Fives Pillard 1

COMBUSTION IN ROTARY KILNS

& PRECALCINERS
NEW TARGETS AND SOLUTIONS
Fives Driving Progress
Fives Pillard 2
Brief overview of Fives Pillard,
Marseilles, France...
J.C.P.
3 Fives Pillard
Kiln burner concepts of the 90's
BURNERS WITH
AXIAL & RADIAL
CHANNELS
ADJ USTABLE AT SITE
The ROTAFLAM

burner
FIXED BURNER
HIGH IMPULSE
LIMITING MISTAKES
OF OPERATORS
The traditional burner
versus
(+) Can be tuned to
each kiln at site
(-) Difficult to adjust
Complex
Heavy
The two concepts have been applied for over 15 years,
both have shown their limitsnone is a clear winner.
NEW PATENTS
DE 3933050C2 of Oct. 4, 1989
EP 90.430017.5 of Sept.14,1990
(+) Avoid mistakes of
operators
(-) Damages on refractories
High NOx emission
Limited adjustments
Sticking on tips
4 Fives Pillard
New (priority) millennium targets
Target Year
Assess burner operation in a kiln, using Fluent

CFD software
Cement kiln simulations 1 1999
Develop the use of Alternative Solid Fuels(A.S.F.) in Europe
Powders (animal, biomass, urban) and "Fluff"
Decrease the running costs of European Cement Plants
By conversion to high % of A.S.F.
Put Clinker quality as a priority
(+) The Sulphur cyclemust be improved
Address new Sustainable developmentrequirements
Reducing CO and NOx emission AT STACK
2001
-
2005
Simplify burners use : the NOVAFLAM

burner
Improve precalciners / Urea Ammonia injection
2000
-
2004
2 2002
3 2003
4
5
6 2005
Control combustion in real time
Fives Pillard 5
Target 1:
Assess burner operation in a kiln,
using Fluent

CFD software
6 Fives Pillard
First cement kiln simulations (with Fluent

CFD software)
The Fluent

CFD tool allows to compare burner tip geometries

Stream lines around flames
Question : Are there big recirculation
areas inside the kiln ?
Answer : No
Extract from competitor article
U
N
T
R
U
E
High intensity flame Long lazy flame
Question : Can we evaluate the influence
of flame intensity on the
clinker bed ?
Answer : Yes
Bad air distribution
(white cement)
Improved
Question : What is the influence of air
distribution ?
Answer : essential
MUST be optimized first
Fives Pillard 7
Target 2:
Develop the use of A.S.F. in Europe
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A.S.F.: how to improve the combustion of fluff?
First dispersor New dispersor (2005)
NEW PATENTS
FR 9808254 of June 24, 1998
EP 99.430010.1 of June 23, 1999
A fast dispersion into the flame
A new "fluff dispersor" has been developed
Fluff being heterogeneous, its combustion requires:
Suction of secondary air Radiation on clinker
An acceleration of the combustion, by SLOT
EFFECT , enabling
to Adapt the amount of Hot Secondary Air
(H.S.A.) introduced in the flame
And, - as a consequence- , to affect the flame
temperature
Few H.S.A. in flame,
SOFT FLAME
Fast/high H.S.A. in flame,
HIGH INTENSITY FLAME
Fives Pillard 9
Target 3:
Decrease the running cost of European Cement Plants
by conversion to high % of A.S.F.
10 Fives Pillard
The ROTAFLAM

Version 2 with SLOT EFFECT

allowed for a huge increase of A.S.F. use (%)
(A.S.F.) Alternative Solid Fuels
End user Kiln (tpd)
% Heat release Type
HOLCIM HOVER, Germany DRY 3200
75
Fluff + Animal meal ROTAFLAM V2

HEIDELBERGER LENGFURT, Germany DRY 2500

80
Fluff + Animal meal + Solvents ROTAFLAM V2

HEIDELBERGER SCHELKLINGEN, Germany DRY 2500

75
Fluff+ Dry sewage sludge ROTAFLAM V2

ROHRDORF, Germany SEMI WET 3000

80
Tetrapack, Plastic ROTAFLAM

WITTEKIND, Germany DRY 2500

52
Bram ROTAFLAM V2

DYCKERHOFF, DEUNA, Germany DRY 3000

50
Fluff + Plastic ROTAFLAM

HOLCIM ECLEPENS, Switzerland DRY 2000

30
Sawdust + Animal meal ROTAFLAM V2

Burner
11 Fives Pillard
The ROTAFLAM

Version 2 with SLOT EFFECT

Focus on Holcim plant, Hver (G) : Clinker quality improved and Fluff consumption increased
up to 75 %, i.e. 13 tons/hr
NEW PATENTS
FR 0705305 of July 20, 2007
EP 08.160478.7 of July 16, 2008
Fives Pillard 12
Target 4:
Put Clinker quality as a PRIORITY
Fives
13 Fives Pillard
Clinker quality & Sulphur cycle
The ROTAFLAM

