From ROTAFLAM® RV2 to NOVAFLAM® The new high efficiency burner
Presentation at: Ecra Seminar S10-03 Opole,Poland, 30 June 2010
“Requirements of the Cement Producers”
Reduction of CO2 Increasing the amount of Climafuel as much as possible High or better Clinker quality by using Climafuel Improving the Sulphur cycle This a.m. requirements are totally fulfilled by the ROTAFAM® RV2 Burner
…but the clients asked more and more to simplify the adjustment of the burner to reduce the installation and running costs to reduce the electrical consumption This additional requirements are now achieved by the new “high efficiency” rotary kiln burner NOVAFLAM ®, by keeping the advantages of the ROTAFLAM RV 2
PILLARD FEUERUNGEN GmbH - Aarstraße 168, 65232 Taunusstein - Tel.: 061282420 - Fax: 06128242112 - Mail:
[email protected] - Web: www.pillard.de
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ROTAFLAM® RV 2 – Proved advantages ® ROTAFLAM ROTAFLAM®RV2 RV2 Increased sulphur integration in the clinker Compact and short Flame Better clinker quality Lower kiln shell temperature High amount of A.S.F., more than 80% Combustion of the A.S.F. inside the Flame Reduced coatings in the preheater tower up to 80 % Easy Adjustment of the burner tip via hydraulic cylinder at the Burner / from the PLS PILLARD FEUERUNGEN GmbH - Aarstraße 168, 65232 Taunusstein - Tel.: 061282420 - Fax: 06128242112 - Mail:
[email protected] - Web: www.pillard.de
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Summary of the modifications - ROTAFLAM® RV2
Axial Air Swirl air Coal Fluff Auxiliary Air Center Line ROTAFLAM®
ROTAFLAM® RV2 – new Design
ROTAFLAM® Standard
PILLARD FEUERUNGEN GmbH - Aarstraße 168, 65232 Taunusstein - Tel.: 061282420 - Fax: 06128242112 - Mail:
[email protected] - Web: www.pillard.de
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Fluent – Flow Simulation Standard ROTAFLAM® - Axial channel:
New channel design – Axial channel:
(advantageous for standard fuels)
(additional very good results with A.S.F.)
Less Slot effect
Optimum Slot effect
Less Slot effect
Optimum Slot effect
PILLARD FEUERUNGEN GmbH - Aarstraße 168, 65232 Taunusstein - Tel.: 061282420 - Fax: 06128242112 - Mail:
[email protected] - Web: www.pillard.de
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Fluent – Flow Simulation Standard ROTAFLAM® - Axial channel: Less & Optimum Slot effect
New Channel design – Axial channel: Less & Optimum Slot effect
PILLARD FEUERUNGEN GmbH - Aarstraße 168, 65232 Taunusstein - Tel.: 061282420 - Fax: 06128242112 - Mail:
[email protected] - Web: www.pillard.de
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CLINKER QUALITY IMPROVEMENT WITH 75 % OUTPUT FROM FLUFF
Results after modification from Rotaflam to RV2 SO3 CLINKER (%)
CEMENT STRENGHT (MPa)
1.2
70 65 60 55
0.8
50 45 40 0.4
35 30 25
ROTAFLAM
RV2
20
22 days strenght Days
7 days strenght 7 Days
RV2 8/ 4/ 07
19 /3 /0 7 29 /3 /0 7
9/ 3/ 07
17 /2 /0 7 27 /2 /0 7
7/ 2/ 07
19 /1 2/ 06 29 /1 2/ 06 8/ 1/ 07 18 /1 /0 7 28 /1 /0 7
/1 2 29 /06 /1 2/ 06 8/ 1/ 0 18 7 /1 /0 28 7 /1 /0 7 7/ 2/ 0 17 7 /2 /0 27 7 /2 /0 7 9/ 3/ 0 19 7 /3 /0 29 7 /3 /0 7 8/ 4/ 0 18 7 /4 /0 28 7 /4 /0 7 8/ 5/ 07
19
1 day strenght 1 Day
ROTAFLAM 0
2828 days strenght Days
PILLARD FEUERUNGEN GmbH - Aarstraße 168, 65232 Taunusstein - Tel.: 061282420 - Fax: 06128242112 - Mail:
[email protected] - Web: www.pillard.de
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Modifications - ROTAFLAM® RV2 to RV2i
RV2
RV2i
PILLARD FEUERUNGEN GmbH - Aarstraße 168, 65232 Taunusstein - Tel.: 061282420 - Fax: 06128242112 - Mail:
[email protected] - Web: www.pillard.de
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Results after modification RV2 to RV2i
Temperature cyclone 1 east & west°C
Burner optimization
Reduction of temperature cyclone 1 east and west PILLARD FEUERUNGEN GmbH - Aarstraße 168, 65232 Taunusstein - Tel.: 061282420 - Fax: 06128242112 - Mail:
[email protected] - Web: www.pillard.de
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Results after modification RV2 to RV2i
PILLARD FEUERUNGEN GmbH - Aarstraße 168, 65232 Taunusstein - Tel.: 061282420 - Fax: 06128242112 - Mail:
[email protected] - Web: www.pillard.de
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Optimized mixing chamber for Climafuel
Modification of the mixing chamber
Auxiliary Air Old design CL ROTAFLAM®
Fluff + Transport Air Auxiliary Air
PILLARD FEUERUNGEN GmbH - Aarstraße 168, 65232 Taunusstein - Tel.: 061282420 - Fax: 06128242112 - Mail:
[email protected] - Web: www.pillard.de
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Optimized mixing chamber for Climafuel
Modification of the mixing chamber
Auxiliary Air Fluff + Transport Air CL ROTAFLAM®
Auxiliary Air New “Mixing chamber”
New ASF auxiliary air nozzle
PILLARD FEUERUNGEN GmbH - Aarstraße 168, 65232 Taunusstein - Tel.: 061282420 - Fax: 06128242112 - Mail:
[email protected] - Web: www.pillard.de
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Optimized mixing chamber for Climafuel
AIR ASF +
TRA
NSP O
RT A IR
AIR
OPTIMIZED MIXING CHAMBER
FAST FASTAERATION AERATIONAND ANDDISPERSION DISPERSION ==HIGHER HIGHERASF ASFRATES, RATES, SHORTER FLAME WITH LOWER SHORTER FLAME WITH LOWERDIAMETER DIAMETER
PILLARD FEUERUNGEN GmbH - Aarstraße 168, 65232 Taunusstein - Tel.: 061282420 - Fax: 06128242112 - Mail:
[email protected] - Web: www.pillard.de
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Mixing Chamber for Climafuel
Concentration of ASF particles with following bulk densities:
high density
normal density
lower density
PILLARD FEUERUNGEN GmbH - Aarstraße 168, 65232 Taunusstein - Tel.: 061282420 - Fax: 06128242112 - Mail:
[email protected] - Web: www.pillard.de
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Summary of the modifications - ROTAFLAM® RV2
ROTAFLAM® RV2 – Burner tip without outer tube
Mixing chamber
Slots
PILLARD FEUERUNGEN GmbH - Aarstraße 168, 65232 Taunusstein - Tel.: 061282420 - Fax: 06128242112 - Mail:
[email protected] - Web: www.pillard.de
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The NOVAFLAM® burner: a simplified use From the ROTAFLAM… to the NOVAFLAM burner… ROTAFLAM®
ROTAFLAM® version 2
NOVAFLAM®
Burners with axial & swirl channels adjustable at site
Addition of "slot effect"
“Tailor-made" engineered design Allows much more simple adjustments
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 EP 07.290663.9 FR0852836 FR2009/050593
of of of of
June 26,2006 May 23, 2007 April 28, 2008 April 07, 2009
PILLARD FEUERUNGEN GmbH - Aarstraße 168, 65232 Taunusstein - Tel.: 061282420 - Fax: 06128242112 - Mail:
[email protected] - Web: www.pillard.de
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The NOVAFLAM® : THE NEW KILN BURNER
A mono channel burner : Axial and Radial air are supplied by a same burner channel More efficient in term of impulse and swirl : Limited loss of pressure in the burner Easy to understand, to use, to adjust : 2 parameters to be adjusted
PILLARD FEUERUNGEN GmbH - Aarstraße 168, 65232 Taunusstein - Tel.: 061282420 - Fax: 06128242112 - Mail:
[email protected] - Web: www.pillard.de
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The NOVAFLAM® : THE NEW KILN BURNER
Axial air injected in the flame by holes CONSTANT CROSS SECTION ADJUSTEMENT BY PRESSURE CONTROL
Adjustable radial air angle NO NEED TO CHANGE RADIAL AIR QUANTITY FOR FLAME SHAPING VERY EASY TO ADJUST FLAME WIDTH
Coal and central air channels IDENTICAL TO THE ROTAFLAM® RV2
PILLARD FEUERUNGEN GmbH - Aarstraße 168, 65232 Taunusstein - Tel.: 061282420 - Fax: 06128242112 - Mail:
[email protected] - Web: www.pillard.de
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The NOVAFLAM® : THE NEW KILN BURNER
By moving back the radial tip, we adjust the flame width By controlling the primary air pressure, we adjust the burner impulse
VERY EASY TO ADJUST !
