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In parallel flow kilns the fuel is introduced at the upper end of the
burning zone and the combustion gases travel parallel to the
material. Fig. 1b shows a typical temperature profile where the green
line represents the material temperature, the blue lines in the preheating and cooling zone the relevant air temperatures and the red
line the combustion gas and kiln exhaust gas temperatures. As the
fuel is injected at the upper end of the burning zone where the material can absorb most of the heat released by the fuel the temperature
in the burning zone is typically as low as 950 C on average. Because
of this, parallel flow heating is the best solution for the production
of soft burned, reactive lime and dolomitic lime as required in most
applications.
The second important characteristic of the PFR-Kiln is the
regenerative preheating of the combustion air. In kilns with counter
flow heating the combustion air is preheated in the cooling zone by
the sensible heat contained in the calcined lime. The amount of
preheating is limited, however, by the enthalpy of the lime. In the
counter flow heating process there is a surplus of usable sensible
heat contained in the exhaust gas that is not recovered prior to being
exhausted. As a consequence some single shaft kiln designs have
incorporated recuperators in an effort to recover this waste heat, but
such heat exchangers are susceptible to operating problems caused
by dust contained in the hot exhaust gases.
In the parallel flow regenerative kiln the combustion air is
preheated in an optimal way. The regenerative process requires two
connected kiln shafts. Each shaft is subject to two distinct modes of
operation, burning and non-burning. One shaft operates in the