Introduction to Kiln Control
Operator Development
Combustion
Presentation & Instructor Notes
Combustion Learning Objectives
To understand the mechanism of combustion and be able to:
discern between the 3 types of firing systems define combustion air and components of combustion air list 3 main flame characteristics and how they can be controlled
state importance of fuel/air mixing and variables to control mixing list 3 main indicators of combustion state and how they can be controlled state the main goal in combustion control
Kiln Control: Combustion
Combustion
Definition of combustion
a rapid oxidation of a combustible with a release of heat a reaction between fuel and oxygen (air)
Requirements for combustion
sufficient oxygen (combustion air) to mix with fuel
efficient mixing of fuel and air heat to ignite fuel
fuel
heat (ignition)
air
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Combustion Air
The amount of air necessary to efficiently burn at a certain fuel rate.
Combustion air consists of primary air and secondary air.
Primary air
Secondary air
primary air fan solid fuel transport air inleakage
air from cooler
COMBUSTION AIR
Kiln Control: Combustion
Combustion Air Needs
Neutral combustion air
practically impossible to achieve due to poor mixing of fuel and air
Excess combustion air
complete combustion too much air results in heat loss
Lack of combustion air
incomplete combustion => CO loss of efficiency
Adequate combustion air
low CO and low O2 at kiln exit
Kiln Control: Combustion
Types of Firing Systems
Direct Firing System Semi-direct Firing System Indirect Firing System (newest technology)
Kiln Control: Combustion
Direct Firing System
One fan to vent the mill, convey the coal, classify the ground coal and blow it into the kiln (no control of flame shape) All moisture goes to kiln High primary air (30-35% of combustion air) resulting in high SHC. Relatively safe, simple operation and low capital cost
Kiln Cooler
Kiln Control: Combustion
Semi-Direct Firing System
Two fans to classify ground coal and to blow the fuel into the kiln
Can add additional fans for flame shaping
All moisture goes to kiln Low primary air Higher capital cost than direct firing system
Kiln Cooler
Kiln Control: Combustion
Indirect Firing System
Coal is ground in a separate system
Moisture removed from system
Pulverized fuel bin with high precision metering system Primary air is low
Blowers (low volume, high pressure) added to control flame shape
Highest capital cost; safety and environmental issues
Cooler
Kiln
Kiln Control: Combustion
Combustion Air in Indirect Firing System
Primary air w. impulse ~4% axial air ~2% swirl air ~9% fuel transport air Secondary air ~85%
plus inleakage
COMBUSTION AIR
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Primary Air - MOMENTUM
Required to drive flame High momentum shortens, stabilizes and compacts the flame
momentum Turbulence at burner tip
Higher turbulence results in better mixing of fuel and air
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Primary Air - Axial and Swirl Air
Axial Air
minimum flow to cool down the burner pipe increase or decrease the flame temperature which changes flame length
Swirl Air
increase or decrease the mixing of air and fuel, allowing a higher or lower flame temperature, which changes the shape of the flame
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Primary Air - Transport Air
Transport Air
for solid fuel transport only does not vary with fuel flow must be at the minimum flow sufficient velocity at burner tip is required for flame momentum for solid fuel transfer, velocity should be 24 to 30 m/s (too low => fuel deposition, too high => abrasion and wear)
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Primary Air - In leakage
In leakage at the kiln hood
an expensive nuisance significant impact on kiln production, kiln stability, flame length, specific heat consumption and ID fan capacity
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Secondary Air
Heat recuperation
higher SAT => lower SHC (kcal/kg)
Flow controlled by ID fan Temperature controlled by grate speed
clinker bed depth
Kiln hood pressure
low is better for heat recuperation air inleakage increases with more negative pressure constant kiln hood pressure => stabilizes flame
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Secondary Air
How much secondary air is required
total combustion air required minus primary air
Where is it coming from
from the hottest cooler chambers
Impact of secondary air on flame
low SAT => long, lazy flame
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Mixing of Fuel and Air
Variables to control
Pulverized solid fuel fineness moisture Natural gas gas pressure Fuel oil atomization pressure temperature viscosity
Faster, more effective mixing => efficient combustion
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Ignition
Fuel ignition point
temperature at which fuel ignites spontaneously and starts to burn
heat (ignition)
fuel
Flame ignition point
air
the point just after the plume where the brilliant part of the flame starts
Factors affecting flame ignition point
secondary air temperature type of fuel design of burner design of kiln hood
min. ignition temp. 225 C 350 C 500 C 800 C
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diesel coal nat. gas coke
Kiln Control: Combustion
Flame
Definition Temperature Heat transfer Shape
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Flame - Definition
Controlled combustion (burning) of a determined fuel All flames have a short plume of air and fuel Fuel ignites at end of plume and forms the flame
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Flame - Definition
CO2 SO2 NOx H2O
A large volume of very hot gases controllably generated
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Flame - Temperature
Flame temperature is affected by:
O2 level secondary air temperature type of fuel
nat. gas oil coal flame temp. 1700 C 1900 C 2200 C
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Flame - Heat Transfer Rate
Rate at which MJ (calories) are exchanged to the material (load), coating and refractory Heat transfer mechanisms:
radiation from flame to load convection from kiln gases to load conduction from refractory/coating to load
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Flame - Shape
Shapes:
short long snappy lazy
Shape controlled by:
type and position of burner type of fuel primary air (axial, swirl air, impulse) ID fan flow, secondary air temp. O2
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Flame - Shape
Goal
the shortest and highest temperature flame without adversely affecting clinker quality, coating formation, ring formation, refractory life or causing damage to kiln discharge area
A hot flame is always shorter than a cold flame Always wait for a stable kiln to make changes to the flame shape and discuss changes with other operators and Production management
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Combustion State
Kiln exhaust gases:
O2 CO SOx
CO2 SO2 NOx H2O
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Combustion State - O2
Ideal O2 level determined from:
clinker quality refractory protection requirements shell temperature
Goals:
keep O2 as low as possible maintain constant O2 (which maintains constant kiln temperature profile) low CO
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Combustion State - CO
Can we accept some CO?
Most plants operate with some CO since it is difficult to achieve complete combustion of fuel.
CO caused by lack of combustion air and poor fuel preparation (fineness, viscosity, mixing, process of pulverization) Incomplete combustion => longer and colder flame
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Combustion State - SOx (SO2/SO3)
Represents sulfur oxidation from all fuel types SO2 formation decreases with more oxidizing combustion SO3 volatilization increases with hotter burning zone and length of flame SOx reacts faster than CO to changes in combustion
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Summary
fuel + air => kiln flame + exhaust gases C + S + O2 => heat + O2 + CO2 + SOx
Combustion quality issues
heat quality => calcination flame quality => clinkerization
Keep O2 as low as possible, but too low O2 results in:
kiln instability incomplete combustion, high CO sulfur volatilization short refractory life poor clinker quality
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Summary
High O2
high SHC (kcal/kg) long flame possible production limitation
SO2 is inverse of O2
Combustion Goal: short, hot flame (but beware of refractory life) with low O2 and low CO
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