Flame shape adjustment device
PILLARD FEUERUNGEN GmbH - Aarstraße 168, 65232 Taunusstein - Tel.: 061282420 - Fax: 06128242112 - Mail:
[email protected] - Web: www.pillard.de
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The NOVAFLAM® : technical design choices COMMON or DIVIDED primary air outlet ? LOW SWIRL
COMMON swirl and axial primary air outlet Influence of increasing SWIRL
DIVIDED
in swirl and axial primary air outlet Influence of increasing SWIRL Choosen! (NOVAFLAM®)
COMMON primary air outlet Max velocity for 250 mbar fan pressure
Flame OK
HIGH SWIRL ble a t ep cc a Un
LOW SWIRL
HIGH SWIRL
Flame OK
Flame OK
bl e a t ep cc a Un
DIVIDED
primary air outlet Max velocity for 250 mbar fan pressure (NOVAFLAM®)
Max velocity # 100 m/s
Max velocity # 250 m/s Choosen!
Higher pressure at burner tip available by optimizing the pressure drop between fan and burner tip outlet
A DIVIDED primary air outlet is mandatory PILLARD FEUERUNGEN GmbH - Aarstraße 168, 65232 Taunusstein - Tel.: 061282420 - Fax: 06128242112 - Mail:
[email protected] - Web: www.pillard.de
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CASE STUDY : Holcim Lumbres, France, Feb. 08
PROCESS
TYPE
WET LINE
PROD.(TPD)
800
SEC. AIR (°C)
750
FUELS
MIX COAL/PETCOKE+STEP, IMPREGNATED SAWDUST, ANIMAL MEAL,SOLVANT
REASON OF BURNER REPLACEMENT
INCREASE IMPREGNATED SAW DUST %
BURNER
BEFORE
AFTER
TYPE
3 CHANNELS
NOVAFLAM®
PA %
10
8
pres.(mbar)
220
130-170
SAWDUST SUBSTITUTION INCREASE FROM 20 To 40 % MAIN BENEFIT
BETTER KILN STABILITY EASIER TO RECOVER CRITICAL/WEAK CONDITIONS BETTER COMBUSTION (no more CO) ENERGY SAVING (PRIMARY AIR, ELECTRICAL CONSUMPTION)
PILLARD FEUERUNGEN GmbH - Aarstraße 168, 65232 Taunusstein - Tel.: 061282420 - Fax: 06128242112 - Mail:
[email protected] - Web: www.pillard.de
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CASE STUDY: Holcim Dannes, France, Sept. 08
PROCESS
TYPE
LEPOL GRATE, SATELLITE COOLER
PROD.(TPD)
1200
SEC. AIR (°C)
750
FUELS
MIX COAL/PETCOKE+STEP, IMPREGNATED SAWDUST, ANIMAL MEAL,SOLVANT
REASON OF BURNER REPLACEMENT
INCREASE IMPREGNATED SAW DUST %
BURNER
BEFORE
AFTER
TYPE
3 CHANNELS
NOVAFLAM®
PA %
10
9
pres.(mbar)
220
130-180
SAWDUST SUBSTITUTION INCREASE FROM 30 To 50 % MAIN BENEFIT
BETTER KILN STABILITY EASIER TO RECOVER CRITICAL/WEAK CONDITIONS NO MORE RING AND BUILD UP ENERGY SAVING (PRIMARY AIR, ELECTRICAL CONSUMPTION)
PILLARD FEUERUNGEN GmbH - Aarstraße 168, 65232 Taunusstein - Tel.: 061282420 - Fax: 06128242112 - Mail:
[email protected] - Web: www.pillard.de
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The NOVAFLAM® : a shorter Return on Investment Running costs
Installation costs
Kiln production
Existing carriage
Stability increased
Recovered
Production increased (typically 2-4%) A low quality coal can be used
Use of High A.S.F. % Cancelling fuel costs
Huge savings!
Existing P.A. fan Recovered
Minimized!
Payback time of 8 months for the 2 HOLCIM French plants PILLARD FEUERUNGEN GmbH - Aarstraße 168, 65232 Taunusstein - Tel.: 061282420 - Fax: 06128242112 - Mail:
[email protected] - Web: www.pillard.de
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The NOVAFLAM® : a lower carbon assessment CO2 emission
Electric consumption
Specific consumption
Solid fuel conveying lines
Reduced (average 3 %)
Concentration can be increased
CO2
Electric Consumption: less15%
Use of higher Biomass fuel % CO2
Primary air fan Pressure can be reduced Flow reduced El. Consumption: less 30/40%
CO2 Reduced!
