The document discusses Greco kiln burners designed for petcoke combustion. It provides details on Greco's Flexiflame burner design which uses double swirling air flows to control ignition and allow complete combustion of petcoke. The Flexiflame burner can accommodate both solid and alternative liquid fuels. Examples are given of Flexiflame burner installations operating on 100% petcoke at cement plants worldwide.

1. GRECO KILN BURNERS FOR
GRECO KILN BURNERS FOR
„
„PETCOKE COMBUSTION
PETCOKE COMBUSTION“
“
Specific burner design for your kiln
Specific burner design for your kiln
Loesche Round Table / India 2012

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ABOUT GRECO
Founded in 1966 – Uni. Prof. Clemento Greco
90th – Conversion from fuel oil to petcoke
Since more than 10 years around 300pc. installed burners
Since 2010 part of the A TEC Group
Worldwide Offices

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WORLDWIDE OFFICES

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NEW: Solid Alternative Fuel Handling System
COMPETENCE IN THE
ROCK INDUSTRY
Kiln Burners Calciner Burners Hot Gas Generators Fuel Systems

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COMBUSTION OF
PETCOKE

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DESIGN OF FLEXIFLAME
PETCOKE
Combustion of petcoke:
Petcoke is harder to ignite as conventional coal (low volatile)
Petcoke provides a higher flame radiation then coal
Petcoke has a typicall high sulfur content
Petcoke develops a higher NOx formation
Usually petcoke changes the kiln profile
Petcoke needs a special burner design

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PETCOKE COMBUSTION
The combustion of petcoke requires:
Quick mixing of secondary air to the flame, to allow the complete
combustion which is iniciated by primary air.
Primary air jets need to accellerate the secondary air.
Internal recirculations are controlling the ignition distance of the fuel

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FLAME CONTROL

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Design criteria for kilnburners working with 100% petcoke:
PETCOKE COMBUSTION

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Design criteria for kiln working with 100% petcoke:
PETCOKE COMBUSTION

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Tendency of buid ups (clorine vs. sulfur) in hot meal
Build ups – out of control
Build‐ups
under control
No build‐ups
Source:
VDZ Forschungszentrum
Düsseldorf
The additional sulfur input by petcoke requires a check of raw material mix.
PETCOKE COMBUSTION

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High flame momentum has advantages in:
Kiln operations becomes more stable & improved fuel efficiency
Improved clinker reaktivity and shorter sintering zone
Lowered volatility and recirculation of sulfur in kiln gases (control of
surfur into the clinker)
Tendency for ring formation is lower
Clinker granulometry more uniform
PETCOKE COMBUSTION

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FLEXIFLAME™
KILN BURNER

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Design Philosophy:
Each kiln burner will be designed individually according to the process of
each kiln and its characteristics. That provides operation safety for the
entire combustion and sintering process.
FLEXIFLAME KILN BURNER

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Maximum use of solid alternative fuels
Clinker quality
Kiln operation
Lowest possible NOx & CO emissions
Wear resistance + low maintenance
– Compromise between different parameters
– Flexibility to operate with different fuels
REQUIREMENTS FOR
KILN BURNERS
•
• TAILOR MADE
TAILOR MADE
•
• HIGH FLEXIBILITY
HIGH FLEXIBILITY

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DESIGN OF FLEXIFLAME
BURNERS FOR PETCOKE
EXTERNAL AIR
TANGENTIAL AIR (ROTATION)
COAL/PETCOKE
DISPERSION AIR (ROTATION)
CENTRAL AIR
(RECIRCULATION/COOLING
SLUDGES / ANIMALMEAL
IGNITOR
MIXING AIR FOR ASF
RDF / FLUFF
DOUBLE SWIRL EFFECT
DOUBLE SWIRL EFFECT

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DESIGN OF FLEXIFLAME
KILN BURNERS
Cooling Air Dispersion Air
Tangential
Air
External Air
Coal / Petcoke
RDF+mixing air
MBM+mixing air

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DESIGN OF FLEXIFLAME
KILN BURNERS
Conveying air ratio Conveying air flow
Pulverized solid fuel
(Coal / Petcoke)
Up to 5,0 kg of material
per kg of air
2-3,5 % of stoichiometric air
Animal meal and/or
Sewage sludge
Up to 4,0 kg of material
per kg of air
1-3,5 % of stoichiometric air
Fluff / RDF
Up to 2,5 kg of material
per kg of air
1-3,5 % of stoichiometric air

