Technical Development Program

for Mugher cement factory operation team

Burner, Flame &

combustion systems

Eng. Gezehagn Dechassa- Senior process engineer

JUNE 2021
 COURSE OBJETIVE
FOCUS AREAS

• FLAME SHAPES
• COMBUSTION ENGINEERINRG
• BURNER SETTINGS
Flames
 The ideal flame is:
Stable over entire length of flame, i.e.

• Continuous (controlled) combustion along

the whole length

•No local temperature peaks

•No reducing atmosphere over clinker bed

•Complete burn-out at end of flame

 Prerequisites for ideal flame
Completeness of combustion within available time
(burning zone depends on three main factor:
• Fuel preparation(oil droplet size, coal
fineness)
• Fuel feed to burner(accurate and
constant feed and transport )
• Availability of oxygen for complete
combustion (excess air factor)
 FLAMES VARY IN LENGTH, SHAPE,
DIRECTION, POINT OF IGNITION AND
COLOUR.
 SWIRL

AS THE SWIRL IS INCREASED THE

FLAME IS:

• WIDENED,
• SHORTENED and
• INCREASED IN TEMPERATURE.
 FLAME LENGTH

• STOICHIOMETRIC FLAME LENGTH.

• EFFECTIVE FLAME LENGTH: DISTANCE REQUIRED TO
BURN THE MAJORITY ( 95 %) OF THE FUEL, i.e., UP TO THE POINT AT
WHICH THE AXIAL CONCENTRATION OF CO IS ABOUT 1 %.
 FACTORS WHICH INFLUENCE THE FLAME SHAPE
VARIABLES OVER WHICH THE KILN OPERATOR
VARIABLES OVER WHICH THE KILN HAS CONTROL:
OPERATOR HAS LITTLE OR NO
CONTROL: • TEMPERATURES AND FLOW RATES OF THE
PRIMARY AIR AND OF THE SECONDARY AIR
• DESIGN OF THE BURNER • FUEL RATE
• DIAMETER OF THE KILN • BURNING ZONE TEMPERATURE
• HEAT VALUE OF THE FUEL • POSITION OF THE BURNER
• DUST CONTENT OF THE SECONDARY AIR
• CROSS SECTION LOADING OF THE KILN
• AIR REQUIREMENT OF THE FUEL
 FLAME CLASSIFICATION

• ACCORDING TO FLOW CONDITION:

LAMINAR FLAME: ITS FLOW IS PARALLEL AT ALL
POINTS.
TURBULENT FLAME: ITS FLOW HAS PERPENDICULAR
COMPONENTS AT SOME POINTS.
 FLAME CLASSIFICATION
• ACCORDING TO THE TYPE OF MIXING BETWEEN FUEL
AND AIR:
PREMIXED FLAME : WHENEVER THE MIXING OF FUEL AND AIR
IS EFFECTED BEFORE REACHING THE COMBUSTION CHAMBER.
NON–PREMIXED FLAME : WHENEVER THE MIXING OF FUEL AND
AIR IS EFFECTED IN THE COMBUSTION CHAMBER.
 GENERAL RULES IN FLAME CONTROL
SHORTEST POSSIBLE FLAME, BUT WITHOUT HURTFUL
INFLUENCE ON:
• CLINKER QUALITY,
• COATING FORMATION,
• RING FORMATION,
• REFRACTORY SERVICE LIFE and
• NOT CAUSING DAMAGE TO THE KILN EQUIPMENT IN
THE DISCHARGE AREA.
A FLAME SHOULD NOT WILFULLY BE CHANGED
DURING KILN OPERATION, UNLESS SPECIFIC
CONDITIONS NECESSITATE A CHANGE.
WHENEVER THINKING ABOUT FLAME ADJUSTMENT,
REMEMBER THAT :

