Directions

1) Input Fuel characteristics

2) Input kiln production data
3) Determine (goal seek) transport air flow rate : 5 kg/m3 for blower, 7 kg/m3 for pump
- vary the transport flowrate - Nm3/h
- note that blowers cannot take the higher material density rate
4) Obtain optimum or target flow rates values (swirl & axial)
For a first calculation, start with static pressures of 40.000 Pa for axial, and
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
the swirl static pressures. Add constraints on the axial pressure (35.000-60.000 Pa),
and to the swirl pressure (>18.000 Pa if fan, 20.000-30.000 Pa if blower).

6) Once the barrel is complete, adjust the tip cross sectional areas
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
diameter and the width of groove for the swirl.
7) Optimise static pressures at tip, tip cross sectional area and all other
constraints. Obtain the best balance for:
Target of Is = 1.8 and Sw = 0.15,.
Optimum flow rates
8) Confirm choice of fan or blower for swirl air based on static
pressure in the tip - choice effects bias coefficient
9) Determine range for blowers: maximum for (Is,Sw)=(1.8,0.15), and
minimum for (0.9,0.05). Check that , doing this, we stay in the range
of 7 to 12% primary air.

Note the optimum flow rates as well as cross section areas (mm2)
Ultimate target is Is = 1.8 and Sw = 0.15.
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
18 to 22 vanes (or slots), 8 mm depth minimum
No straight stream through the swirler = long enough
2) Transport: Velocity in tip and barrel: 25 to 35 m/s
radial gap of annulus > or = to 10 mm (concentricity, plugging)
A slight reduction of the cross section area is being done at the tip, for
a better fuel distribution around the annulus (automatic)
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

Transport design: drawing instructions

Maximum angle of inlet = 12.5 degree with the burner axis
Enter from the top (better distribution)
Inlet rectangle: Internal width should be equal to internal
diameter of outer pipe of the fuel annulus. The velocity
should never decrease from the fuel intoduction into the line
to the burner tip. (Settlement)

Page 1

318388865.xls

SWIRL AND MOMENTUM DETERMINATION

Original: CLV / S.THIERS
Update: CTEC / H. REITERER

COMMENTS :
Plant altitude:

Apr-95
Oct-00

PLANT : HOG
Date : 28-Aug-06
Name : Lucian Calinoiu

480 m

Atm. Pressure :

Err:511 mmH2O =

Err:511 mmHg =

TIP CROSS SECTION AREAS

Diameters :

% cross section reduction

(mm)
523.0

AXIAL AIR
Holes 1, Vanes 2 :
9123

1
mm2

TRANSPORT AIR
38600

Err:511 Pa

8.5

### m/s

471.0

77.5%
12.5

23 m/s

446.0
387.0
343.0
311.6

22

### m/s

Err:511 m/s

47.1%

Err:511 m/s

mm2
265
DETAILS OF THE TIP
Swirl
Axial (if vanes)
Axial (if holes)

GENERAL DATA
Kiln TYPE :

23.3

Swirler
angle (o)
35
-

thk :

Number
of vanes
16

Number of holes :
Pitch cirle (mm):

24
497

slots
width(mm)
33.0

524

470.0
446
387.0
362

298.5

7.1

284.3

radial gap
vanes(mm)
0.5

radius
raccord.
1

22.00
65.06

Production (t kk/d) :

NP : no preca, AT : air through, AS : air seperat.

85.14
3.26
3.70

SPECIFIC HEAT CONSUMPTION

AT THE BLAST PIPE
Petcoke
textile
PVC
wood

%O
NCA
Nm3/kg fuel

Throughput
t/h
14.30
0.00
0.00
0.00

3660

Specific heat consumpt.kcal/kg CK :

840

Swirl Air: F=Fan; B=Blower

FUEL ANALYSIS, AS FIRED (DRY BASIS)

%C
%S
%H

groove width
(mm)
27.0

Diameter :
Spacing (mm):

NP

540.0

Err:511 Nm3/h
Dext :
thk :
12
Dext :
thk :
12.5
17,839 Pa
Err:511 Nm3/h
Dext :

23.2 m/s

mm2

SWIRL AIR
7000

Dext :
thk :
76,694 Pa

2.70

Percent of heat at back-end :

SR (%) :

