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Chapter – 1
Preheater
Amount of Water spray for cooling gas can be calculated as mentioned below:
Where
ΔT = gas cooling, 0C
Tw = water temperature 0C
volume or 1% increase in O2
content
Air leakage between two points in the kiln exhaust system can be
Where G1 = initial O2 %
G2
= final O2 %
Chapter – 2
Kiln
% m/s = Lp % x C
Where :
Model calculation:
Axial A1 = 0.0101 m2
Radial A2 = 0.0075 m2
Air flow at Burner tip:
= 5397 Nm3/hr
= 2754 Nm3/hr
Lower Primary Air Momentum causes longer flame & high kiln shell
tip :
– Feed of solid fuel (kg/s) divided by the transport air flow in duct
(m3/s)
(acceptable)
the area of the solid fuel injection channel at the burner tip.
Assume a typical bituminous coal with ultimate analysis (as dried basis)
C 80.0%
H 5.0
S 1.0
O 5.0
N 0
Ash 8.0
under:
Or 0.222 Nm3
Or 0.835 Nm3
CO2 from calculation of raw meal to yield 1kg clinker (assuming kiln feed
LOI of 35%)
H2O)
Upper limits and lower limits of Gas velocities at different areas in Pre
a) Upper Limits:
m/sec
Hood 6
Riser 28
b) Lower Limits:
m/sec
Tertiary duct 30
Chapter -3
Cooler
(m2)
grate wear)
Installed specific cooling air volume < 2.0 Nm3/Kg cli (for new coolers)
(Kg/hr)
-Vent air take off velocity < 5 m/s For new installations
respective location.
3.2 Cooler recuperation efficiency:
Where
R = Cooler radiation
Typical efficiencies:
Chapter – 4
• 1 dm3 (Liter) = 10-3 m3 = 0.03532 ft3 = 1.308×10-3 yd3 = 0.220 Imp gal
1 L liquid
C3A = 0
> 30 indicates heavy unstable coating, rings & snow men4.5 Burnability factor8:
(ie calcite)
feed
Q = 4.11 Al2 O3+ 6.48 MgO + 7.646 CaO – 5.116 SiO2 – 0.59 Fe2O3
Kiln feed to clinker factor = Raw meal to clinker factor/ (1- DL/100)
Concrete was damaged in cases where alkali content of the cement was
more than 1%. Highest admissible alkali content in cement is 0.6%. with
0.9%. further total alkali of limit of 2% is allowed for cement with slag
More than 25% kiln bypass volume has negative impact on the Kiln heat
% R 90 μm ≤ 0.5 * (% volatiles)
% R 212 μm ≤ 2%
could be as below:
% R 90 μm ≤5 %
% R 212 μm ≤1 %
%R 212 μm ≤1 %
factor, which is the ratio between inhomogenity before and after silo.
Where
H = Homogenising factor
Obtained result:
When the true homogeneity of the kiln feed is less than 1% LSF,
be achieved.
Chapter 5
5.1 Introduction
of fluids and gases with the surfaces used in engineering. CFD analysis
heat, mass transfer, phase change and chemical reaction, etc. using set
that time are operating close to its design limits in the current scenario
optimum cost.
CFD study was conducted to pinpoint high pressure drop zones in ducts
& cyclones by several cement plants. Benefits from CFD study are
temperature
that it can be optimized the use of materials, tools, shape, time and
can be a big driver for reduction in Pressure drops and there by Energy Savings.
Pre heater exit temperature in Cement plants is higher than the standard
value during the steady operation also. In a plant It was observed that
PH exit temperature is 3100C for similar stage Pre heater. This indicates
Benefits:
cyclone efficiency:
Pre heater exit losses play a major role in specific thermal energy
Pre heater dust losses depend on the efficiency of top stage cyclone.
Modern cement plants are operating with top stage cyclone efficiency
preheater.
Benefits:
possible.
this project i.e the installation of flow diverter plates inside the ducts.
2. Phase 1:
-Mesh generation
– Solution
♦♦ Mesh generation
♦♦ Solution
♦♦ Post Processing
SECTION 2
Case Studies
Chapter 6
In Cement Plant
6.1 Lower dispersion box height in riser duct and increase heat transfer in Preheater
The Preheater system is one of the major areas for potential reduction
system is to recover maximum heat from the kiln exhaust gases and to
Maximum heat transfer between the kiln feed & calciner exit hot gases
takes place in the riser ducts. In the Preheater cyclones, the separation
of feed material and hot air takes place. The feed material is then fed
to the lower cyclone and the hot air moves to the higher elevation
cyclone.