THE KILN REACTS SLOWLY TO ANY CHANGE ON

FLAME ADJUSTEMT, HENCE IT IS USELESS TO TRY
TO ADJUST A FLAME WITHIN ONE SHIFT.
 Firing Systems
Coal versus oil versus gas firing

Provided complete combustion there is

theoretically no significant difference between oil
and coal firing, whereas with natural gas firing a
slightly higher energy consumption (approx.+5 %)
is attributed to the higher stoichiometric exhaust
gas quantity.
IGNITION POINT, PLUME
THE PLUME IS THE PART OF THE FLAME IN
BETWEEN THE BURNER NOZZLE AND THE
POINT OF IGNITION OF THE FUEL.

CONTROL OF PLUME LENGTH IS NOT EASILY

ACCOMPLISHED AND IS INFLUENCED BY:

SECONDARY AIR TEMPERATURE,

KILN INTERIOR TEMPERATURE and
PRIMARY AIR TEMPERATURE.
IGNITION TEMPERATURES

NATURAL GAS…600 - 700°C

PETCOKE ……… 620˚C
FUEL OIL………. 300 - 550°C
COAL …….…….. 200 - 300°C

THE NATURAL GAS IGNITION TEMPERATURE IS HIGH , SO SPECIAL

CARE HAS TO BE TAKEN WHEN THE LINING / COATING OF THE BZ
IS NOT WARM ENOUGH TO IGNITE IT.
PETCOKE FIRED KILNS TEND TO HAVE THEIR IGNITION POINT OF
THE FLAME FURTHER BACK IN THE KILN THAN COAL OR FUEL
OIL FIRED KILNS.
 DIRECTION OF THE FLAME
IT IS ABSOLUTELY ESSENTIAL THAT ALL THE
COMBUSTION REACTION – THE BURNING OF
FUEL – TAKES PLACE IN THE BURNING ZONE.
IMPINGEMENT OF PARTIALLY BURNED FUEL
UPON THE CLINKER BED OR KILN WALL MUST
BE AVOIDED AT ALL TIMES.
ALIGNEMENT AND MECHANICAL CONDITION
OF THE BURNER IS FUNDAMENTAL TO AVOID
FLAME IMPINGEMENT.
 TEMPERATURE OF THE FLAME
THE AMOUNT OF HEAT RELEASED BY THE
FLAME DEPENDS ON ITS TEMPERATURE.
THE FLAME TEMPERATURE CAN BE INDICATED
BY ITS COLOUR.

ONLY ABOUT 1% OF THE HEAT RADIATED FROM

A FLAME IS EMMITED IN THE VISIBLE PART OF
THE SPECTRUM , THE REMAINING PART IN THE
INFRARED AREA.

.
 HOW TO RAISE THE FLAME
TEMPERATURE ?
• INCREASING THE SECONDARY AIR TEMPERATURE,
• USING LESS PRIMARY AIR,
• PROMOTING RAPID MIXING OF THE AIR AND FUEL
UPON LEAVING THE BURNER, BY A BETTER DESIGN OF
THE BURNER OR BY ADJUSTMENT OF THE AIR/FUEL
COMPONENTS and
• OPERATING THE KILN WITH NEITHER A DEFICIENCY
NOR EXCESS OF AIR, BY MAINTAINING OXYGEN
CONTENT IN THE RANGE 0.8 – 3.5% IN THE KILN EXIT
GASES.
Secondary Firing / Precalciner
The burning conditions for a secondary firing or
precalciner burner are quite different from the kiln
firing:

•In most cases combustion in gas/air

mixture instead of pure air
•Combustion in very dusty atmosphere
Secondary Firing / Precalciner

•Temperature range of 1000°C instead of

2000°C

•higher gas temperature at bottom cyclone

outlet than at precalciner outlet

•moderate drop of gas temperature over

the two lowermost cyclone stages
 COMBUSTION STEPS
THE COMBUSTION PROCESS OF A GIVEN FUEL PARTICLE
MIGHT BE SUB–DIVIDED INTO FOUR CONSECUTIVE STEPS:

• HEATING-UP OF THE PARTICLE,

• HYDROCARBONS CH RUPTURE AND LIBERATION OF HYDROGEN
AND CARBON,
( HYDROGEN MOLECULES IN CONSEQUENCE OF
THEIR HIGH DIFFUSION VELOCITY ARE THE
FIRST TO BURN OFF )
• BURNING OF FREE CARBON OR ITS AGGLOME-
RATION AS SOOT, ACCORDING TO LOCAL
OXYGEN CONCENTRATION, and
• COMBUSTION OF SOOT PARTICLES .
Combustion indicators
 Combustion

Under Outside
Control Control

• Fuel Type • Secondary air momentum

• Fuel handling • Tertiary air momentum
• Heat Transfer • Kiln aerodynamics
• Excess Air • Calciner aerodynamic
• Burner momentum
• Emission
Combustion since is the scince of exothermic chemical
reactions in flow of heat and mass transfer

Gas H22 or natural gas

Fuel Liquid Alcohol or oil

: Solid Na, pure carbon or coal

Carbon CO22
Hydro Carbons
Hydrogen H22O
(fuels)
Sulfur SO22
C + O22 CO22 + ( 94 kCal/mole)

+ 116 kCal/mole
Water as steam
2H + O22 2H22O
+ 137 kCal/mole
Water condensed
G.C.V: Gross calorific
values Water condensed
H.H.V: High heating values

N.C.V: Net calorific values

Water remain as steam
L.H.V: Low heating values
 The incomplete Oxidation of carbon
Not all of the carbon in the fuel will be oxidized to carbon
dioxide but some will be partially oxidized to carbon
monoxide

Carbon monoxide: Reduce the heat release from the fuel

2C + O22 2CO + ( 53 kCal/mole)

Reversible chemical reaction
2CO + O22 2CO22 + ( 41 kCal/mole)
Natural
Natural gas
gas requires
requires more
more combustion
combustion air
air per
per kCal
kCal of
of heat
heat released
released than
than most
most other
other fuels,
fuels,
produces
produces more
more exhaust
exhaust gases,
gases, smallest
smallest CO
CO22
 Physics of Combustion

Combustion Stages
Mixing Ignition Chemical reaction Dispersal of product

slow Very
fast

If it’s mixed, it’s burn

 1 Kg fuel 1 Nm3 fuel
Or

Oxygen is required

Combustion equation Empirical formula

Fuel analysis is known Heat Value is known

Air → 21%
Oxygen

Minimum air required = 4.762 times of the minimum Oxygen

The kiln gas consists of :
• combustion products
• excess air of combustion
• false air
• gas from the raw meal

carbon dioxide (CO2 )

water vapor
sulfur absorbed (Circulation Phenomena)
 Oxygen required for combustion of 1 kg fuel
(liquid + solid fuel)
Nm3 / kg fuel

22.4
C + O22 CO22 12
)C) = 1.864 (C)
1 KM 1 KM 1 KM
12 Kg 32 Kg 44 Kg

22.4 = Volume occupied by 1 Mol Nm3/Mol Nm3

12 = Molecular wt of carbon = Kg(C)/Mol = Kg(C)

 Combustion Products

CO2 , H2O , some SO2

a) Complete Combustion

CO2 , H2O , N2 , & O2 excess from combustion

b) Incomplete Combustion

CO2 , H2O , N2 , & CO

 Incomplete
Combustion

The specific heat

explosion in the
consumption of the
kiln system
kiln increases

If the false air increase then the secondary air decreases

Novaflame burner training
• Axial air and radial air through the same channel, It can reduce the air
resistance, the pipe installation is more convenient and simple, also It
is more simple to control the flame sharp.
Axial air channel