8.50
8.50

8.58

L.H.V.
Kcal/kg
8195
3600
6000
4000

Total (Gcal/h) :
GAS FLOW MEASUREMENTS
Static pressure in the tip (Pa)
Temperature in the pipe (deg C)
Theoretical flow rate (Nm3/h)
Bias coefficient :
Accepted flowrate (Nm3/h)

Axial
76,694
103
Err:511
0.77
Err:511

Swirl
17,839
33
Err:511
1.00
Err:511

Axial / Swirl distribution

Err:511

Err:511

Total combust. air (Nm3/hr) :

140,804
Therm.power Total combust. air (Nm3/kg kk) :
0.923
Gcal/h
Shell internal diameter (m) :
5.80
117.21
0.00
0.00
0.00
Recalculated SHC :
117.21
Transport
1,000
20
-

840

kcal/kg CK

Fuel to air ratio:

3000

4.44
7 for pump
5 for blower

kg/m3

Swirl
Err:511
0.15
0.15
0.15

RESULTS
Axial

Swirl

Transport

Nature of flow

Err:511

Err:511

velocity

Release tip velocity (m/s)

Err:511

Err:511

23

Is
Nh/Gcal
Err:511

Targets:

Fuel-Oil
Coal
Coke

5.0
6.3
7.5

FLOW VELOCITIES

Primary air rate, axial :

swirl :
transport :
Axial + Transport:
Primary air rate

Lucian Calinoiu

Err:511
Err:511
2.13%
Err:511
Err:511

THERMAL LOAD (MW/m2) :

Page 2

05/18/2016

5.94

318388865.xls

Lucian Calinoiu

Page 3

05/18/2016

318388865.xls

SWIRL AND MOMENTUM DETERMINATION

Original: CLV / S.THIERS
Update: CTEC / H. REITERER

PLANT : HOG
Date : 28/08/2006
Name : Lucian Calinoiu

DETAILED RESULTS
GEOMETRY
Height of spacers/blades (mm)
Width de fraise d'usinage (mm)
Width of blades in front (mm)
Surf. masque par les raccords
Surf. apparente de sortie (mm2)
Exit effective area (mm2)
gyration radius(mm)

Axial

9123
8849
-

Swirl
15.2
27.0
34.2
7
8546
6790
164

Transport
38600
-

DETENTE
massic flowrate(kg/s)
exit volumic flowrate(m3/h)
specific gravity in the pipe (kg/m3)
specific gravity at the B-tip(kg/m3)

Axial
Err:511
Err:511
Err:511
Err:511

Swirl
Err:511
Err:511
Err:511
Err:511

Transport
1.078
3220
1.205
1.205

Velocity in the burner pipe (m/s)

Velocity at the nozzle (m/s)
Expansion velocity (m/s)

Err:511
Err:511
Err:511

Err:511
Err:511
Err:511

23
23
23

Axial momentum (N)

Impulsion normale (N)
Rotation Momentum (N.m)

Err:511
0
0

Err:511
Err:511
Err:511

25
0
0

Momentum Equivalent Diameter :

Flow-type:
Expansion velocity (m/s)
Axial primary air ratio: :
radial:
transport :
Total :

Err:511

Axial

Swirl

subsonique

subsonique

Err:511

Err:511

Err:511
Err:511
2.13%
Err:511

Targets:

mm

Is
N.h/GJ
Err:511

Err:511

5.0
6.3
7.5

0.15
0.15
0.15

Fuel-Oil
Coal
Coke

Swirl

MEASUREMENTS-CROSSCHECK BY ENERGY CONSERVATION

Axial
Err:511
Err:511
Err:511

E gases into the nozzle (KJ/kg)

E gases at the exit (KJ/kg)
E/E (%)
Geometry of the swirl body
Radial gap (mm) :

0.5

Height of blades (mm) :

15.2

Slot width (mm) :

33

Swirl
Err:511
Err:511
Err:511

Transport
294
295
0.1

312
343
Groove width (mm) :

27

35

Minimum lenght of swirl body (mm) :

Lucian Calinoiu

91

Page 4

05/18/2016

318388865.xls

5.11

Lucian Calinoiu

Page 5

05/18/2016

318388865.xls

Lucian Calinoiu

Page 6

05/18/2016

318388865.xls

Lucian Calinoiu

Page 7

05/18/2016

Algorithm for burner control

Data`s burner Kujawy
Effectiver exit area Axial (Aa)

8849 mm2

Effectiver exit area Radial (Ar)

