056. ROTAFLAM PILLARD

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R O T A F L A M PRESENTATION

2002

PILLARD R O T A F L A M

Rotary Kiln Burner

Development and actual Design


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ROTAFLAM

The flexible combustion tool for rotary kilns(protected by patent)


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History

PILLARD burner type VRFirst multi channel burner

developed over 30 years ago.

Over 600 burners have been

operated successfully.


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Initial requirements

for new burner development

Significant reduction of NOx emission

Most efficient adaption of heat transfer to the product

Energy saving


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ROTAFLAM/ VR burner design

Axial air channel

Coal channel

Radial air channel

Axial air channel

Coal channel

Radial air channel

Flame stabilizer

VR burner:

Static pressure 120 mbarg

Pressure at tip Pu 85 mbarg

Flow Q 10 12 % of total

Specific kinetic energy:Q x Pu = 10 x 850 = 850

ROTAFLAM:

Static pressure 160 mbarg

Pressure at tip Pu 150 mbarg

Flow Q 6% of totalSpecific kinetic energy:

Q x Pu = 6 x 150 = 900


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ROTAFLAM characteristics

Flame stabilizer

Coal duct

Radial air swirler

Axial air slots

Axial ring


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ROTAFLAM

main targets of development

More equal heat distribution avoidingtemperature peaks to decrease NOformation and reduce thermal stresson kiln lining

Concentration of fuel along burner axis byarrangement inside swirl air duct, in orderto avoid that fuel particles leave the mainflame contour and burn in the hot secon-dary air atmosphere under superstoichio-metric conditions

Variations of the primary air flows forflame adjustment by changingburner tip geometry during operation

Flame stabilization without using the swirlair component, thus reduction of totalprimary air input for flame shaping anddecrease of oxygen concentration in theprimary combustion zone

Early fuel ignition and stable flame evenin cold kiln

Improved burner tip aerodynamicsallowing flame shaping with a minimum ofprimary air input and maximum outletvelocity


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ROTAFLAM type O(single oil operation)


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ROTAFLAM type GO(gas and oil operation)


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ROTAFLAM type KO(coal and oil operation)


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ROTAFLAM type KGO(coal, gas and oil operation)


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ROTAFLAM adjusting device

Mechanical adjusting device

Hydraulic adjusting device


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ROTAFLAM type KGO


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Burner tip variation by longitudinal

adjustment

Reset


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Flame shaping by air flow variation

START

100% 100%

xial

Radial

STOP


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ROTAFLAM small scale test

Flame adjustment by air flow variation

with a small ROTAFLAMtest burner

showing short hot flame, long flame and wide soft flame

Click on picture to start and stop the video


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Flame shape adjustment by variation

of fuel flow distribution

PILLARD MYS atomizer gun for rotary kiln burners


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Atomizer system MYS


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Flame shaping by variation of oil

differential pressure

START

40 bar

rimary

STOP

39 bar

Secondary


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13 years of continuous improvement

Increasing flexibility to satisfy more critical process requirements

NOx reduction and low primary air consumption are no longer the cement producers

main requirements.

Stable kiln conditions and energy saving by substitution of primary fuels by low

cost secondary or alternative fuels without affecting the kiln operation havebecome new main targets.

Revision of the former basic design criteria was essential:

ROTAFLAM - New generation

Designed for 8% of primary air

Fan capacity 10% of primary air

Static pressure 250 mbar

ROTAFLAM - 1. Generation

Designed for max. 6% of primary air

Fan capacity max. 7% of primary air

Static pressure 160 mbar


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Extended burner operation with low cost liquid (waste) fuels

Waste oil

Solvents

Residues from oil industryContaminated water

Complete individual fuel supply system is required.

Varying chemical properties and content of solid impurties have

to be considered for the design of equipment to prevent from

incredible wear and the risk of interruption of kiln operation

due to plugging of atomizer system.


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Fuel pressure: 8-12 bar

Atomizing air: 6- 8 bar

Max. particle size: 6 mm

Liquid waste atomization



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Flame stabilizer and central air circuit

allow installation of additional fuel

feeding systems

Liquid waste atomization


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Extended burner operation with low cost solid (waste) fuels

Petroleum coke

Bark powder

Wood powderMunicipal waste (depending on degree of preparation)

Tyres (depending on degree of preparation)

Agricultural derived fuels

Plastics

Paper

Animal powder


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Examples of solid (waste) fuels



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New development

The PILLARD solid (waste) fuel swirler unit

(protected by patent)

Portion of primary air

(pressure 250 mbar)

Solid waste

with transport air

Swirler

nozzles


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The PILLARD solid waste swirler unit

Test arrangement : First sequence without swirl air



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The PILLARD solid waste swirler unit

Test arrangement : Second sequence with swirl air



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ROTAFLAM

Three ROTAFLAMburners KO-S ready for shipment



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+20/-45

+10/-30

+10/-50

+20/-50

Coal: 15.000 kg / h

Heavy fuel oil: 11.000 kg / hPlastics (Tetrapak): 12.000 kg / h

ROTAFLAM burner KO-S 125 MW

for Rohrdorf Zement Plant

Actually 10.000 kg / h of Tetrapak

primary fuel substitution rate: 60%


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Coal: 9.855 kg / h

Heavy fuel oil: 6.300 kg / hPlastics (Tetrapak): 3.500 kg / h

ROTAFLAM burner KO-S 93 MW

for HOLCIM Untervaz Zement Plant

Waste oil: 6.750 kg / h

Animal powder: 3.000 kg / hDistillation residuals: 1.500 kg / h

Contaminated water: 500 kg / h

Solid wastesLiquid wastes

Heavy fuel oilFlame stabilizer


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Petcoke: 10.000 kg / h

Heavy fuel oil: 9.050 kg / hNatural gas: 9.970 Nm/ h

ROTAFLAM burner KGO 98 MW

for Mrida Yucatan Plant Cementos Maya Kiln 5

Installation of the burner Start-up flame


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Petcoke: 3.700 kg / h

Heavy fuel oil: 3.300 kg / hNatural gas: 3.600 Nm/ h

ROTAFLAM burner KGO 35 MW

for Plant Monterrey Kiln 5


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More than 500

ROTAFLAM burnerssince 1989

testify success

ROTAFLAM

The most flexible combustion tool for rotary kilns
http://c/Bahrain/Bahrain3.pps

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056. ROTAFLAM PILLARD