BURNER DESIGN CRITERIA

Theoretical

combustion air required

Hu= (Kj/kg)/4.19*1000 +0.5505 Hu (=CV of fuel)

(as per Atto Labahan)
Emperical

eqn for theoretical air required /

1000 cv
= 1.05 Nm3/kg (solid fuel)
= 1.10 Nm3/kg (liquid fuel) = 1.15 Nm3/kg (gaseous fuel)

BURNER DESIGN CRITERIA

Theoretical

combustion gases

= Theoretical air required * 1.07

CO2

generated from raw mix

= 0.27 0.29 Nm3/kg (depending on the total carbonate content)

FLAME SHAPE DEPENDS

Percentage Primary Primary Mixing Flame

Air

Air Velocity

of Coal & Air

Momentum Depend on Percentage Air Velocity Air Temperature

Air & Primary Air Velocity

Secondary Secondary

FLAME SHAPE DEPENDS

Recirculation Primary

Air Velocity / Secondary Air Velocity

Ratio
Burner

Dia / Kiln Dia ratio

Burner
Excess

Position

Air

EFFECT OF PERCENTAGE OF PRIMARY AIR

Higher

the percentage Primary Air, higher the Heat Consumptions in Kiln. 1% increase of Primary Air, Heat Consumption increase by 4 kCal/Kg Clinker.
Primary Air can be even 6%. 2% on Transport Air & 3 to 4% as Axial Air & Radial Air. Air generally 30% & Axial Air 70% for a good flame shape.

Percentage

Radial

EFFECT OF PERCENTAGE OF PRIMARY AIR

6 % Primary Air

2% Transport Air

4% (Axial Air + Radial Air)

1.2% Radial Air

2.8% Axial Air

PRIMARY AIR VELOCITY

Flame

length decreases with higher Primary Air velocity & then again it increases with increase of Primary Air velocity.

Flame Length

Optimum Flame length vis-a-vis velocity

Velocity of Primary Air

Velocity

of coal tip = 30 m/sec Velocity of radial air tip = 90 130 m/sec Velocity of axial air tip = 140 210 m/sec

MIXING OF COAL & AIR

For

a good flame, it is essential that coal & air has to be mixed thoroughly. Better is the mixing, better is the flame. Swirler in radial air line & coal line have to be in opposite direction for better mixing.
Axial Coal Radial Radial Coal Axial

FLAME MOMENTUM
momentum = % PA x (Velocity)2 1,00,000 1,20,000 Flame momentum has more influence by velocity of Primary Air than % PA. As percentage Primary Air decreases, the velocity has to be increased to satisfy the flame momentum. For 6% PA, the velocity of Axial Air is required 130 140 m/sec.
Flame

SECONDARY AIR VELOCITY

Secondary

air velocity should be in the range of 4 5 m/sec. the secondary air velocity inside the Kiln, more dust carryover into Kiln. leads wear / tear on tip casting back.

More

It

It

creates a dust envelope around the flame & flame temperature goes down.

SECONDARY AIR TEMPERATURE

Higher

the secondary air temperature, higher is the flame temperature for same quantity of secondary air.
2200C 2000C 1800C

Flame Temp.

1000C 900C 800C Secondary Air Temp. C

SECONDARY AIR TEMPERATURE

Secondary

air temperature has to be measured just above the clinker bed height.
air temperature can be increased by 200C due to full height of clinker from cooler.

Secondary

RECIRCULATION
For

a good flame recirculation of air & coal is a must. Better is the recirculation, better formation & stability of flame.
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RECIRCULATION
High

velocity of primary air creates a sudden vacuum & leads to recirculation. At the time of recirculation, mixing with secondary air temperature& quantity is important.

PRIMARY AIR / SECONDARY AIR VELOCITY RATIO

Up

should be in the range of 25 ~ 35

Us Lower Up/Us < 25, lower is the recirculation & inferior is the flame. Higher Up/Us > 35, heavy high recirculation & unstable flame shape.
Where: Up Primary Air Velocity, m/sec Us Secondary Air Velocity, m/sec

BURNER DIA / KILN DIA RATIO

D/2 Material thickness do Coating thickness Brick thickness

Half

width of flame = D/2 (Brick thickness + Coating thickness + Material thickness)

BURNER DIA / KILN DIA RATIO

Flame

should just touch the material & it should not penetrate.

= 11 = 0.06 0.11

tan

do/D

EFFECT OF BURNER PIPE POSITION

Preferably Burner Burner

at the center of the Kiln

axis and Kiln axis should coincide

preferably may be inside of the kiln by 0.8 1.0 m, for Better secondary air distribution & flame stability
Better life of the tip casting block / refractory Reduce snowman formation at the cooler throat Higher C3S in clinker formation Higher cement strength

EXCESS AIR
Zero

ppm of CO at 1.5% O2 at Kiln inlet

ppm CO

0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6

O2 at Kiln Inlet

EXCESS AIR

Flame Temp. C

1000C 900C 800C 0 0.5 1 1.5

% O2

Higher

excess air quantity, leads to higher false air in the system & reduce flame temperature.