Effectiver exit area Transport (At)
Blade angle
gyration radius (Rg)
Temperature burner inlet Axial (Tax)
Temperature burner inlet Radial (Trot)
Ambient temperatur (Tu)
Temperature burner inlet Transport (Ttran)
Axial pressure after blower (Pax)
Axial pressure burner Pax1
Radial pressure after fan (Prot)
Radial pressure burner Prot1
Axial air (Qmeax)
Radial air (Qmerot)
Transport air (Qtran0)
Spec. heat consumption kiln (Qkiln)
Output kiln (Pkiln)
Percent of heat at back-end (SF)

Thermal power of the burner (Pth)

6790
38600
35
0
20
35
20
75
487
487
128.99
128.99
1421
1094
3000
840
3660
8.5

mm2
mm2

m
C
C
C
C
mbar
mbar
mbar
mbar
m3/h
m3/h
Nm3/h
kJ/kg kk
t/d

Konstant
Konstant
Konstant
Konstant
Konstant
Measurement
Measurement

I=
Sw =

0.86 N/GJ/h
0.074

Konstant
Measurement
Measurement
Measurement
Measurement
Measurement or from curves
Measurement or from curves
Konstant
From the Reporting
From the Reporting
From the Reporting

= 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
ROrot0

= 1,293 * (101325 + 100*Pax1) / 101325 * 273 / (273 + Tax(e))

= 1,293 * (101325 + 100*Prot1) / 101325 * 273 / (273 + Trot)

1.330 kg/m3
1.292 kg/m3

Density of the air at the burner nozzle

ROax1
ROrot1
RO tran

= ROax0 * (101325/(101325+100.Pax1))^0,7143
= ROrot0 * (101325/(101325+100.Prot1))^0,7143
= 1,293 * 273 / (273+Ttran)

1.005 kg/m3
1.186 kg/m3
1.014 kg/m3

Overview gas and mass flow

Qnax
Qnrot
Qax =
Qrot =
Qtran

=
=
=
=
=

Qmeax * (101325 +100* Pax) / 101325 * 273 / (273 + Tax)

Qmerot * (101325 +100* Prot) / 101325 * 273 / (273 + Trot)
Qnax * 1,293 / ROax1
Qnrot * 1,293 / ROrot1
Qtran0 * (273 + Ttran) / 273

Qmax
Qmrot
Qmtran

= Qax * ROax1 / 3600

= Qrot * ROrot1 / 3600
= Qtran * ROtran / 3600

1961.0
1093.0
2523.5293
1191.6246
3824

Nm3/h
Nm3/h
m3/h
m3/h
m3/h

0.704 kg/s
0.393 kg/s
1.078 kg/s

Expansion velocity of the air

Vsax
Vsrot
vstran

= Qmax / ROax1 / Aa * 1000000

= Qmrot / ROrot1 / Ar * 1000000
= Qmtran / ROtran / At * 1000000

79 m/s
49 m/s
28 m/s

Impuls
Gax
Grot
Gtran
Gaxial
Gradial

= Qmax * Vsax
= Qmrot * Vsrot * cos 35
=Qmtran * Vstran
=Gax + Grot + Gtran
=Qmrot * Vsrot * sin 35

56
16
29.7
101.1
11

N
N
N
N
N

MED

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

0.239 m

Operation figures burner

Is
Sw

= (Gax + Grot + Gtran) / Pth

= (Gradial x Rg) / (Gaxial x MED)

0.86 N/GJ/h
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/318388865.xls/burner control

05/18/2016

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)
Percent of heat at back-end (SF)
Temperature burner inlet Axial (Tax)
Temperature burner inlet Radial (Trot)
Temperature burner inlet Transport (Ttran)

X/TPP/Rt/ALLGEBERE/318388865.xls/Sketch

Calculation

Is

Sw

05/18/2016

Data logging system

Kiln feed
{kiln output (Pofen)}

X/TPP/Rt/ALLGEBERE/318388865.xls/Sketch

05/18/2016

Fuel Charac
Fuel characteristics (dry basis)

Coal
%
% volatiles
%C
%S
%H
%O
LHV (BTU/lb)
LHV(Kcal/kg)
LHV(kJ/kg)
LHV(kcalkg)

coke

Blend

0%

100%

100%

26.06

4.73

4.73

64
0.71
3.05
6.9

91.3
1.88
3.69
1.64

91.30
1.88
3.69
1.64

11763
6535
27361
6,546

14617
8121
34000
8,134

14617
8121
34000
8,134

Page 11