Almost 80% of the entire heat transferred from the hot gases to raw
ducts, the feed pipe from the higher stage should be lowered as much
as possible.
This increases the heat transfer between the hot gases and feed material
in each stage, before they are separated in the cyclone. This will result in
The optimum point of feed inlet to the riser duct is at 1.0 m height from
Most of the Cement plants modified the dispersion box height and
Benefits:
Conventional Burner:
-The exit speed obtains a fixed velocity at the tip of the burner
during operation.
– This will not help the kiln operator as necessary “tool” to quickly
Multichannel Burners:
momentum will make the flame longer and lazier. Swirl will help
stabilize the flame and give a short ignition distance. Too much
swirl however can cause high kiln shell temperatures due to flame
nozzles.
refractory.
-This will in all cases provide the kiln operator with the necessary
into the primary air (i.e into the main burner); utilization of oxy-fuel
burner in addition to standard air – fuel burner and oxygen lancing into
the rotary kiln (between the load and the flame) for improved flame
characterstics.
Primary air limits the oxygen capable of being introduced into kiln (only
5-10% of the total air used as primary air). Oxygen enriched air in fuel
prior to its arrival into kiln’s combustion space can burn too early and
400 to 9000C. From figures oxygen is injected into the air before entering
the systems blowers . The oxygen enriched air can split between burner
oxidant inlet and the clinker cooler oxidant inlet. Oxidant enriched air
then allowed or cause to flow into the kiln chamber and pre calciner as
conventional methods.
The most common type of clinker cooler used in Indian cement industry
and desired clinker temperature, the amount of air used in this cooling
cooler, this corresponds to a total loss of about 120 -150 kCal/ kg clinker.
stands at less than 100 kCal/ kg clinker and has recuperation efficiency
in excess of 75%.
Benefits:
Replacement of Kiln inlet pneumatic seal with Graphite seal gives the
following adavantages.
Advantages:
maintenance
– Prevents false air into the kiln and ensures pressure stability in
kiln
Principle:
-Graphite plates are held in contact with circular bearing with help
tight ness
Benefits:
particularly higher early strength, more and more C3S is being targeted
in the raw mix. Ideally speaking, LSF is desired in clinker such that the
with the other constituent oxides of clinker viz. silica, alumina and iron.
OPC clinker with lower LSF values are produced with low grade limestone
mix with lower LSF require lower burning temperatures and the same are
The main disadvantage of OPC clinker with low LSF compared to OPC
clinker with higher LSF is the reduced content of Alite and relatively
the output of the mill. Since the grindability of the clinker will depend
due to relatively lower LSF and thereby corresponding low CaCO3 content
of raw mix
etc.
kiln
-Oxides, (viz., B2O3, Cr2O3, CuO, ZnO, MgO, MnO, TiO2, etc.)
Recent studies carried out have established that copper slag, a waste
1,4500C.
• Process adopted;
availability;
Benefits
Manufacture:
properties of input fuel & feed materials diversely varying and product
are therefore vital for achieving optimum results and lower costs of
manufacture.
monitoring of the raw mix composition with the help of X-ray analyzer
control over raw mix. The analyzer quickly and reliably analyses the
corrective mechanism is not as per the requirement (or set value), the
itself to meet the system fluctuations and keeps improving with time.
Benefits:
installations for disposal of industrial wastes through co processing route in an environmentally sound
manner.
temperature up to 1400oC)
• Oxidizing atmosphere
• Alkaline environment
The use of waste as alternative fuels and raw materials in the cement
iron ore etc and non-renewable fossil fuels such as coal. This also
natural materials.
final residues.
landfills.
energy is used directly in the kiln for clinker production and the noncombustible
part of the waste becomes part of clinker.
includes
1. Plastic waste
2. ETP sludge
3. Risk husk
4. Coal dust
5. Tire chips
operation, build-ups in the kiln riser ducts and higher SOx, NOx, and CO
emissions.
Latest dry process plants with state of the art technology however
has many controlling facilities and equipments like low NOx burners,
accuracy & control that enables the cement plants worldwide to achieve
PAT scheme:
As per the current version of BEE PAT scheme any alternate fuel used in
energy consumption.