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HIGH EFFICIENT BURNER DESIGN
Customized primary air pressure (250 – 500 mbar)
Less possible transport air flow for coal/petcoke
Primary air with high pressure (high momentum)
• 6 – 12% of stoichiometric combustion air
• NOX emission control
DESIGN OF FLEXIFLAME KILN
BURNERS

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SOLID ALTERNATIVE FUEL FIRING
SAF – solid alternative fuels
with pneumatic mixing device
SAF pipes in compound wear resistant
material
„O2 – READY“ design to improve the
kiln performance
Pulverized fuel inlet in hardened
material– outer pipe
Pulverized fuel inlet with ceramic
protection – inner pipe
No wear at SAF nozzles !
DESIGN OF FLEXIFLAME
KILN BURNERS

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NEW FLEXIFLAME RS
NEW FLEXIFLAME RS
KILN BURNER
New FLEXIFLAME RS® kiln burner with advantages of:
Easy flame setting and control
Smaller burner diameter
-30% steel burner weight
Less internal air pressure drop
Quicker and simpler burner tip service
Shorter kiln burner lenght, easier in handling
Maintaining of a high burner momentum

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New FLEXIFLAME RS® kiln burner
NEW FLEXIFLAME RS
NEW FLEXIFLAME RS
KILN BURNER

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External Air
Tangential Air
with air control slide
Dispersion Air
with air control slide
Cooling air
Petcoke/Coal
NEW FLEXIFLAME RS
NEW FLEXIFLAME RS
KILN BURNER

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External Air
Tangential Air
with air control slide
Dispersion Air
with air control slide
Cooling air
Petcoke/Coal
NEW FLEXIFLAME RS
NEW FLEXIFLAME RS
KILN BURNER

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BURNERS LANCES

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„OC- JET“ nozzle – for dirty alternative liquids
Waste oil, Animal fat, Residues…
Range 1:8
Viscosity: up to 300cSt
BURNERS LANCES

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BURNERS LANCES

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HANSON – KETTON / UK
Nominal thermal power: 66 MW
Burner operational range: 80 – 105 % of nominal thermal power.
Multi-fuel burner firing coal, gas-oil, solvent and solid alternative fuels.
Nominal fuel flows:
Coal: 12,000 kg/h.
Liquid fuel: 6,000 l/h.
Solvents: 7,000 l/h.
Solid alternative fuel #1: 7,000 kg/h.
Solid alternative fuel #2: 7,000 kg/h.

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AALBORG CEMENT /
DENMARK
Thermal power: 73,4 Gcal/h.
- Coal+Petcoke: 10.300 kg/h -> 100% of burner thermal power
- Fuel oil: 7.340 kg/h -> 100% of burner thermal power
- Glycerin: 4.000 kg/h -> 22% of burner thermal power
- MBM: 3.000 kg/h -> 16% of burner thermal power
- RDF: 6.000 kg/h -> 33% of burner thermal power
- Optional waste fuel: 4.000 kg/h ->16% of burner thermal power

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CBR – ANTOING / BELGIUM
Thermal power: 50 MW (43,1 Gcal/h).
•Petcoke: 6.015 kg/h.
•Coal: 7.515 kg/h.
•Light fuel oil: 1,775 kg/h.
•Animal meal: 5.000 kg/h
•Dry sewage sludge or Resofuel: 2.500 kg/h
•Fluffs: 3.000 kg/h.

