Directions

1) Input Fuel characteristics 6) Once the barrel is complete, adjust the tip cross sectional areas
2) Input kiln production data Ultimate target is Is = 1.8 and Sw = 0.15, by adjusting the tip dimensions.
Change the tip cross sectional areas by adjusting the axial holes
3) Determine (goal seek) transport air flow rate : 5 kg/m3 for blower, 7 kg/m3 for pump diameter and the width of groove for the swirl.
- vary the transport flowrate - Nm3/h
- note that blowers cannot take the higher material density rate 7) Optimise static pressures at tip, tip cross sectional area and all other
constraints. Obtain the best balance for:
4) Obtain optimum or target flow rates values (swirl & axial) Target of Is = 1.8 and Sw = 0.15,.
For a first calculation, start with static pressures of 40.000 Pa for axial, and Optimum flow rates
25.000 Pa for swirl - 10% primary air; 7% axial + transport (in case that no swirl
is used). Use solver, changing the groove width, the axial holes diameters, the axial and 8) Confirm choice of fan or blower for swirl air based on static
the swirl static pressures. Add constraints on the axial pressure (35.000-60.000 Pa), pressure in the tip - choice effects bias coefficient
and to the swirl pressure (>18.000 Pa if fan, 20.000-30.000 Pa if blower).
9) Determine range for blowers: maximum for (Is,Sw)=(1.8,0.15), and
Note the optimum flow rates as well as cross section areas (mm2) minimum for (0.9,0.05). Check that , doing this, we stay in the range
Ultimate target is Is = 1.8 and Sw = 0.15. of 7 to 12% primary air.

5) Dimension the barrel:

What is the free diameter required in the centre? Depends on how many fuels
the plant wants to burn simultaneously: waste, oil, etc…
In theory, min. of 200 mm (8 in.) is needed for the bluff body effect although
6 in. has been used.
Use standard pipes (see table). The outer diameter of this first pipe is the inside
diameter for the swirl air channel. Continue to build, using the criteria below:

1) Swirl: Velocity in barrel: 15 to 25 m/s

Swirler angle = 30 - 40°; common to use 35° Transport design: drawing instructions
18 to 22 vanes (or slots), 8 mm depth minimum Maximum angle of inlet = 12.5 degree with the burner axis
No straight stream through the swirler = long enough Enter from the top (better distribution)
2) Transport: Velocity in tip and barrel: 25 to 35 m/s Inlet rectangle: Internal width should be equal to internal
radial gap of annulus > or = to 10 mm (concentricity, plugging) diameter of outer pipe of the fuel annulus. The velocity
A slight reduction of the cross section area is being done at the tip, for should never decrease from the fuel intoduction into the line
a better fuel distribution around the annulus (automatic) to the burner tip. (Settlement)
3) Axial: Velocity in barrel = 15 to 25 m/s (trade-off weight of burner pipe versus
pressure drop). Target 20 holes, generally 16 to 24
Diameter of holes >or = to 12 mm

Page 1
 393694230.xls

SWIRL AND MOMENTUM DETERMINATION

Original: CLV / S.THIERS Apr-95 PLANT : HOG
Update: CTEC / H. REITERER Oct-00 Date : 28-Aug-06
Name : Lucian Calinoiu
COMMENTS :
Plant altitude: 480 m
Atm. Pressure : Err:511 mmHg = Err:511 mmH2O = Err:511 Pa

TIP CROSS SECTION AREAS Diameters : % cross section reduction Dext : 540.0
(mm) thk : 8 524
AXIAL AIR 523.0 8.5 76,694 Pa
Holes 1, Vanes 2 : 1 ### m/s 471.0 77.5% Err:511 m/s Err:511 Nm3/h
9123 mm2 Dext : 470.0
446.0 12.5 thk : 12 446
TRANSPORT AIR 23 m/s 387.0 23.2 m/s Dext : 387.0
38600 mm2 thk : 12.5 362
343.0 22 17,839 Pa
SWIRL AIR ### m/s 311.6 47.1% Err:511 m/s Err:511 Nm3/h
7000 mm2 Dext : 298.5
265 23.3 thk : 7.1 284.3

DETAILS OF THE TIP Swirler Number slots groove width radial gap radius
angle (o) of vanes width(mm) (mm) vanes(mm) raccord.
Swirl 35 16 33.0 27.0 0.5 1
Axial (if vanes) -

Axial (if holes) Number of holes : 24 Diameter : 22.00

Pitch cirle (mm): 497 Spacing (mm): 65.06

GENERAL DATA
Kiln TYPE : NP Production (t kk/d) : 3660

NP : no preca, AT : air through, AS : air seperat. Specific heat consumpt.kcal/kg CK : 840