Say a plant with Average thermal SEC for baseline years 2007-08 to
2009-10
Rotor weigh feeder is highly accurate and reliable gravimetric feeding of pulverised fuel.
Benefits:
rounds per minute. The only moving part, the rotor itself, is made
rotor.
5.Eliminated CO-peaks
6.Reliable Feeding:
Installation of Rotoscale for Kiln coal and PC coal firing will result
in atleast 2 kCal/Kg clinker thermal energy.
Sampling of the material either the crushed lime stone or the raw meal
(input to the kiln) is done to maintain the stockpile quality and control
the chemistry of the raw mix thereby the chemical composition in the
quality control methods where the samplers installed does the sampling
for a few grams of material collected from large quantity of the material
samples and the analysis, results in time delay and manual error. This
results a lag time in doing the corrective measures for changing the
chemical composition and thereby affects the clinker quantity and the
energy consumption.
the materials and can take the corrective actions much quicker when
be installed either in the upstream of the stock pile and or before the
raw mill. The former option helps to track the cumulative chemistry
of the pile thus allowing the operator to direct haul trucks to different
sections of the quarry in a way that it will result in the final elemental
composition of the pile close to target. While the installation before the
raw mill can monitor the chemistry of the raw mix and automatically
Benefits:
Overburning causes
2. Reduced production
minerals.
Benefits:
process engineers are able to construct control regimes that allow the
A modern cement kiln at present operates with 6 stage pre heater suitable
precalciner system with tertiary air ducts and highly efficient burning and
or optimum cost. In order to keep pace with the present scenario where
lining scheme and its performance in a cement rotary kiln system For
In general practice in the kiln 40% Alumina brick lining will provided
1.4 W/m.K (at 12000C hot surface temperature). Resulting in Kiln surface
Because of high surface temperatures, The heat loss through the surface
is high. The radiation loss from Kilns will be 25- 35 KCal/Kg clinker, which
is in higher side.
Thermal energy savings are possible by replacing these bricks with low
thermal conductivity Bricks. Replacing the 40% Alumina bricks with low
helps to maintain Kiln shell temperature less than 2500C in the Kiln inlet
area.
Benefits:
plant for replacement of power input to the plant will not be considered
CHAPTER 7
7.1 Introduction:
exhaust gas and cooler exit air. Depending on the number of stages
in the pre-heater and the type and technology adopted in the cooler
section the temperature in these gas streams vary from 200 0C to 360 0C
/400 0C.
If the moisture content in the raw material such as limestone, fly ash is
-Rankine Cycle
-Kalina Cycle
Both the Rankine cycle and Organic Rankine cycle plants are being
The Kalina cycle which is more efficient of all the three, is under
-PAT benefits
Many of the cement plants in India / world have taken up this initiative
The graph shows the recovery of heat from various technologies for the same preheater outlet
temperature of 316 Deg C (5 stages). Cooler exit gas is considered as the preheating source in
combination with the preheater waste heat recovery boiler and hence 33 % heat recovery is considered
for cooler air for all the systems.
Most the clinker manufacturing units in India have 2 and more kilns in
the same location or site to meet the clinker demand. It may be noted
that though the heat availability in individual kiln / cooler may be less,
the total heat availability in the locating including all the kilns may work
coating over the heat transfer areas in the Waste Heat recovery .Boiler which in turn will affect the
efficiency of the cycle.
Preheater.
-Reducing the aeration velocity at the top of clinker bed in the case of cooler by increasing the grate
area or maintaining optimum
cooler loading.
– Carefully designing the WHRB such that the gas velocity is within acceptable range.
7.3 Estimation Of Waste Heat Recovery Potential
c. Temperature TC : 3000C
14. Heat requirement for moisture in raw mill & Coal mill: 950 kCal /
kgwater
Heat available in the PH gas minus heat required for Coal mill & raw mill
Excess heat available (preheater) : 170.6 – (29 + 33) : 108.6 kCal / kg clinker
7.4 PAT Benefits:
Chapter 8
the flue gas at various points such as before air preheater, and after APH
indicates that there is air leakage into the system. The leakage estimation
The quantity of air leakage into the flue gas path is about-31.12 %.
This air leakage into the flue gas path leads to further reduction in flue
the low temperature end corrosion and further increases the leakage
level. The air infiltration also leads to increased load on the ID fan and
hence increases ID fan power consumption.
in the APH. This will also results in marginal reduction in ID fan power
consumption.
