02_Pillard_Gemmer

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From ROTAFLAM

®

RV2 to NOVAFLAM

®

The new high efficiency burner

Presentation at:

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PILLARD FEUERUNGEN GmbH - Aarstraße 168, 65232 Taunusstein - Tel.: 061282420 - Fax: 06128242112 - Mail: [email protected] - Web: www.pillard.de

Reduction of CO

2 Increasing the amount of Climafuel as much as possible

High or better Clinker quality by using Climafuel

Improving the Sulphur cycle

This a.m. requirements are totally fulfilled by the ROTAFAM

®

_{RV2 Burner}

…but the clients asked more and more

to simplify the adjustment of the burner

to reduce the installation and running costs

to reduce the electrical consumption

This additional requirements are now achieved by the new “high efficiency” rotary

kiln burner NOVAFLAM

®,

_{by keeping the advantages of the ROTAFLAM RV 2}

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ROTAFLAM

®

_RV2

ROTAFLAM

®

_RV2

Increased sulphur integration in the clinker

Better clinker quality

High amount of A.S.F., more than 80%

Lower kiln shell temperature

ROTAFLAM

®

_{RV 2 – Proved advantages}

Compact and short Flame

Reduced coatings in the

preheater

tower

up to 80 %

Easy Adjustment of the burner tip via hydraulic

cylinder at the Burner / from the PLS

Combustion of the A.S.F. inside the Flame

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ROTAFLAM

®

_Standard

ROTAFLAM

®

_{RV2 – new Design}

Summary of the modifications - ROTAFLAM

®

_RV2

Axial Air

Swirl air

Coal

Fluff

Auxiliary Air

Center Line

ROTAFLAM

®

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Standard ROTAFLAM

®

_{- Axial channel:}

(advantageous for standard fuels)

Less Slot effect Optimum Slot effect

Fluent – Flow Simulation

New channel design – Axial channel:

(additional very good results with A.S.F.)

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Standard ROTAFLAM

®

_{- Axial channel:}

Less & Optimum Slot effect

New Channel design – Axial channel:

Less & Optimum Slot effect

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0

0.4

0.8

1.2

19 /12/

06

29 /12/

06 8/

1/

07 18/

1/0

7 28/

1/0

7 7/

2/

07 17/

2/

07 27/

2/

07 9/

3/

07 19/

3/

07 29/

3/

07 8/

4/

07 ROTAFLAM

RV2

20

25

30

35

40

45

50

55

60

65

70 19/

12 /06

29 /1

2/

06 8/

1/0

7

18 /1/

07 28/

1/

07 7/

2/

07 17/

2/

07

27 /2

/0

7 9/

3/

07

19 /3

/0

7

29 /3/

07 8/

4/

07

18 /4

/0

7 28/

4/

07 8/

5/

07

1 day strenght 2 days strenght 7 days strenght 28 days strenght

ROTAFLAM

RV2

CEMENT STRENGHT (MPa)

SO

₃

CLINKER (%)

1 Day

2 Days

7 Days

28 Days

CLINKER QUALITY IMPROVEMENT WITH 75 % OUTPUT FROM FLUFF

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Modifications - ROTAFLAM

®

_{RV2 to RV2i}

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Results after modification RV2 to RV2i

Burner optimization

Temperature

c

y

c

lone 1 east & west°

C

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Modification of the mixing chamber

CL ROTAFLAM

®

Old design

_{Fluff + Transport Air}

Auxiliary Air

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Modification of the mixing chamber

CL ROTAFLAM

®

Fluff + Transport Air

Auxiliary Air

New ASF auxiliary air nozzle

New “Mixing chamber”

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FAST AERATION AND DISPERSION

= HIGHER ASF RATES,

SHORTER FLAME WITH LOWER DIAMETER

FAST AERATION AND DISPERSION

= HIGHER ASF RATES,

SHORTER FLAME WITH LOWER DIAMETER

OPTIMIZED

MIXING

CHAMBER

ASF + T

RANSP

ORT A

_IR

AIR

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Mixing Chamber for Climafuel

high density

normal density

lower density

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Summary of the modifications - ROTAFLAM

®

_RV2

Mixing chamber

Slots

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The NOVAFLAM

®

_{burner: a simplified use}

Burners with axial & swirl

channels adjustable at site

ROTAFLAM

®

Addition of "slot effect"

“Tailor-made" engineered design

Allows much more simple adjustments

NEW PATENTS

EP 06.778673.1

of June 26,2006

EP 07.290663.9

of May 23, 2007

FR0852836

of April 28, 2008

FR2009/050593

of April 07, 2009

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

From the ROTAFLAM… to the NOVAFLAM burner…

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A mono channel burner :

Axial and Radial air are supplied by a same burner channel

More efficient in term of impulse and swirl :

Limited loss of pressure in the burner

Easy to understand, to use, to adjust :

2 parameters to be adjusted

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The NOVAFLAM

®

_{: THE NEW KILN BURNER}

Axial air injected in the flame by holes

CONSTANT CROSS SECTION

ADJUSTEMENT BY PRESSURE

CONTROL

Adjustable radial air angle

NO NEED TO CHANGE RADIAL AIR

QUANTITY FOR FLAME SHAPING

VERY EASY TO ADJUST

FLAME WIDTH

Coal and central air channels

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By moving back the radial tip,

we adjust the flame width

By controlling the primary air pressure,

we adjust the burner impulse

VERY EASY TO ADJUST !

