR 2011 52
VALVE TRAINS FOR LIQUID & GASEOUS FUELS 2011 53
FUEL PROCESSING Oil Valve Trains & Gas Valve Trains design according DIN EN 746 2 Oil Pump stations HFO Preheater stations BMS (Simatic, Alain Bradely ) 2011 54
FUEL PROCESSING Fuel supply system for liquide alternative fuels - Used oil - Animal fat - Any liquid fuel residue - Solvents - Glycerine 2011 55
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 2011 56
SOLID ALTERNATIVE FUELS HANDLING SYSTEMS 2011 57
RDF PREPARATION SYSTEM 2011 58
CONTACT US If you have any questions or need any assistance, please do not hesitate to contact your GRECO team: GRECO Combustion Systems Europe +43 2732 75680 info-europe@atec-greco.com info@atec-greco.com 2011 59
THANK YOU FOR YOUR ATTENTION www.grecotec.com / www.atec-ltd.com GRECO Combustion Systems Europe GmbH Kasernstraße 16-18. 3500 Krems/Donau. Austria info-europe@atec-greco.com A TEC GRECO Projetos e Equipamentos Ltda. Av. Brigadeiro Faria Lima 1912 Cj B. 01451-000 São Paulo. Brasil info@atec-greco.com