Radial air channel

Coal airchannel

Central air channel

Oil Gun
 Novaflam structure
• 1.The primary air is separated into two parts in
the burner tip, axial air flow : radial air flow
is 6:4.
• 2. The primary air flow percent is about 7-
11% ; you should adjust it according to
different kinds of fuel (coal calorific value,
volatile matter, moisture, fineness, etc.)
The swirler angle is from 17 to 50 degrees , You can adjust the swirler position
to change the flame strength and shape. Because when you change the swirler
position , its angle will be changed also.
• when we adjust swirler position to 0% ,The swirler angle is minimum, the flame is slender
• When we adjust swirler position to 100% ,the swirler angle is the largest, flame is short and strong.
• Through the burner middle tensioner wrench to adjust the swirler angle, and change the flame shape
and strength.
 Adjust the flame method

• Change the swirler position

• Change the pressure of the primary air
 - Swirler +

Normal primary air

pressure; Swirler Normal Primary air short
Thin and
angle minimum pressure; Swirler
short
angle maximum flame
flame
-

!
pressure

Attention
Decrease the primary Decrease the primary air
air pressure; Swirler
angle minimum
pressure; Swirler angle Wide and
Soft and maximum long flame
,
long flame
 About burner’s position
• The tip of the burner should be in centre of kiln , a
little change is allowed.
• The burner ‘s inclination is the same as the kiln.
• Attention ： If you want to adjust the position of burner,
you had better changed slowly and observe the shell
temperature.
FLAME DIRECTION
FLAME SHAPE AND DIRECTION
FLAME AND “DARK” MATERIAL
 Burner setting
• When only oil is used to increase the
temperature, please open the cooling valve.
• Before the coal air blower is running, please
close the cooling valve.
please do remember it!
Cooling valve
 Flame shape setting
• If the flame temperature is normal, the
swirler position below 60% in long time is
not recommended.
 About ignition of the matters needing
attention
• Diesel valve group of control
• Oil gun maintenance
• ignition burner setting
 Control valve

Shut off Valve

Spill valve
• before ignition , please close oil pipe line shutoff valve, open the control
valve, for cleaning oil gun blowback by the compressed air.
• Use the tool to adjust oil pressure in pump export, above 3Mpa is not
permitted
• Had better to clean oil system and valve group every time before ignition
 Oil gun maintenance
• When the system temperature increase high enough,
you can stop using the oil gun ,and then pull it out 2
meters from the burner, certainly you can pull out the
oil gun completely , and check up it .
• You had better to clean oil gun and check its work
conditions before igniting the kiln every time , in order
to get good effect.
 Burner daily maintenance
• About anchors and castable
• Coal channel wear plate
• Flame shape set
The castable was destroyed
 Coal channel wearproof plate

• In the entrance of coal channel there are two pieces of wearproof

plate, after several months, the wearproof plate need to be checked, if
one piece is destroyed slightly, you should repairing weld it , or
exchange its position(overturn 180°).

• If wearproof plate is destroyed seriously, please spend more time to

weld it carefully .
BURNER PIPE DIRECTION ADJUSTMENT - A CASE STUDY

DURING KILN RUNNING AFTER A LONG STOPPAGE, IT WAS NOTICED:

• FREQUENT KILN STOPPAGES,

• NO COATING FORMATION IN THE BZ,
• VERY HIGH KILN SHEL TEMPERATURE IN THE BZ,
• DUSTY CLINKER FORMATION,
• HIGH CLINKER FREE LIME CONTENT,
• ORANGE FLAME COLOR,
• FLAME IMPINGEMENT ON BRICK LINING and
• FAST WEAR OF BASIC LINING IN THE BZ.

AFTER CORRECTION OF SEVERAL PROCESS PARAMETERS, IT WAS

DECIDED TO CHANGE THE BURNER PIPE DIRECTION.
DISCUSS THE POSSIBLE BURNER SETTING & RECOMMEND
CORRECTIVE ACTIONS?
Thank you !