The document describes the DUOFLEX burner, which features improved heat economy, adjustable flame shape, and easy fuel changeover. It has a central duct for gaseous and liquid fuels surrounded by two concentric ducts for primary air, allowing adjustment of the axial/radial air ratio and flame shape. The burner can fire various fuels individually or in mixtures and has a robust design suitable for large rotary kilns. It uses less primary air than traditional burners to form a short, stable flame beneficial for heat transfer and clinker production.
The document describes the DUOFLEX burner, which features improved heat economy, adjustable flame shape, and easy fuel changeover. It has a central duct for gaseous and liquid fuels surrounded by two concentric ducts for primary air, allowing adjustment of the axial/radial air ratio and flame shape. The burner can fire various fuels individually or in mixtures and has a robust design suitable for large rotary kilns. It uses less primary air than traditional burners to form a short, stable flame beneficial for heat transfer and clinker production.
The document describes the DUOFLEX burner, which features improved heat economy, adjustable flame shape, and easy fuel changeover. It has a central duct for gaseous and liquid fuels surrounded by two concentric ducts for primary air, allowing adjustment of the axial/radial air ratio and flame shape. The burner can fire various fuels individually or in mixtures and has a robust design suitable for large rotary kilns. It uses less primary air than traditional burners to form a short, stable flame beneficial for heat transfer and clinker production.
Widely adjustable flame shape Easy change-over between fuels Main features Application Design The DUOFLEX burner fires ro- The burner is based on a novel tary kilns with pulverised coal or concept featuring a central duct coke, oil, natural gas or any mix- for gaseous and liquid fuels ture of these fuels. The burner placed inside an annular coal may be fitted with extra ducts for duct which is surrounded by two secondary fuels such as plastic concentric ducts that form two chips, wood chips, sewage primary air channels, one for sludge, etc. radial air and one for axial air. Standard types are available for The two air flows are mixed any fuel combination and a before being injected via the maximum capacity ranging from conical air nozzle. 20 to 250 MW, catering for even The two outer ducts form a very the largest of rotary cement rigid supporting structure, kilns. minimising deflection of the Robust design Low primary air consumption Adjustable swirl Adjustable air nozzle area Central fuel injection Suitable for alternative fuels K i l n
s y s t e m s COOL AIR COAL AXIAL AIR SWIRL AIR OIL COOL AIR COAL AXIAL AIR SWIRL AIR OIL Primary air change by adjusting nozzle area burner pipe and ensuring long carbon monoxide (CO) and without compromising refractory life. nitrogen oxides (NOx). If stability during normal or The primary air is supplied by a relevant, the burner must be upset operating conditions. high pressure fan that yields a able to handle alternative Primary air is basically false maximum pressure of 250 mbar. fuels without requiring air, in other words air that has The air nozzle area can be change of its original design. not been used for clinker heat adjusted within the range 1:2. In this way, only minor recuperation while passing The axial/radial air ratio - and modifications to meet the through the clinker cooler. consequently the degree of swirl special requirements must be - is also adjustable. necessary. The primary air is usually expressed as a percentage of The burner must produce a These adjustments offer wide the stoichiometric combustion short, narrow, strongly radiant scope of shaping the flame. air needed to burn the amount flame, as this is a condition of fuel fired through the burner. for good heat transfer from Process and function the flame to the material in Flame momentum From a process point of view, a the sintering zone of the kiln. burner used for heating the The crucial parameter of flame Flame formation must be burning zone of a rotary cement formation is the primary air conducive to a dense, stable kiln must fulfil the following momentum which may be coating on the refractory in requirements: expressed as the primary air the burning zone of the kiln percentage (per cent of The burner must be able to as well as a nodular clinker stoichiometric air requirement) fire coal, coke, fuel oil and with low dust content and multiplied by the injection natural gas or any mixture correctly developed clinker velocity. Consequently, if the thereof, ensuring complete phases. velocity is doubled, the primary combustion, low excess air The burner must use as little air percentage may be reduced and minimum formation of primary air as possible to half. The burner nozzle is adjustable both vertically and horizontally The primary air consumption will formation is only possible if the lining will strip off the coating, normally be in the range of 6-8 inner surface is cold enough for resulting in very high kiln shell per cent, corresponding to a the liquid to