Nitric oxide emissions can be reduced as combustion rates are improved.
A rotary kiln, often used the production of gray and white cement, lime and nickel, as well as in waste management, can be optimized successfully in terms of its combustion rate. Kiln simulations offer an experimental way of predicting which changes of the kiln's structure, temperature, burner position and flame shape will result in enhanced combustion in real world applications, many of which have been tested with measurable increases in combustion rate and burn efficiency.
Instructions
1. Increase the air flow to the burners to create a smoother combustion process. Improve the symmetry of the flame inside the burner for more efficient combustion. Distribute the air flow more evenly around the combustion chamber. Simulations show that the influence of combustion air distribution is very large and offers an excellent way of increasing the incident radiation received by the clinker bed, according to Fives Group.
2. Add hot, secondary air to the flame inside the combustion chamber to increase the temperature of the flame and to radiate more heat towards the calcinated bed. Install a modern replacement burner with temperature distribution capabilities. Keep the hot gas primary inflow temperature at 550 degrees Celsius. Measure temperature using a heat-resistant probe. Ensure the cooler, secondary air channel remains constant at 20 degrees Celsius. Measure the tube connected to the kiln hood using a tape measure. Replace it with a 315-feet long stainless steel tube if it is not the correct size.
3. Reduce the velocity of air flowing through the hood if the flame is unstable using hot and cold perforated plates. Increase the velocity if the flame is too small by inserting plates with larger perforations. Avoid badly distributed air velocities using a flow correction device. Random, unchecked distributions cause fragmentation of the ideal, single air channel, resulting in turbulence inside the kiln hood, and later, a flickering flame in the chamber with poor radiation to the bed.
4. Determine the reaction zone, which is where the majority of fuel gets burned. Balance the flue gas to give a temperature and velocity profile at the outlet point by adding extra secondary injectors to the auxiliary burner. These will be above the first level injectors, which will result in droplet optimization within the kiln. A two-level injection process is adequate.
5. Use coal to power the burner and set the secondary air temperature to 800 degrees Celsius, because these parameters give the most optimized processing result. Pulverized coal improves combustion in coal-fired plants, such as rotary kilns, by raising the steam pressure and temperature, enhancing the air flow and distribution and improving the loading capacity (which is the rate and efficiency coal is loaded into the mechanism and heat is produced by the mechanism). According to the Clean Coal Center, the coal must be pulverized into a fine powder so less than 2 percent is 300 micrometers and 70-75 percent is below 75 micrometers in diameter.
6. Alter the kiln dimensions by replacing the combustion chamber. Reduce the size of the chamber if the burner is receiving an unstable air flow. Expand the dimensions of the chamber if the internal area is too small to take in enough air for steady combustion. Centralize the position of the burner inside the kiln to aid flame distribution and improve combustion. Starve the system of oxygen if you want to rapidly reduce burn times, but consider the compound implications, such as if a sudden lack of oxygen will detrimentally affect other parts of the process, including air draw and distribution. A starved kiln can handle an extra 10 tons of waste, as described by the Drilling Waste Management Information System.
7. Use a simulator attached to a computer to measure the difference in combustion due to your changes to the flame geometry, chamber size, air flow distribution and fuel usage. Alter the parameters further using a trial and error method to fully optimize the processing power of the rotary kiln. Ask a professional simulations engineer to advise you which parameters need adjusting if you are not sure at any stage of development. Aim for a narrower temperature profile with reduced static temperatures, to illustrate an enhanced, more efficient system overall.
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