Flame shape adjustment device

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Higher pressure at burner tip available by optimizing the pressure drop between fan and burner tip outlet

A DIVIDED primary air outlet is mandatory

swirl and axial primary air outlet

Influence of increasing SWIRL

Flame OK

primary air outlet

Max velocity for 250 mbar fan pressure

Max velocity # 100 m/s

Un

ac

ce

pt

ab

le

in swirl and axial primary air outlet

Influence of increasing SWIRL

(NOVAFLAM

®

₎

_{Flame OK}

primary air outlet

Max velocity for 250 mbar fan pressure

(NOVAFLAM

®

₎

Max velocity # 250 m/s

COMMON or DIVIDED primary air outlet ?

COMMON

DIVIDED

COMMON

DIVIDED

Choosen!

LOW SWIRL

HIGH SWIRL

Un

ac

ce

pt

ab

le

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BETTER COMBUSTION (no more CO)

ENERGY SAVING (PRIMARY AIR, ELECTRICAL CONSUMPTION)

BETTER KILN STABILITY

EASIER TO RECOVER CRITICAL/WEAK CONDITIONS

SAWDUST SUBSTITUTION INCREASE FROM 20 To

40 %

MAIN BENEFIT

130-170

220 pres.(mbar)

8

10 PA %

NOVAFLAM®

3 CHANNELS

TYPE

BURNER

AFTER

BEFORE

INCREASE IMPREGNATED SAW DUST %

REASON OF BURNER

REPLACEMENT

MIX COAL/PETCOKE+STEP, IMPREGNATED SAWDUST, ANIMAL

MEAL,SOLVANT

FUELS

750 SEC. AIR (°C)

800 PROD.(TPD)

WET LINE

TYPE

PROCESS

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CASE STUDY: Holcim Dannes, France, Sept. 08

NO MORE RING AND BUILD UP

ENERGY SAVING (PRIMARY AIR, ELECTRICAL CONSUMPTION)

BETTER KILN STABILITY

EASIER TO RECOVER CRITICAL/WEAK CONDITIONS

SAWDUST SUBSTITUTION INCREASE FROM 30 To

50 %

MAIN BENEFIT

130-180

220 pres.(mbar)

9

10 PA %

NOVAFLAM®

3 CHANNELS

TYPE

BURNER

AFTER

BEFORE

INCREASE IMPREGNATED SAW DUST %

REASON OF BURNER

REPLACEMENT

MIX COAL/PETCOKE+STEP, IMPREGNATED SAWDUST,

ANIMAL MEAL,SOLVANT

FUELS

750 SEC. AIR (°C)

1200

PROD.(TPD)

LEPOL GRATE, SATELLITE COOLER

TYPE

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Running costs

Installation costs

Existing carriage

Existing P.A. fan

Recovered

Payback time of 8 months for the 2 HOLCIM French plants

Huge savings!

Minimized!

Kiln production

Use of High A.S.F. %

Stability increased

Production increased

(typically 2-4%)

A low quality coal can

be used

Cancelling fuel costs

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CO2 emission

Electric consumption

Specific consumption

Concentration can be increased

Electric Consumption: less15%

Use of higher Biomass fuel %

Pressure can be reduced

Flow reduced

El. Consumption: less 30/40%

Solid fuel conveying lines

Primary air fan

CO

₂

Reduced!

Consumed electricity

Reduced!

Reduced (average 3 %)

CO

₂



CO

₂



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Absolutely avoid a burner oversizing



Dry or wet process, Ø 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 ?

Process data (incl. kiln geometry)



Past experience with the kiln (difficulties, rings, other)



Priority targets (Increase prod ? Improve clinker quality ? Sulphur cycle problems ? Decrease NOx ?



Increase A.S.F. %?)

Running data

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Assembly & Commissioning

If required our trained personal supports you for erection and supervision of assembly

The commissioning and the optimization of the burners will be carried out with our

commissioning engineer together with the customers staff

During the commissioning your staff will be trained

Process optimization

Our specialists from R & D as well as from after sales service will carry out, if necessary,

further optimizations

Use of the latest technology tools – for example POWITEC camera

Use of intelligent software tools for flow analysis (Fluent)

Spare parts

We support you in all matters of spare parts planning, procurement, storage and assembly.

In every phase of our cooperation, we try to optimize the handling of spare parts for you.