FUEL ANALYSIS, AS FIRED (DRY BASIS) Swirl Air: F=Fan; B=Blower F

%C 85.14 %O 2.70 Percent of heat at back-end : 8.50

%S 3.26 NCA SR (%) : 8.50
%H 3.70 Nm3/kg fuel 8.58

Total combust. air (Nm3/hr) : 140,804

SPECIFIC HEAT CONSUMPTION Throughput L.H.V. Therm.power Total combust. air (Nm3/kg kk) : 0.923
AT THE BLAST PIPE t/h Kcal/kg Gcal/h Shell internal diameter (m) : 5.80
Petcoke 14.30 8195 117.21
textile 0.00 3600 0.00
PVC 0.00 6000 0.00
wood 0.00 4000 0.00 Recalculated SHC :

Total (Gcal/h) : 117.21 840 kcal/kg CK

GAS FLOW MEASUREMENTS Axial Swirl Transport

Static pressure in the tip (Pa) 76,694 17,839 1,000
Temperature in the pipe (deg C) 103 33 20
Theoretical flow rate (Nm3/h) Err:511 Err:511 - Fuel to air ratio:
Bias coefficient : 0.77 1.00
Accepted flowrate (Nm3/h) Err:511 Err:511 3000 4.44 kg/m3
7 for pump
Axial / Swirl distribution Err:511 Err:511 5 for blower
RESULTS
FLOW VELOCITIES Axial Swirl Transport Is Swirl
Nature of flow Err:511 Err:511 velocity Nh/Gcal
Release tip velocity (m/s) Err:511 Err:511 23 Err:511 Err:511

Primary air rate, axial : Err:511 Targets: Fuel-Oil 5.0 0.15

swirl : Err:511 Coal 6.3 0.15
transport : 2.13% Coke 7.5 0.15
Axial + Transport: Err:511
Primary air rate Err:511 THERMAL LOAD (MW/m2) : 5.94

Lucian Calinoiu Page 2 08/03/2018

 393694230.xls

SWIRL AND MOMENTUM DETERMINATION

Original: CLV / S.THIERS PLANT : HOG
Update: CTEC / H. REITERER Date : 28/08/2006
Name : Lucian Calinoiu

DETAILED RESULTS
GEOMETRY Axial Swirl Transport
Height of spacers/blades (mm) 15.2 -
Width de fraise d'usinage (mm) 27.0 -
Width of blades in front (mm) 34.2 -
Surf. masquée par les raccords 7 -
Surf. apparente de sortie (mm2) 9123 8546 -
Exit effective area (mm2) 8849 6790 38600
gyration radius(mm) - 164 -

DETENTE Axial Swirl Transport

massic flowrate(kg/s) Err:511 Err:511 1.078
exit volumic flowrate(m3/h) Err:511 Err:511 3220
specific gravity in the pipe (kg/m3) Err:511 Err:511 1.205
specific gravity at the B-tip(kg/m3) Err:511 Err:511 1.205
Velocity in the burner pipe (m/s) Err:511 Err:511 23
Velocity at the nozzle (m/s) Err:511 Err:511 23
Expansion velocity (m/s) Err:511 Err:511 23
Axial momentum (N) Err:511 Err:511 25
Impulsion normale (N) 0 Err:511 0
Rotation Momentum (N.m) 0 Err:511 0

Momentum Equivalent Diameter : Err:511 mm

Axial Swirl Is Swirl

Flow-type: subsonique subsonique N.h/GJ
Expansion velocity (m/s) Err:511 Err:511 Err:511 Err:511
Axial primary air ratio: : Err:511 Targets: Fuel-Oil 5.0 0.15
radial: Err:511 Coal 6.3 0.15
transport : 2.13% Coke 7.5 0.15
Total : Err:511

MEASUREMENTS-CROSSCHECK BY ENERGY CONSERVATION

Axial Swirl Transport
E gases into the nozzle (KJ/kg) Err:511 Err:511 294
E gases at the exit (KJ/kg) Err:511 Err:511 295
¯E/E (%) Err:511 Err:511 0.1
Geometry of the swirl body

Radial gap (mm) : 0.5

Height of blades (mm) : 15.2

Slot width (mm) : 33

312

343

Groove width (mm) : 27

35°

Minimum lenght of swirl body (mm) : 91

Lucian Calinoiu Page 3 08/03/2018

 393694230.xls

5.11

Lucian Calinoiu Page 4 08/03/2018

 393694230.xls

Lucian Calinoiu Page 5 08/03/2018

Algorithm for burner control

Data`s burner Kujawy

Effectiver exit area Axial (Aa) 8849 mm2 Konstant I= 0.86 N/GJ/h
Effectiver exit area Radial (Ar) 6790 mm2 Konstant Sw = 0.074
Effectiver exit area Transport (At) 38600 mm2 Konstant
Blade angle 35 ° Konstant
gyration radius (Rg) 0 m Konstant
Temperature burner inlet Axial (Tax) 20 °C Measurement
Temperature burner inlet Radial (Trot) 35 °C Measurement
Ambient temperatur (Tu) 20 °C
Temperature burner inlet Transport (Ttran) 75 °C Konstant
Axial pressure after blower (Pax) 487 mbar Measurement
Axial pressure burner Pax1 487 mbar Measurement
Radial pressure after fan (Prot) 128.99 mbar Measurement
Radial pressure burner Prot1 128.99 mbar Measurement
Axial air (Qmeax) 1421 m3/h Measurement or from curves
Radial air (Qmerot) 1094 m3/h Measurement or from curves
Transport air (Qtran0) 3000 Nm3/h Konstant
Spec. heat consumption kiln (Qkiln) 840 kJ/kg kk From the Reporting
Output kiln (Pkiln) 3660 t/d From the Reporting
Percent of heat at back-end (SF) 8.5 From the Reporting