solidify upon temperature and short refractory primary air momentum of contact. life. Flame impingement upon approximately 1250 - 1780 per the material charge will increase cent m/s. The adjustable air The use of a narrow flame in a the evaporation of sulphates, nozzle is ideally suited for cement rotary kiln is extremely which usually leads to increased adapting the momentum to the important since a divergent coating formation in the kiln conditions for attaining the best flame that impinges upon the riser duct. flame shape. The burner in a rotary kiln functions as an injector, the purpose of which is to draw the secondary air coming from the cooler into the flame in order to make the fuel burn as close as possible to the centre line of the kiln. This explains why the momentum of the burner is the parameter that determines flame formation. A higher momentum means faster mixing and a shorter and hotter flame. Divergent feeding of fuel and primary air should be avoided as it inevitably leads to wider flames and higher temperatures on the inner surface of the burning zone. Good coating 100% 100% 90% 90% 80% 80% 70% 70% 60% 60% 50% 50% Momentum P o w e r
c o n s u m p t i o n Traditional burner with damper P r i m a r y
a i r 10% 100% 8% 90% 6% 80% 4% 70% 2% 60% 0% 50% Momentum Effect of nozzle area control versus traditional damper control DUOFLEX with adjustable nozzle area Traditional burner with damper DUOFLEX with adjustable nozzle area Since good flame formation in flame, high kiln shell tempera- The very easy adjustment of the the kiln permits operating with tures above the burning zone nozzle area and the different air very little excess air and without and in the kiln back end as well flows, helped by clear position the formation of CO, a burner as unstable kiln operation with a indicators, make it possible to operating with correct flame too long and cold burning zone find and maintain any precise momentum despite the higher thereby permitting undesirable setting during operation as well flame temperature will result in clinker crystal growth. as between the different produc- less formation of NO than a low tion campaigns. momentum burner operating The two different kiln tempera- with more excess air. ture profiles, before and after The DUOFLEX burner normally introducing the DUOFLEX operates with 6 - 8 per cent pri- Practical experience has shown burner, clearly show the huge mary air but is designed for max- that the formation of a strong, effect on both coating formation imum 10 per cent. This will in all stable, short and narrow flame and kiln shell temperature. No cases provide the kiln operator requires a momentum of mini- lining repairs were made while with the necessary "tool" to mum 1400 - 1600 per cent m/s. exchanging the two burner quickly stabilise any upset con- A flame momentum below this installations. ditions. range will result in too long a 100 0 10 20 30 40 50 60 70 metres 200 300 400 MAX/MIN o C DUOFLEX Kiln shell temperature Traditional burner Data in this brochure is intended for preliminary project planning only. Manufacturer reserves the right to modify equipment details and/or specifications without notice. DENMARK F.L.Smidth & Co. A/S GERMANY F.L.Smidth-Fuller GmbH F.L.Smidth & Co. (SA) (PTY) Ltd. Vigerslev All 77, DK-2500 Valby, Copenhagen Tel: +49 - 211-591-038 Tel: +27 - 11-470-9700 Tel: +45 - 36 18 10 00 Fax: +49 - 211-593-223 Fax: +27 - 11-475-7665 Fax: +45 - 36 30 18 20 INDONESIA FLS Indonesia-Fuller Indonesia SPAIN F.L.Smidth & Cia Espaola, S.A. Internet: http://www.flsmidth.com Tel: +62 - 21-251-2738 / 2739 Tel: +34 - 1-634-90-00 Cement Projects Division Fax: +62 - 21-251-2740 Fax: +34 - 1-636-11-50 Fax: +45 - 36 30 18 20 ITALYF.L.Smidth & C. Italiana S.r.L. THAILAND Mr. Per Mejnert Kristensen Products Division Tel: +39 - 35-46 83 11 c/o Mitsiam International, Limited Fax: +45 - 36 17 47 24 Fax: +39 - 35-46 08 38 Tel: +66 - 2-285-1020 Parts & Services Division JAPAN F.L.Smidth & Co. J apan Ltd. Fax: +66 - 2-285-1968-9 Fax: +45 - 36 44 11 19 Tel: +81 - 3-3578-0541 TURKEY F.L.Smidth & Co. A/S Liaison Office Fax: +81 - 3-3578-0548 Tel: +90 - 212-251-13-31 USA Fuller Company MEXICO F.L.Smidth-Fuller Mexico, S.A. de C.V. Fax: +90 - 212-251-62-82 2040 Avenue C, Bethlehem, Tel: +52 - 836-33150 UNITED KINGDOM F.L.Smidth-Fuller Ltd. Pennsylvania 18017-2188 Fax: +52 - 836-33421 Tel: +44 - 181-686-2422 Tel: +1 - 610-264-6011 PAKISTAN FLS Pakistan (Pvt.) Ltd. Fax: +44 - 181-681-7229 Fax: +1 - 610-264-6170 Tel: +92 - 51 29 31 95 Fax: +92 - 51 29 31 96 Licensees/joint ventures F.L.Smidth subsidiaries: PHILIPPINES F.L.Smidth & Co. A/S INDIA Larsen & Toubro Ltd. (Licensee) BRAZIL F.L.Smidth Comrcio e indstria Ltda. Tel: + 63 - 2-824-7676 Cement Machinery Division, Powai Works Tel: +55 - 11-532-8500 Fax: +63 - 2-824-7676 Tel: +91 - 22-5781401 Fax: +55 - 11-533-9612 P. R. OF CHINA F.L.Smidth & Co. A/S Fax: +91 - 22-5783437 FRANCE F.L.Smidth-Fuller S.A. Tel: 86 - 106 4677070 Tel: +33 - 1-4944-6800 Fax: 86 - 106 4677071 A member of the F.L.SMIDTH-FULLER Fax: +33 - 1-4308-5099, +33 - 1-4308-5188 SOUTH AFRICA Fuller-F.L.Smidth (PTY) Ltd. ENGINEERING GROUP Traditional burner DUOFLEX