Pyrojet burner to used in cement industry

1. KHD PYRO-JET®-Burner
The reliable kiln burner
Prism Johnson Cement.

2. Our Goal:
Cutting costs - on investment, operation and maintenance
• Reduction of fuel costs and benefits for the environment
Reducing primary air portion
• Reduction of electrical costs and investment costs for fans
Reducing specific waste-gas quantity

3. PYRO JET® BURNER Major Difference!
1. Primary air not more than 5%, Secondary air 95%
2. Jet air @ 3.2%, Super sonic speed (330 – 350
m/s), High Pressure Jet 900 mbar,
3. Swirl Air @ 1.6%, Speed 150 – 160 m/s. Swirl
Pressure 160 mbar
4. Coal Transport Air @3.6% (Approx.), Velocity
28 – 30 m/s

4. BurnerDesignandFunctioning
For all kinds of fuels
• Coal and Pet coke
• Oil
• Gas
THE PYRO-JET®-Burner – The reliable solution

5. 5
 Safety
 Burner Data
 Burner Main Components
 Burner Design and Functioning
 Burner Commissioning
 Burner Centering Procedure
 Advantage of HPJ Burner
Content:
PYROJET BURNER

6. SAFETY:

7. Safety
7
Risktohealth
Pyrojet Burner can cause the following risk to staff due to improper
operation, maintenance, assembly or conversion.
• Burns by radiated heat, touch of hot surface, emerging of hot media.
• Injury of the ears by medium of noise emissions.
• Risk of fire or explosion due to emerging coal dust, gas or oil.
• Risk of electrical shock.
• Breathing of gases or coal dust in case of defective seals

8. Safety
8
MachinerelatedSafety
• Prior to starting of work, the drives and auxiliary must be electrically secured.
• The lifting tools capacity must be insured for the burner equipments weight.
• All warning at the Pyrojet Burner must completely be kept in a legible condition.
• All works on the Pyrojet burner must generally be performed upon stand still in cold and
secure state
• During operation, protective devices of the machine must be in protective position as
directed.

9. HPJBURNERSPECIFICATION:

10. HPJBURNERSPECIFICATION:
H – High Pressure
PJ – Pyro Jet
382 – Heating Efficiency (Gj/hr)
KO – Coal / Oil
HPJ 382 KO
1 Gj = 2.39 x 105 K Cal

11. KHD PYRO-JET® Burner
Kiln 1 Kiln 2
Type HPJ 382 KO HPJ 428 KO
Burner Capacity GJ/hr. 382 428
Fuel Coal / Pet Coke Coal / Pet Coke
Control Range 10: 1 10: 1
Fuel Throughput
Coal (TPH) 16.26 (Min CV-5600) 18.32
Pet Coke (TPH) 12.16 (Min CV-7500) 13.68
Fuel Fineness (90
mic)
Coal 8 - 10 8 - 10
Pet Coke 2 - 3 2 - 3
Burner Specification

12. Burner data
Primary air portion – KILN 1
Component Volume (m3
/hr.) Pressure (mbar) % Primary Air
Jet Air 4200 900 3.2
Swirl Air 2100 160 1.6
Fuel Transport Air 3619 600
Total Air (Without Conv. Air) 4.8

13. KHD PYRO-JET® Burner
Primary air portion – KILN 2
Component Volume (m3
/hr.) Pressure (mbar) % Primary Air
Jet Air 4691 900 3.2
Swirl Air 2346 160 1.6
Fuel Transport Air 4581 600
Total Air (Without Conv. Air) 4.8

14. MAINCAMPONENTOFPYROJETBURNER
• Burner Tube
• Burner Tip
• Emergency Valve
• Swirler
• Telescopic Pipe
• Jet and Swirl Air Blowers

15. Pyrojet Burner

16. BurnerTube

17. 17
Pyrojet Burner Tip
Coal dust channel
Jet nozzle ring
Swirl element
Inner tubes for pilot, oil gun

18. MAIN CAMPONENT OF PYROJET BURNER
• Swirler

19. MAINCAMPONENTOFPYROJETBURNER
Emergency Valve

20. MAINCAMPONENTOFPYROJETBURNER
• Telescopic Pipe

21. MAINCAMPONENTOFPYROJETBURNER
• Jet & Swirl Air Hose
Note: With this all above
arrangement, this burner
is design to adjust during
kiln operation.

22. 22
Jet and Swirl Air Blowers

23. Refractoryoftheburner
Burner tube with anchors

24. BurnerMountingArrangements
24

25. Overhead Hanging
Floor Mounting

26. BURNERDESIGNANDFUNCTIONING
Function of Burner:
1. Provide good and stable flame.
2. Mixing of fuel with hot gases.
3. Short and less peak temperature.
4. Adjustable flame shape and size.
5. Less primary air consumption.

27. Jet Air
The axial jet air nozzles ring generates jet air streams with near sonic velocity. The jet air works like
an injector and mixes hot secondary air into the fuel, which leads to accelerated combustion.