Thermal power of the burner (Pth) = Pofen * Qofen * (100 - SF) / 24 / 100000 117.2115 GJ/h

Overview air density

Increase of the axila air temperature in the burner pipe
Tax(e) = Tax + 100 120 °C

Density ambient air

ROu = 1,293 * 273/(273+Tu) 1.205 kg/m3

Density of the air in the burner pipe

ROax0 = 1,293 * (101325 + 100*Pax1) / 101325 * 273 / (273 + Tax(e)) 1.330 kg/m3
ROrot0 = 1,293 * (101325 + 100*Prot1) / 101325 * 273 / (273 + Trot) 1.292 kg/m3

Density of the air at the burner nozzle

ROax1 = ROax0 * (101325/(101325+100.Pax1))^0,7143 1.005 kg/m3
ROrot1 = ROrot0 * (101325/(101325+100.Prot1))^0,7143 1.186 kg/m3
RO tran = 1,293 * 273 / (273+Ttran) 1.014 kg/m3

Overview gas and mass flow

Qnax = Qmeax * (101325 +100* Pax) / 101325 * 273 / (273 + Tax) 1961.0 Nm3/h
Qnrot = Qmerot * (101325 +100* Prot) / 101325 * 273 / (273 + Trot) 1093.0 Nm3/h
Qax = = Qnax * 1,293 / ROax1 2523.5293 m3/h
Qrot = = Qnrot * 1,293 / ROrot1 1191.6246 m3/h
Qtran = Qtran0 * (273 + Ttran) / 273 3824 m3/h
Qmax = Qax * ROax1 / 3600 0.704 kg/s
Qmrot = Qrot * ROrot1 / 3600 0.393 kg/s
Qmtran = Qtran * ROtran / 3600 1.078 kg/s

Expansion velocity of the air

Vsax = Qmax / ROax1 / Aa * 1000000 79 m/s

Vsrot = Qmrot / ROrot1 / Ar * 1000000 49 m/s
vstran = Qmtran / ROtran / At * 1000000 28 m/s

Impuls

Gax = Qmax * Vsax 56 N

Grot = Qmrot * Vsrot * cos 35 16 N
Gtran =Qmtran * Vstran 29.7 N
Gaxial =Gax + Grot + Gtran 101.1 N
Gradial =Qmrot * Vsrot * sin 35 11 N

MED =2 * Wurzel ((Qmax + Qmrot + Qmtran) * (Qax + Qrot + Qtran) / 3600 / Pi / Gaxial) 0.239 m

Operation figures burner

Is = (Gax + Grot + Gtran) / Pth 0.86 N/GJ/h
Sw = (Gradial x Rg) / (Gaxial x MED) 0.074

Remark:
Sometimes the PDL system is not able to calculate y = x^0,7
In this case we will make a mathematical transformation
Y = EXP( 0,7 * LN( X))

X/TPP/Rt/ALLGBERE/393694230.xls/burner control 08/03/2018

 Reporting
Fuel consumption (Qofen)

Radial air

Radial air flow (Qmerot)

Radial pressure (Prot)
Measurement
Axial air flow (Qmeax)
Axial pressure (Pax)

Axial air

Constant values
Effectiver exit area Axial (Aa)
Effectiver exit area Radial (Ar)
Effectiver exit area Transport (At)
Blade angle
gyration radius (Rg)
Transport air (Qtran0) Calculation
Percent of heat at back-end (SF)
Temperature burner inlet Axial (Tax) Is Sw
Temperature burner inlet Radial (Trot)
Temperature burner inlet Transport (Ttran)

X/TPP/Rt/ALLGEBERE/393694230.xls/Sketch 08/03/2018
 Data logging system
Kiln feed
{kiln output (Pofen)}

X/TPP/Rt/ALLGEBERE/393694230.xls/Sketch 08/03/2018
 Fuel Charac

Fuel characteristics (dry basis)

Coal coke Blend

% 0% 100% 100%

% volatiles 26.06 4.73 4.73

%C 64 91.3 91.30
%S 0.71 1.88 1.88
%H 3.05 3.69 3.69
%O 6.9 1.64 1.64

LHV (BTU/lb) 11763 14617 14617

LHV(Kcal/kg) 6535 8121 8121
LHV(kJ/kg) 27361 34000 34000
LHV(kcalkg) 6,546 8,134 8,134

Page 9