Periodically monitor the O2 level in the locations like before the air
preheater, after the air preheater and after the ESP. Reduce the quantity
of air infiltration in the ESP by improving the sealing. Cover the expansion
joints with materials like thermofabric etc. Check for leakages in APH tubes.
-The steam consumption is estimated indirectly by measuring the quantity of water flow and the
temperature difference across the ejector condenser. The detailed calculations are given in the backup
sheet.
ejector is:
♦♦ TG : 1.00 TPH
the water flow through the condenser and the temperature difference
heaters, one Deaerator feedwater heater and four LP heaters to heat the
boiler feed water at various stages. The order of heating is as follows:
Condenser gLPH-1gLPH-2gLPH-3gLPH-4gDEAgHPH-5 g
HPH-6gECOgBoiler
design.
The design work output, heat (( rate and overall system efficiency of
♦♦ Turbine = 55.01 MW
-The operating work output, heat rate and overall system efficiency
♦♦ Turbine = 49.63 MW
valves
for higher heat rate. Two basic parameters are required for any
temperature.
-The design and operating parameters of DCA & TTD of all the
of 232.70C.
outlet, the flue gas temperature at the boiler outlet may increase,
operation.
-Check the status of drain valves, drag valves and control valves to
a pressure of 95 kg/cm2.
0.2 ppm.
-In the four boilers installed, continuous blow down is practiced.
from the blow down are being vented out in atmosphere and the
– There is a good potential to recover flash steam from boiler blow down by putting flash vessel. The
flash steam from the CBD vessel can be utilized in the deareator.
Bi Fuel Conversion :
Conversion of Diesel Engines to Bi Fuel (two fuels at the same time Diesel/
With Bi-fuel conversion of the standard diesel engine the actual dieseling
process must be always maintained. No Bi-fuel kit can replace 100% of the
The natural gas will be introduced to the engine cylinders for the Bi-fuel
conversion and used as the substitute fuel for the generation of cylinder
power.
automatically:
Bi-fuel conversion requires virtually no engine modification and brings double benefits in every
application:
– Affordable diesel engines combined with inexpensive natural gas
engines
payback period.
4 MW Engine Block Cooling Jacket Hot water based Chiller Capacity : 130 TR
Hot water generation from engine waste heat and use the hot water for absorption chiller to use in air
conditioning application / cold storage.
8.5.4 Know the Fuel Oil Quality and its effects on Engine:
High dirt matter: Increased wear and tear and increase in specific fuel
consumption.
High Sulphur : Increased wear and tear and increase in specific fuel
Section 4
Latest Developments
In-Line Calciners:
emissions.
from the second lowest stage between the calciner and the kiln riser.
This material split is also used to control possible build-up within the
kiln riser. Above the reduction zone is the main calciner vessel, which is
effective mixing of fuel, raw meal and gas, improving heat transfer and
combustion.
The calciner outlet loop duct ensures optimum gas retention time,
third-lowest stage cyclone material can be further split to allow for diversion of a portion of the meal
directly into the upper section of the
calciner. This creates a “hot zone” in the lower section of the calciner
solid fuels.
zone which lowers the NOx content of the kiln waste gases.
The reducing gas strand from the LowNOx zone is united with the
oxidizing gas strand and later intensely mixed in the PYROTOP® compact
substituted
The reducing gas strand from the Low NOx zone is united with the
oxidizing gas strand and later intensely mixed in the PYROTOP® compact
swirl chamber. Due to this turbulent mixing, the remaining CO oxidizes to CO2 with the oxygen present
in the gas stream. The use of lumpy
– staged combustion
– Emission level: < 500 mg NO2/Nm3 with gas,oil, lignite and most
kind of coals
Static inlet:
The HE-Module opens up from the kiln drop point to the transport lanes
while also ensuring a protective clinker layer on the module itself. The
HE module is aerated via independent zones, each zone has it’s own flap
to adjust the air volume. Due to the flexibility of the air distribution, it is
possible to control the kiln discharge conditions even with the changing
fluctuations.
