2nd generation polflame VN
CemTech Webinar I 08.07.2020
Stephan Pallmann
thyssenkrupp Industrial Solutions AG
BU Cement
Agenda
Sintering Zone
the polflame VN philosophy
optimized design of 2 generation polflame VN
combustion of alternative fuels
Low NOx operation
polflame® - burner design
polflame VN MC – Burner
(Variable Nozzles) (Multi Channel)
Momentum of Burner
Primary air
Momentum Primary air flow
speed
should be limited: should be limited:
Adjusted to fuel type Heat consumption Power consumption
NO generation
Most reasonable Momentum is in the range of 4-7 N/MW
Momentum and primary air - adjusted to the needs
Alternative Fuels Alternative Fuels
Natural Gas Natural Gas
Anthracite Anthracite
Petcoke Max Petcoke
Coal Normal Coal
Lignite Lignite
0 5 10 0 5 10
N/MW Primary air (%)
Nozzle air speed: 220 – 250 m/s
CFD illustration – contours of temperature in °C
polflame VN multichannel
Significant higher combustion temperatures at constant primary air flow
Open jet – effects explained by simplified calculation
Io = I1 = constant
polflame VN
multi channel polflame VN high p
Primary air flow 1 kg/s 0,77 kg/s 0,54
Primary air speed 177 m/s 230 m/s 325 m/s
Primary air pressure 180 mbar 330 mbar 820 mbar
Momentum 177 N 177 N 177 N
Speed at jet end 10 m/s 10 m/s 10 m/s
Installed power fan/ compressor 72 100 175
Operation cost of polflame VN
Constant momentum Electric energy
consumption
Primary air
%
77
% 57
%
MC polflame VN polflame VN MC polflame VN polflame VN
high p high p
High p solution needs extremely high electrical energy!
Agenda
Sintering Zone
the polflame VN philosophy
optimized design of 2 generation polflame VN
!
combustion of alternative fuels
Low NOx operation
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polflame VN - overview
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Easy flame adjustment with hydraulic motor
hydraulic pump hand lever pressure gauge for
primary air
hydraulic motor for swirl
Easy and fast change of flame shape over hydraulic system
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Agenda
Sintering Zone
the polflame VN philosophy
optimized design of 2 generation polflame VN
combustion of alternative fuels
Low NOx operation
"
Alternative fuel combustion - Experience with the Polflame VN
RDF channels
Alternative fuel in the core always the best solution?
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Alternative fuel usage > 50% - recommended to use satellite pipe
RDF trough an Additional residence time
better distribution
external pipe
Feeding pipe
limited O in the core
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Effect on flame length and undesired coating formation – kiln drive
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RDF through the burner
RDF through external pipe
Agenda
Sintering Zone
the polflame VN philosophy
optimized design of 2 generation polflame VN
combustion of alternative fuels
Low NOx operation
"
Thermal NOx formation in the sintering zone
simplified Zeldovich Mechanism (thermal NOx)
theoretical
equlibrium
concentrations
temperature
needed
Thermal NOx emissions can be optimized (lower O ) but the potential is limited (T is needed)
,
"
Primary air amount is not a good indicator for NOx - generation
I = I = constant
polflame VN
multi channel polflame VN high p
Primary air flow 1 kg/s 0,77 kg/s 0,54
Primary air speed 177 m/s 230 m/s 325 m/s
Primary air pressure 180 mbar 330 mbar 820 mbar
Momentum 177 N 177 N 177 N
Speed at jet end 10 m/s 10 m/s 10 m/s
Aspired secondary air 16,7 kg/s 16,93 kg/s 17,16 kg/s
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polflame configuration: Effect on flame shape and temperature
15° swirl, low temperature 28° swirl, stable flame, 40° swirl,
low NOx average temperature extreme temperature
weakest flame average NOx high NOx
Strongest flame
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Influence of sintering zone on total NOx emission –
example of Petcoke fired plant
Only 30-40% from sintering zone
60-70% from calciner
Stephan Pallmann
thyssenkrupp Industrial Solutions AG
BU Cement
Pyro-processing
Phone: +49 2525 99 2875
stephan.pallmann@thyssenkrupp.com