28. Jet Air
 The essential difference from Other`s burner lies in the patented construction of the
axial air jet system.
 In PYRO-JET® burner, the axial air passes out of the outermost burner channel through
several individual round nozzles distributed around the circumference. Owing to their
high velocity, the resultant individual jet air streams draw-in the slow-flowing but hot
secondary air from surroundings and lead to stable and controlled ignition of fuel.
 CFD studies shown that the secondary air absorption into flame is nearly 25% within
first 2 meters of flame length due to jet streams high velocity and uniform spacing
between jet air nozzles.

29. Swirl Air:

30. Swirl Air:
 The tangential air flow generated by the swirl body results in negative
pressure near the burner tip.
 Hot gases from the kiln are sucked into the flame root and also fuels
are safely ignited.
 Part of Thermal NOx formed will break down into free N2 by internal
recirculation of flue gases, as a result of the swirl air emerging from the
inner part of the burner.
 The swirl has a stabilizing effect on the flame in the burner axis.

31. Low NOx Emissions
NOx formation is strongly dependent on:
Temperature peaks of flame with available concentrations of O2 and N2.
Residence time at peak temperatures.
The flame of the PYRO-JET® burner has both an internal recirculation zone and a long external one which
results in NOx reduction. The unique jet air streams facilitate substantially uniform heat distribution.

32. Standard Design Parameters:
Jet Air | 330-350 m/s | 3.20%
Swirl Air | 150-160 m/s | 1.60%
Coal dust | 28-31 m/s |
 Total Primary Air quantity excluding fuel transport air amounts to 4.8% as per KHD standard
design.
 For special requirements, the burners can be designed with high amount of primary air also.

33. TypcialflowsheetofaPYRO-JET®-Installation
M
M
M
M

34. 34
Burner Re-commissioning

35. 35
Re - commissioning of Pyrojet Burner:
• General inspection for burner system.
• Check for any damage of burner due to handling
• Check all the burner channels for any foreign materials and debris.
• Check the Swirl and Jet air hose for any leakages.
• Check the telescopic pipe and greasing to avoid leakages
• Check the operation of Butterfly valve.
• Set the oil gun nozzle position at burner tip.
• Check the burner centering.
• Check the Lubrication of jet and swirl air blower.
• Lubrication of jet and swirl air blower motor
• Check the Jet, Swirl and Coal blower V-belt tension.
• Blower suction filter are cleaned.
• All safety guard is in place.

36. 36
KILN
Burner
x X = 0.0 – 0.5 mtr
Burner Centering
Following are the main consideration while burner centering
1. Kiln length and Dia.
2. Snowman and Rhino tendency.
3. Volatiles in feed material.
As per KHD standard: Burner can be inserted from 0.0 – 0.5 m

37. b
c
d
a
a = b
c = d
Burner Centering
KILN
Burner
Note: It is always good to keep the burner at center of the kiln. As
it will reduce the volatile recirculation in the kiln.
Generally burner kept towards material side to protect the refractory.

38. 38
Characteristic of Good Flame:
1. Flame Orientation
2. Flame Intensity.
3. Flame Tightness
4. Plume Length

39. 39
Burner / Flame Optimization:
• Kiln operating condition –
- Temperature & Flow of secondary air,
- CO / O2 at Kiln inlet,
- BE Temp etc.
• Fuel Quality:
- Fired coal fineness,
- Coal Moisture ,
- Volatile Matter
• Burner Parameter:
– Jet air,
- Swirl air and
- Coal conveying air velocity.
Factor Influencing Burner Flame

40. 40
Burner / Flame Optimization:
• Kiln shell temperature
• Kiln coating condition
• Colour of flame
• Coal pulsation.
• Burner Parameter – Jet air, Swirl air pressure and Coal conveying air velocity.
• Flame visual inspection
Flame Optimization

41. Advantageof PyrojetBurner
41

42. • High efficiency, low primary air quantity
• Low NOx Emission
• Optional fuel combination
• Reduces Specific Heat Consumption
• Short and Stable Flame improves the
clinker quality. Better Granulometry and
reduces Free Lime.
• Variable Flame Setting by changing the
Jet & Swirl proportion
• Reducing specific waste-gas quantity
and reduction of PH Fan power.
• High availability
The essential advantages of the PYRO-JET burner are the following:

43. 43
• Easy to assemble, De-assemble and
adjustment.
• Ceramic liner at coal conveying pipe
reduce wear and tear
• Very easy to adjust the burner even
during Kiln Operation

44. 44
Trouble Shooting - Burner
Cause Measures
ation
ed by CO-
n the kiln inlet
Fluctuating of coal dust dosing a) Ensure a uniform coal dust flow.
b) Throttle dosing control
Secondary air temperature too low Raise secondary air temperature
Insufficient conveying velocity in coal
dust pipe
Reduce pipe cross section
a long black
O at kiln inlet
The out-flow velocity is too high Reduce coal dust conveying air rate
Insufficient flow of Jet-air Increase the Jet-air supply.
Excessive coarse ground coal,
Fine coal moisture high
Increase grinding fineness and drying
ing directly at
outflow
Excessive amount of Jet - air Reduce Jet - air volume by flap adjustmen
Too large cross section of coal dust
nozzle
a) Increase coal conveying air
b) Install a coal dust nozzle of smaller out

45. Thanks for your kind attention!