Version 2 with " SLOT EFFECT improves the clinker quality and impedes
the Sulphur cycle formation, thanks to:
No contact between flame and the clinker bed
Low diameter " cigar" shaped flame in the kiln axis
High intensity flame (DRY PROCESS), softer (WET)
End user Main fuel
Kiln
(tpd)
Former burner New burner Improvement
TIANRUI RUIZHOU, China High ash coal 6000 ROTAFLAM

<2001 ROTAFLAM

V2
1 day strength increase 13 => 14 Mpa,
production increase by 3,5 %
HOLCIM, Sri Lanka Coal + sawdust 900 ROTAFLAM

<2001 ROTAFLAM

V2
same clinker quality & production, with 2 times more ASF
( 2 to 4 t/h rice husk)
LIULIHE, China High ash coal 3000 ROTAFLAM

<2001 ROTAFLAM

V2
3 days strength increase 28 => 30 Mpa,
production increased by 2%
WULAN CEMENT 2, China High ash coal 3000 Chinese burner (copy ROTA) ROTAFLAM

V2 3 days strength increase 28 => 30 Mpa

Fives Pillard 14
Target 5:
Address New Sustainable developmentrequirements
15 Fives Pillard
Sustainable development : a struggle against pollutants
NEW PATENT: EP 04.290293.2 of Feb.4, 2004
CO and NOx reduction at stack needs FIRST to limit them AT KILN INLET !
Patented concept: Low NOx Tips, joint development between Italcementi & Fives Pillard
(Grant awarded from the European Community) :
0
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1400
0 1 2 3 4 5 6 7
OXYGEN (%)
N
O
x



(
m
g
/
N
m
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@

1
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%

O
2
)
-

2
8
%
-
4
6
%
-
2
4
%
O
R
I
G
I
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L
1
S
T

L
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W

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T
I
P
2
N
D
L
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W
N
O
X
T
IP
NOx AT KILN INLET
DIFFERENT
BURNER TIPS
First tests at ITALCEMENTI's SARCHE plant (It) (1997-2001), confirmed in ITALCEMENTI's BRONI plant (It) (2002-2004) tests
led to developing special LOW NOx tips.
16 Fives Pillard
Sustainable development : a struggle against pollutants
Low NOx tips have proven sizeable benefits
End User Kiln (tpd) Main fuel
NOx at kiln inlet
@ 10% O
2
dry
Improvements (NOx reduction, capacity)
ITALCEMENTI SALERNO, Italy 1400 Petcoke 1020 Increase production from 1300 to 1400 tpd. in a narrow furnace
ITALCEMENTI BRONI, Italy 730 Petcoke 775 NOx reduction -46% compared with previous ITC burner
ITALCEMENTI SARCHE, Italy 800 Petcoke 1020 NOx reduction -29% compared with the Monochannel burner in narrow furnace -
ITALCEMENTI SCAFA, Italy 950 Petcoke 1063 NOx reduction -26% compared to the previous ROTAFLAM

ITALCEMENTI CALUSCO, Italy 4000 Petcoke 510 Good performances - fully satisfied (new plant)
CALCIA VILLIERS, France 1200 Coal 880 Kiln more stable and use of a higher LSF meal with same NOx emission
CCB GAURIN, Belgium 1650 Petcoke 755 NOx reduction -30% compared to the previous ROTAFLAM

HOLCIM MERONE, Italy 2300 Petcoke 730 NOx reduction -27 % compared to the previous ROTAFLAM

ITALCEMENTI COLLEFERO, Italy 2300 Petcoke 920 NOx reduction -17% compared to FLS and no hot spot
ITALCEMENTI VASSILIKO, Cyprus 6000 Coal Under com.
17 Fives Pillard
Prediction software for NOx emissions at kiln inlet
Coal concentration
0
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400
600
800
1000
1200
0.5 1 1.5 2 2.5 3 3.5
kg coal/Kg (Transport +Central) air
N
O
x