Transport System:
The η-Cooler uses a transport system that is unique to any of the present
coolers. The transport is based on the well proven ‘moving floor’ system
that has long been in operation for materials handling. The η-Cooler
independent rollers.
aerated lanes), the flow behaviour and material speed at the sides can
be actively influenced. The slots for the air supply are integrated in
the transport lanes by utilizing the Mulden grate plate principle Each
need for a dust removal system. This together with the fact that the
Aeration Concept:
Since no installations are required inside the clinker layer the entire
the η-Cooler allows for a longitudinal division into chambers. This gives
at the critical side areas of the cooler. With Chamber Side Aeration (CSA)
Features:
Benefits:
-High reliability
Advantages:
– No sealing air
– No fall-through of clinker
– Easy operation
– Easy maintenance
against heat and wear, so the plates will remain in service for a long
system effectively convey, mix and shear the clinker while at the same
time preparing the clinker for efficient exposure to the cooling air.
cooler grates, but gradual wear of the cross-bars has no effect on cooler
which regulates the airflow to each plate via a self-adjusting orifice. The
MFR maintains a constant airflow through the air distribution plate and
temperature, etc.
If for some reason the restriction of airflow through the clinker layer
without any electrical controls. The MFR prevents the cooling air
from taking the “path of least restriction”. This helps to optimise heat
The air distribution plates of the SF Cross- Bar Cooler are characterised by low pressure drop. The MFR
system adds little to the pressure drop
during normal operation, due to the large orifice area. So the undergrate
when fitting the modules side by side together. The SF Cross-Bar Cooler
Modular concept
are preassembled in the workshop to ensure high quality and swift and
The drive plate penetrates the grate line via two slots, which extend
the need for a dust spillage conveyor. The sealing profiles extend
throughout the entire cooler length, which means that during the
requirements, etc.
Process improvements
The SF Cross-Bar clinker cooler concept features improved thermal
clinker
Easy maintenance
The number of wear parts has been minimized through the simple
design of:
-Cross-bars
– Retainer brackets
– Sealing profiles.
Grate plates are no longer considered wear parts. All wear parts in the
Advantages:
– Automatic operation
– Less maintenance
HUMBOLDT WEDAG grate coolers with capacities over 5000 t/d have
than 400 rotary kiln cement plants has led to the development of the
ensures that the clinker is uniformly distributed over the full width of
the cooler.
The thermal and mechanical stresses imposed on the step grates are
Zone II
omega plates for aeration in rows. These plates have small pockets in
The lip of the omega plate is also cooled with air to extend the service
cooling air to the moving rows via rigid pipes, thus making hoses and
Zone III
the advantages of a step grate can be fully utilized, even at high clinker
throughput rates, without the risk of clinker flushes.
Zone IV
This is also equipped with omega plates (similar to zone II). The length
Zone V
cooler housing
The sintered clinker leaves the outlet of the kiln with an estimated temperature
of 1400°C and drops onto the static inlet (clinker inlet distribution system),
referred to as KIDS (Fig.1), where the clinker is initially cooled and conditioned
being movable. The clinker bed, 550-650mm deep, travels past the middle air
offtake which is located separately behind the kiln hood. Typically middle air
After travelling the total grate length the clinker temperature will have been
when it falls onto the roller crusher. The crusher has three to six rollers with
Each crusher roll is driven by an electric motor with bevel planetary gear.
After crushing the clinker maximum grain size is 25 x35mm and it leaves the
cooler via a chute which discharges the clinker onto the clinker conveyor for
The Coanda Nozzles of the pendulum section are formed by several blades
which are inserted into a common supporting frame. The curved air
openings between the blades generate the desired horizontal Coanda jets
(Fig.4).
Fig. 4: Coanda-effect
The surface of the frame is completely covered by the blades to form a grate
frame is not subject to wear.The blades are loosely interlocked into a base
frame and are free of mechanical and thermal stress. This is crucial as it
The blades are made as hard as the clinker, significantly increasing the
service life of the grate surface. While each cooler has thousands of such
blades, only single blade replacements have been reported.
The IKN KlDS (Fig.5) distributes the clinker evenly across the grate width and
conditions the clinker bed to improve its air permeability. The inclined slots
of the Coanda Nozzles generate horizontal air jets which pressurize the
bottom layer of theclinker bed. The air jets become vertical upon striking
against clinker particles and uniformly penetrate the clinker bed. Fines are sifted out of the voids
between larger particles and accumulate at the surface where they fluidize.The bed voidage in each
layer within the clinkerclinkebed bed is maximized. The main features of the IKN KIDS are:
– Improved recuperation
The high degree of precision in design and fabrication achieved with the
and stationary rows. This requirement was solved by the LPS support of the
movable structure. LPS is short for Linear Pendulum Support (Fig.6), IKN’s
constant gap width at all times. The LPS is the advancement of IKN’s
blades making up a compact unit with dimensions of 1.3 m x 1.6 m.This makes it easy to place it
underneath the grate or integrate it into the cooler
housing.