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HANSON – RIBBLESDALE / UK
Thermal power (considering future capacity):
44,4 MW (38,25 Gcal/h)
Nominal fuel flows:
Coal: 6.660 kg/h
Kerosene / gas oil: 3.485 kg/h
Cemfuel: 6.000 – 7.000 kg/h
Animal meal: 5.000 – 7.000 kg/h

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CBR HARMIGNIES / BELGIUM
Thermal power: 62 MW
•Petcoke
•Heavy fuel oil
•Solvents
•Plastics & RDF
•Animal meal

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CEMENTOS ALFA / SPAIN
Thermal burner power: 52 MW
•Petcoke
•Heavy fuel oil
•Waste oil
•Plastics & RDF
•Dry Sewage Sludge

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ENCI MAASTRICHT /
NETHERLAND
Thermal burner power: 128 MW
•Petcoke, sludge, anode dust
•Natural gas
•Glycol
•Animal meal
•Paper sludge

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WOPFING CEMENT
AUSTRIA
Thermal burner power: 45 MW
•Petcoke
•Natural Gas
•RDF
•Animal Meal
•Waste Oil

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Adjustable around the front suspension support in all directions to
align the burner well to the kiln requirements.
BURNER TROLLEYS

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Adjustable around the front suspension support in all
directions to align the burner well to the kiln
requirements
BURNER TROLLEYS

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FLEXICAL™
CALCINER
BURNERS

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For all traditional fuels as well as RDF and waste liquids
DESIGN OF FLEXICAL
PRECALCINER BURNERS

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SPRCIAL
DRYER BURNERS

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For all traditional fuels as well as RDF and waste liquids
DESIGN OF FLEXICAL
DRYER BURNERS

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DESIGN OF FLEXICAL
DRYER BURNERS
• Thermal Power: 1‐ 50 MW
• Easy controllable flame
• Safe and robust burner design
• Low maintanance necessary
• Stable flame with refractory
mouth

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DESIGN OF FLEXICAL
DRYER BURNERS
Flexical Burner:
Coal &Fuel Oil burner on a rotary
dryer for calcination of raw
materials or chemicals.

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FLEXIGEN™
HOT GAS
GENERATORS
for solid fuels as Petcoke /Coal…

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VERTICAL DESIGN / SOLID
FUELS

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SPECIFIC DESIGN OF
AIRFLOW

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SPECIFIC DESIGN OF
AIRFLOW

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SECONDARY AIR FAN

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SECONDARY AIR & COOLING
AIR INLET
Secondary air inlet:
 Provides oxygen to the
flame.
Cooling air inlet:
 Controls the refractory
lining temperature.
 Automatic mode, to keep
the temperature bellow
1000 °C (ash melting
point)
 Both flows are adjusted
by pneumatic valves.

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DILUTION AIR INLET
The dilution air is used
to adjust the outlet gases
temperature
Its main inlet is located
just before (above) the
outlet of the HGG

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FLAME ADJUSTMENTS
The flame shape can be
adjusted by changing the
axial and tangential air
ratios
There are two butterfly
valves used for these
adjustments:
- External air channel
- Tangential air channel

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SPECIFIC DESIGN OF
AIRFLOW
FLAME SENSOR
COOLING
AIR
SECONDARY
AIR
SPY-HOLE
BURNER
FLAME SENSOR
IGNITOR
HGG COMBUSTION CHAMBER ROOF VIEW

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VALVE TRAINS FOR
LIQUID & GASEOUS
FUELS

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Oil Valve Trains & Gas Valve Trains
design according DIN EN 746 – 2
Oil Pump stations
HFO Preheater stations
BMS (Simatic, Alain Bradely…)
FUEL PROCESSING

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FUEL PROCESSING
Fuel supply system for liquide alternative fuels
- Used oil - Animal fat - Any liquid fuel residue
- Solvents - Glycerine

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FUEL PROCESSING
40 ft standard container
40m³ double shellstorage tank in one unit
Easy to manipulate and flexible in use
Execution according to valid TÜV and ATEX standards

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SOLID ALTERNATIVE
FUELS
HANDLING SYSTEMS

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RDF PREPARATION SYSTEM

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If you have any questions or need any assistance, please
do not hesitate to contact your GRECO team:
GRECO Combustion Systems
Europe
+43 2732 75680
info-europe@atec-greco.com
info@atec-greco.com
CONTACT US

60. www.grecotec.com / www.atec-ltd.com
GRECO Combustion Systems Europe GmbH
Kasernstraße 16-18 . 3500 Krems/Donau . Austria
info-europe@atec-greco.com
A TEC GRECO Projetos e Equipamentos Ltda.
Av. Brigadeiro Faria Lima 1912 Cj B. 01451-000 São Paulo . Brasil
info@atec-greco.com
THANK YOU FOR YOUR ATTENTION