(
m
g
/
N
m
3
@
1
0
%

O
2
)
Tip position in the kiln
200
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600
800
1000
1200
0 0.05 0.1 0.15 0.2 0.25 0.3
(m/m)
N
O
x

(
m
g
/
N
m
3
@
1
0
%

O
2
)
Primary air amount
0
200
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1000
1200
6 8 10 12 14
(%)
N
O
x

(
m
g
/
N
m
3
@
1
0
%

O
2
)
Secondary air temperature
0
200
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600
800
1000
1200
700 800 900 1000 1100 1200 1300
Temperature (C)
N
O
x

(
m
g
/
N
m
3
@
1
0
%

O
2
)
O
2
at kiln inlet
0
200
400
600
800
1000
1200
1 2 3 4 5 6
O
2
(% dry basis)
N
O
x

(
m
g
/
N
m
3
@
1
0
%

O
2
)
The Fives Pillard NOx ROTA software allows to separate the influencing factors of NOx emission.
The use of computerized multi points measurements is mandatory.
Influencing factors:
0
200
400
600
800
1 000
1 200
1 400
1 600
N
O
x

m
g
/
N
m
3
@
1
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%
d
'
0
2
NOx calculated
NOx Measured
Specific heat per m
3
Material flow density
0
200
400
600
800
1000
1200
0.15 0.2 0.25 0.3 0.35 0.4
(MW/m
3
)
N
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x

(
m
g
/
N
m
3
@
1
0
%

O
2
)
0
200
400
600
800
1000
1200
0.6 1 1.4 1.8 2.2
(MW.s/Kg)
N
O
x

(
m
g
/
N
m
3
@
1
0
%

O
2
)
200
300
400
500
600
700
800
900
0,0 2,5 5,0 7,5 10,0 12,5 15,0 17,5 20,0
Refuse @ 90 mm
N
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x

m
g
/
N
m
3
@
1
0
%
O
2
Coal fineness
200
300
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500
600
700
800
900
1000
0 10 20 30 40
Volatiles %
N
O
x

m
g
/
N
m
3
@
1
0
%
O
2
Volatiles
200
300
400
500
600
700
800
900
1000
0,5 1,5 2,5 3,5
%/m
2
N
O
x

(
m
g
/
N
m
3

@
1
0
%

O
2
)
Burner swirl
The 800 mg/Nm
3
@10%O
2
target at kiln inlet is achievable !
Fives Pillard 18
Target 6:
Simplify burner use : the NOVAFLAM

burner
Improve Precalciners / Urea Ammonia injection
Control combustion in real time
19 Fives Pillard
The NOVAFLAM

burner : a simplified use

From the ROTAFLAM

to the NOVAFLAM

burner
ROTAFLAM

NOVAFLAM

ROTAFLAM

Version2
Burners with axial & swirl
channels adjustable at site
Tailor-made" engineered design
Allows much more simple adjustments
Addition of " slot effect"
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
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
20 Fives Pillard
The NOVAFLAM

burner : Input data for engineering

Process data (incl. kiln geometry)
Dry or wet process, 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 ?
Running data
Past experience with the kiln (difficulties, rings, other)
Priority targets (Increase prod ? Improve clinker quality ? Sulphur cycle problems ? Decrease NOx ?
Increase A.S.F. %?)
Absolutely avoid a burner oversizing
21 Fives Pillard
The NOVAFLAM

burner : technical design choices

primary air outlet
Influence of increasing SWIRL
Flame OK
primary air outlet
Max velocity for 250 mb fan pressure
Max velocity #100 m/s
U
n
a
c
c
e
p
t
a
b
l
e
primary air outlet
Influence of increasing SWIRL
Flame OK Flame OK
primary air outlet
Max velocity for 250 mb fan pressure
Max velocity #250 m/s
SINGLE or DOUBLE primary air outlet ?
SINGLE
DOUBLE
SINGLE
DOUBLE
Adopted!
LOW SWIRL
LOW SWIRL
HIGH SWIRL
HIGH SWIRL
U
n
a
c
c
e
p
t
a
b
l
e
Adopted!
A DOUBLE primary air outlet is mandatory
22 Fives Pillard
The NOVAFLAM