Consumed electricity Reduced!
PILLARD FEUERUNGEN GmbH - Aarstraße 168, 65232 Taunusstein - Tel.: 061282420 - Fax: 06128242112 - Mail:
[email protected] - Web: www.pillard.de
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The NOVAFLAM® : Input data for engineering
Process data (incl. kiln geometry)
Dry or wet process, Ø 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
PILLARD FEUERUNGEN GmbH - Aarstraße 168, 65232 Taunusstein - Tel.: 061282420 - Fax: 06128242112 - Mail:
[email protected] - Web: www.pillard.de
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Pillard - Services
Assembly & Commissioning If required our trained personal supports you for erection and supervision of assembly The commissioning and the optimization of the burners will be carried out with our commissioning engineer together with the customers staff During the commissioning your staff will be trained
Process optimization Our specialists from R & D as well as from after sales service will carry out, if necessary, further optimizations Use of the latest technology tools – for example POWITEC camera Use of intelligent software tools for flow analysis (Fluent)
Spare parts We support you in all matters of spare parts planning, procurement, storage and assembly. In every phase of our cooperation, we try to optimize the handling of spare parts for you.
PILLARD FEUERUNGEN GmbH - Aarstraße 168, 65232 Taunusstein - Tel.: 061282420 - Fax: 06128242112 - Mail:
[email protected] - Web: www.pillard.de
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“Combustion means Mixing”
You can count on: 52 Years Pillard Feuerungen GmbH 89 Years of Fives-Pillard-experience in combustion technology 89 years of customer proximity and technological leadership Thousands of combustion plants successful commissioned 20 Years of continuous development of the ROTAFLAM® - burner family Over 1000 ROTAFLAM® and 47 NOVAFLAM burners worldwide in operation Taylor made solutions for each individual requirements Highest flexibility by adjusting of the flame shape Designable for more than 30 alternative fuels out of 14 different fuel groups Substitution rates of alternative fuels up to 100 %
PILLARD FEUERUNGEN GmbH - Aarstraße 168, 65232 Taunusstein - Tel.: 061282420 - Fax: 06128242112 - Mail:
[email protected] - Web: www.pillard.de
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ROTAFLAM® RV2 with burner trolley
ROTAFLAM RV2 burner at a German Cement Plant
PILLARD FEUERUNGEN GmbH - Aarstraße 168, 65232 Taunusstein - Tel.: 061282420 - Fax: 06128242112 - Mail:
[email protected] - Web: www.pillard.de
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Burner Trolley for ROTAFLAM RV2 Manual or Electrical Drive
Front Vertical Adjustment
Horizontal Adjustment
Rear Vertical Adjustment
PILLARD FEUERUNGEN GmbH - Aarstraße 168, 65232 Taunusstein - Tel.: 061282420 - Fax: 06128242112 - Mail:
[email protected] - Web: www.pillard.de
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Coal Channel – Standard Conditions Under normal operation conditions (only coal firing) the coal channel is maintenance free for one kiln journey.
Verschleißzone Wear Zone 1 1
Verschleißzone 3 Wear Zone 3
Verschleißring Wear Ring
Verschleißzone Wear Zone 22
Verschleißschalen Wear Protection
PILLARD FEUERUNGEN GmbH - Aarstraße 168, 65232 Taunusstein - Tel.: 061282420 - Fax: 06128242112 - Mail:
[email protected] - Web: www.pillard.de
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Coal Channel – Special Conditions
Especially when fuel mixtures, e.g. like coal, bone meal and/or sewage sludge is used a ceramic wear protection is recommend. With the ceramic wear protection the coal channel is normally maintenance free for 18 month. Ceramic Verschleißschutz wear protection keramischer
Ceramic wear protection keramischer Verschleißschutz
PILLARD FEUERUNGEN GmbH - Aarstraße 168, 65232 Taunusstein - Tel.: 061282420 - Fax: 06128242112 - Mail:
[email protected] - Web: www.pillard.de
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Coal Channel – Special Conditions
Oxide ceramic fittings
keramischer Ceramic wear Verschleißschutz protection
PILLARD FEUERUNGEN GmbH - Aarstraße 168, 65232 Taunusstein - Tel.: 061282420 - Fax: 06128242112 - Mail:
[email protected] - Web: www.pillard.de
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PILLARD FEUERUNGEN GmbH - Aarstraße 168, 65232 Taunusstein - Tel.: 061282420 - Fax: 06128242112 - Mail:
[email protected] - Web: www.pillard.de
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