COMMISSIONING EXPERIENCE

at 2 HOLCIM PLANTS
in Switzerland

Presentedat:
Presented at:“1
“1ststBURNER
BURNERDAY”
DAY”
18February
18 February20042004
Limassol/ /Cyprus
Limassol Cyprus

company: PILLARD FEUERUNGEN GmbH

Taunusstein, Germany
speaker: Manfred Gemmer
position: Head of R & D Department
New ROTAFLAM® burner KO-S 93 MW
for HOLCIM Untervaz Cement Plant

View of HOLCIM Untervaz Cement Plant

Page 2 of 1 7
HOLCIM Untervaz Cement Plant
Vision of a new mega burner
Waste oil
Household waste

Conterminated water
Coal

Tetra pack
Paper

Plastic waste
Carton

Liquid waste
Wood

Low calorific gas Heavy fuel oil

Destilation residues

Page 3 of 1 7
HOLCIM Untervaz Cement Plant
Old and new burner

New ROTAFLAM burner with internal pipes

for secondary fuels

Previous burner with external

pipes for secondary fuels

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New ROTAFLAM® burner KO-S 93 MW
for HOLCIM Untervaz Cement Plant

New ROTAFLAM burner

Manufactured with new and
used parts from an other
HOLCIM plant.

Page 5 of 1 7
New ROTAFLAM® burner KO-S 93 MW
for HOLCIM Untervaz Cement Plant

Burner data:
ROTAFLAM® burner 93 MW to
replace three channel type burner

Fuels ( burner design ):

•pulverized coal 9 855 Kg/h
•heavy fuel oil 6 300 Kg/h
•plastics ( Tetrapak ) 3 500 Kg/h
•waste oil 6 750 Kg/h
•animal powder 3 000 Kg/h
•distillation residuals 1 500 Kg/h
•contaminated water 500 Kg/h

Page 6 of 1 7
New ROTAFLAM® burner KO-S 93 MW
for HOLCIM Untervaz Cement Plant
Sintering zone, Flame shape

Previous burner

Burner ~23 m Flame !!

17m (~4xD) Sintering zone Ring formation

ROTAFLAM burner

Rotaflam ~16 m Flame

!!
12m (~3xD) Sintering zone Ring formation

Page 7 of 1 7
New ROTAFLAM® burner KO-S 93 MW
for HOLCIM Untervaz Cement Plant
Previous Burner

= Goal

Page 8 of 1 7
ROTAFLAM® burner KO-S 93 MW
for HOLCIM Untervaz Cement Plant
Coal: 9.855 kg / h Waste oil: 6.750 kg / h
Heavy fuel oil: 6.300 kg / h Animal powder: 3.000 kg / h
Plastics (Tetrapak): 3.500 kg / h Distillation residuals: 1.500 kg / h
Contaminated water: 500 kg / h

Liquid wastes Solid wastes

Flame stabilizer
Heavy fuel oil

Page 9 of 1 7
ROTAFLAM® burner KO-S 93 MW
for HOLCIM Untervaz Cement Plant

Observations after commissioning in April 2001:

Commissioning without problems
Stable and short sintering zone
Temperature reduction at kiln inlet by approx. 50 °C
Low NOx
Potential for further improvements

Page 10 of 1 7
New ROTAFLAM® burner KO-S 70 MW
for HOLCIM Eclepens Cement Plant

View of HOLCIM Eclepens Cement Plant

Page 11 of 1 7
ROTAFLAM® burner KO-S 70 MW
for HOLCIM Eclepens Cement Plant

Burner data:
ROTAFLAM® burner 70MW to
replace three channel type burner

Fuels (burner design):

•pulverized coal 10 000 Kg/h
•heavy fuel oil 6 300 Kg/h
•natural gas 6 000 Kg/h
•animal meal & dried sludge 4 000 Kg/h
•oil impregnated saw dust 4 000 Kg/h
•animal grease 4 000 Kg/h
•solvent 1 500 Kg/h
•waste oil 1 500 Kg/h
•waste water 500 Kg/h

Page 12 of 1 7
ROTAFLAM® burner KO-S 70 MW
for HOLCIM Eclepens Cement Plant

The new ROTAFLAM® burner, ready for installation

Page 13 of 1 7
ROTAFLAM® burner KO-S 70 MW
for HOLCIM Eclepens Cement Plant

Plant data:
•FLS kiln with 4 stages suspension preheater
•kiln size 3.94m diameter (inside bricks) x 66m length
•satellite type cooler
•maximum kiln output 1 650 TPD
•complete tires injection at kiln feed inlet

Commissioning of the ROTAFLAM® burner:

•first fire on Saturday April 27, 2002
•full load with 100% waste fuels firing on May 1, 2002
•100% waste fuels firing from May 1to May 29, 2002
•introduction of heavy fuel oil on May 30, 2002 due to lack of waste fuels

Page 14 of 1 7
ROTAFLAM® burner KO-S 70 MW
for HOLCIM Eclepens Cement Plant

Observation with 100% waste fuels firing (from May 1 to May 29, 2002):
•Flame is short and under control, with only one temperature peak
•better mixing between primary air and waste fuels than with previous burner
•very stable coating
•no change in kiln shell temperature
•L S F in raw feed between 95 and 99
•free lime in clinker < 1.8%

Page 15 of 1 7
ROTAFLAM® burner KO-S 70 MW
for HOLCIM Eclepens Cement Plant

Benefits attributed by HOLCIM to the burner change (*)

•outlet temperature of the 4th cyclone is reduced by 35°C

•no more plugging in the preheater tower

•kiln output is increased by 6% (100 TPD) with 100% waste fuels firing

•no more CO at kiln feed inlet even with 100% waste fuels firing
(CO at kiln inlet was the limiting factor for an increase in waste fuels
injection before the changing the burner)

(*) all operation improvements are attributed to the

ROTAFLAM® burner as it is the only change in the plant at that time

P.S.: You will also find an article about the new ROTAFLAM ® burners
at the two HOLCIM plants in Switzerland, written by Mr. Walter Jaun,
in the July 2003 issue of International Cement Review.

Page 16 of 1 7
New ROTAFLAM® burner

The research, different tests and measurements

during the last 4 – 5 years and the shown results
at this two HOLCIM plants in Switzerland results
in a total new design of the burner tip.

This new burner tip design is shown in the

presentation “Actual Burner Tip Design”

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