burner : references
ASF
End user Main fuel Kiln (tpd)
% Heat release Type
KOHAT CEMENT, Pakistan GAS / COAL DRY 6700 0 - Successfull y commissioned by customer , satisfied
GHARIBWAL CEMENT, Pakistan GAS / COAL DRY 6700 0 - Successfull y commissioned by customer , satisfied
HEBEI, Kuishan, China COAL DRY 5500 0 - Very satisfied, high clinker quality & production
YANBU, Saudi Arabia HEAVY FUEL OIL DRY 11000 0 - Not yet started
FUCHUAN, China HIGH ASH COAL / OIL DRY 5500 0 - Not yet started
CHIFENG YUANHANG, China HIGH ASH COAL / OIL DRY 2900 0 - Started
XIBEI CHANGYE, China HIGH ASH COAL / OIL DRY 4500 0 - Not yet started
LUOYANG TONGLI, China HIGH ASH COAL / OIL DRY 5500 0 - Started
XING KUANG CEMENT, China HIGH ASH COAL / OIL DRY 5500 0 - Not yet started
ZAOZHUANG JINQAO, China HIGH ASH COAL / OIL DRY 6000 0 - Not yet started
DANGOTE CEMENT LINES 1 & 2, Nigeria HFO/GAS/COAL DRY 6000 0 - Not yet started
LARESTAN CEMENT, Iran HFO/GAS DRY 3300 0 - Not yet started
BAOARE CEMENT, Chad HFO DRY 800 0 - Not yet started
MCE CEMENT, Ethiopia HFO/GAS/COAL DRY 3000 0 - Not yet started
WUAN XINFENG CEMENT, China HIGH ASH COAL / OIL DRY 6000 0 - Not yet started
XUZHOU LONGHAN CEMENT, China HIGH ASH COAL / OIL DRY 5500 0 - Not yet started
FURONG JUNLIAN CEMENT, China HIGH ASH COAL / OIL DRY 5500 0 - Not yet started
QUINLIANSHAN MINE CEMENT, China HIGH ASH COAL / OIL DRY 2500 0 - Not yet started
TPI POLENE KILNS 1,2 & 3, Thailand COAL / FLUFF (RDF) / OIL DRY 10000 0 - Not yet started
EL NAHDA CEMENT CO., Egypt HFO/GAS DRY 7000 0 - Not yet started
CAMCE KANT LINES 1 TO 5, Kyrkystan HFO/GAS/COAL DRY 720 0 - Not yet started
CAMCE KANT LINES 6 & 7, Kyrkystan HFO/GAS/COAL DRY 504 0 - Not yet started
HENAN YONGAN CEMENT, Chine HIGH ASH COAL / OIL DRY 5800 0 - Not yet started
QUINLIANSHAN YONGDENG CEMENT, Chine HIGH ASH COAL / OIL DRY 5500 0 - Not yet started
ZAOZHUANG WOFENG, Chine HIGH ASH COAL / OIL DRY 5800 0 - Not yet started
QUYANG JINYU CEMENT, Chine HIGH ASH COAL / OIL DRY 5800 0 - Not yet started
NANJING HOPE, Ethiopia HFO DRY 1700 0 - Not yet started
HOLCIM LUMBRES, France PETCOKE WET 800 30 Sawdust+ Animal meal Commissioned by customer, satisfi ed, sawdust flow x 2
HOLCIM DANNES, France PETCOKE SEMI DRY 1200 50 Sawdust+ Animal meal Very satisfied, 70 % more sawdust (5 t/hr)
SHANDONG DONGHUA, China COAL DRY 5500 0 - Very satisfied, high clinker quality & production
BEIJING LIMA, China COAL DRY 5000 0 - Very satisfied, high clinker quality with low LHV coal
GUANGZHOU, Chi na COAL DRY 4000 20 Plastic chips Commissioning scheduled on June 2009
SHANDONG QUANXING, China COAL DRY 3200 0 - Commissioning scheduled on June 2009
AHLIA CEMENT, Lybia HFO/GAS DRY 3000 0 - Not yet started
CBMI AL BADIA, Syria COAL/PETCOKE DRY 5500 0 - Not yet started
VICAT KAZAKHSTAN, Kazakhstan COAL DRY 3000 0 - Not yet started
HOLCIM, OBOURG PLANT, Belgium PETCOKE WET 3000 50 Schiste / Sludge / Sawdust Commissioning scheduled on Jul y2009
User feedback
23 Fives Pillard
The NOVAFLAM

burner : references
Simplicity of adjustment confirmed.
Intense flame, low with low primary air pressure (< 250 mbar), confirmed.
HOLCIM LUMBRES opinion: "Replacing the previous burner by the NOVAFLAM

has allowed us to increase

the % total kiln energy amount from impregnated sawdust from 11% in 2007 to
20% in 2008Furthermore, the NOVAFLAM