The LPS had to perform a 1.5 million stroke test run with a simulated clinker
bed.The optimum layout and its durability were confirmed by various tests ‘
and calculations. The first installation has been in operation since April 2003.
The effective conditioning of the clinker bed on the KIDS and the efficient
This is created by narrow, inclined and curved slots (Fig. 3a/b). They
generate sharp jets of air with high dynamic pressure horizontally in the
transport direction of clinker. The Coanda effect forces the jets to curve
parallel to the surface of the grate plate instead of following the direction of
the slot. Fines are swept to the clinker bed surface and the Coanda Nozzles
elimination of air ducts and the return to compartment aeration after the
are the very high clinker bed transporting efficiency and strict separation of
and efficient cooling of all particle size fractions over the entire
conditions
other. Between them the cooling air enters the bed of clinker. The required
width of the cooler determines the number of transport track rows. Each row
To convey the clinker bed the transport tracks are moved forward together
and are then individually moved back. By varying the transport stroke length
and frequency, the conveying speed of the clinker bed and thus the clinker
bed depth and the clinker throughput can be optimally controlled over the
the best preconditions for thorough cooling of all particle size fractions.
Aeration concept:
„cooling air distribution in the clinker bed“ are strictly separated from each
The air distribution takes place via static aeration units located between the
transport tracks. These large-area pockets integrated in the aeration floor are
permanently filled with clinker and thus provide autogenous wear protection.
Wear of the transport tracks is minimal, due not least to the robust design,
Sealing concept:
Special, wear-free sliding element pairs reliably seal the few contact zones
the grate. This is a further advantage with regard to minimizing the overall
height.
The modules are 4.8 m or 7.2 m long and available in widths of 1.5 m/2.0 m
and 2.5 m. With small module dimension steps – of 0.5 m over the width and
only 2.4 m over the length – it is possible to precisely design coolers to suit
optimum alignment of the transport tracks and aeration units, saving time
and effort at the plant site, shortening the installation and commissioning
periods and, in the case of conversions, also reducing the plant downtime.
The highly effective clinker bed transportation principle, there is no need for
design.
Despite the limited installation height, it is still possible to install a roll crusher
The intermediate crusher, the cooling process on the second grate is optimised,
reducing the ultimate clinker temperature and thus also producing higher
cooler exhaust air temperatures. These higher exhaust air temperatures have
a decisive influence on the operating economy of cooler waste heat utilisation
systems (e.g. heat utilisation for power generation; heat utilisation for drying
etc. The exposed hot interior of the clinker broken by the intermediate roll
crusher is effectively cooled on the second grate and the extracted heat is
Petcoke is characterised as a high grade fuel with high calorific value of more
than 8,000 KCal per kg, having low ash content and low volatile matter but
Petcoke provides scope for manufacturing higher grade of cement with the
same raw material or same grade of cement using marginal and low grade
However, as the sulphur content in petcoke is high, its larger use increases
the sulphur cycle and aggravates build-up formation in the kiln system. The
total sulphur content in the clinker needs to be maintained below 2 per cent
from product quality point of view. For using petcoke in the cement industry,
there is, therefore, a need for changes in raw mix design and finess of fuel and
Recent studies have shown that fuel costs can be reduced by promoting the
use of petcoke. Fuel alone accounts for about 40% of the cost incurred by the
cement industry.
Alternate fuels like petcoke can reduce fuel costs to a great extent. Studies
shows that green delayed petcoke is suitable for use in calciner, fluid petcoke
Petcoke should be used when the plant is equipped with multi-chanel burner,
when alkali deposits are high, when there is a margin in coal milling capacity
and primary air fan quantity and when riser duct is fitted with coating repellent
refactory.
Studies form the plant 1 and plant 2 shows that almost more than 80% of the
fuel is pet coke only. These plants changed their raw mix design analysis of the
changing the raw mix design. Multi channel burner is used to fire pet coke and
less then alkaline Feldspars added as an additive to fire higher amounts of pet
Some of the plants are operating with 100% fuel as pet coke without any