is very simple to use

HOLCIM DANNES opinion: "The total substitution rate has increased by 70%... The flame is strong and intense
even with pressure from 160 to 180 mbarthe operators highly appreciate the
burner flexibility and the simplicity of the adjustments"
24 Fives Pillard
The NOVAFLAM

burner : a shorter Return on Investment

RUNNING COSTS INSTALLATION COSTS
KILN PRODUCTION EXISTING CARRIAGE
Stability increased
Production increased
(typically 2-4%)
A low quality coal can be used
Recovered
USE OF HIGH A.S.F. % EXISTING P.A. FAN
Cancelling fuel costs Recovered
Huge savings! Minimized!
Payback time of 8 months for the 2 HOLCIM French plants
25 Fives Pillard
The NOVAFLAM

burner : a lower Carbon assessment

CO
2
emission ELECTRIC CONSUMPTION
Concentration can be increased
Electric Consumption: less15%
Pressure can be reduced
Flow reduced
Electric Consumption: less 30/40%
Consumed electricity
Reduced!
SPECIFIC CONSUMPTION SOLID FUEL
CONVEYING LINES
Reduced (average 3 %)
CO
2

USE of higher BIOMASS FUEL % PRIMARY AIR FAN

CO
2

CO
2
Reduced!
Fives Pillard 26
Now, what about
Improving Precalciners
Control combustion in real time
27 Fives Pillard
Improving Precalciners / Urea Ammonia injection
The Fluent

studies on PRECALCINERS focused on:

NEW PATENTS
EP 06.291903.0 of Dec. 11, 2006
FR 06.05355 of June 15, 2006
NOVAFLAM

and NEUTRINOX are complementary

Temperature profiles and recirculation zones
Influence of (preca) burners positioning
They allow to choose the best Urea/Ammonia injection points
to meet NOx limits AT STACK
Control valve set
Re-circulation zones
Levels of injection
Temperature profile
Special atomizer
The NEUTRINOX

SNCR system includes :

A control valve set
Two levels of injectors
Special atomizers
End user
NOx at stack
mg @10% O2, dry
NOx reduction
%
Efficiency
%
Client's feedback
ITALCEMENTI Salerno, Italy 700 73 83 3 years of operation, easy maintenance, high reliability
ITALCEMENTI Colleferro line 5, Italy 800 72 46 2 years of operation, easy maintenance, ammonia tests pending
ITALCEMENTI Colleferro line 6, Italy 1080 60 56 2 years of operation, easy maintenance, ammonia tests pending
ITALCEMENTI Vibo Valentia, Italy 790 50 30 2 years of operation , modifications for 10% increase efficiency
HOLCIM Hon Chong, VI 750 50 25 2 years of satisfactory operation
ITALCEMENTI Vassiliko, Cyprus Target 800 Guaranteed 50 - To be commissioned Dec 2009
28 Fives Pillard
SITE ASSISTANCE SERVICES
Real-time combustion controls
Decreasing NOx emission needs an increase of P.C concentration.
It is servo-controlled by the line pressure drop.
NEW PATENT
EP 00.401340.5 of May 16,2000
Enables to control via INTERNET:
Fives Pillard improved a well-known probe and offers it with
,for SO
2
, NOx, CO, O
2
analyzers
: Our specialists operate worldwide.
coal/petcoke dosing systems :
STAPILDOS
Burner Management System :
ROTASAFE
sampling probes at kiln inlet :
ROTASAMPLER
: 200 m
: 8 kg/Nm
3
: +/- 1,5 %
Max length of conveying line
Max coal/petcoke concentration
Stability of coal/petcoke flow
Flow rates of each fuel (incl. A.S.F.)
Burner adjustments & combustion measurements
29 Fives Pillard
Combustion in rotary kilns & precalciners: conclusions
The NOVAFLAM

burner is simple to adjust

The NOVAFLAM

burner allows:
a very high % of Alternative Solid Fuels
minimum electric consumption
recovering the existing carriage and primary air fan
The NOVAFLAM

LOW-NOx, in association with the NEUTRINOX

system, allows to meet

emission limits AT STACK
The Fives Pillard group wants to develop a SPIRIT OF PARTNERSHIP with your Group aiming at
proposing the best adequate solutions on a case by case basis.
We invite you to come and visit us in Marseilles, where all detailed questions will be answered!
Fives Pillard 30
With our warm thanks!
All the Fives Pillard Management