30 HIGHLIGHTS CEMENT – OCTOBER 2016

INNOVATION

See the animated movie of the

JETFLEX® burner here
jetflex.flsmidth.com

CONTACT MADS NIELSEN

MADN@FLSMIDTH.COM

CARSTEN DAMSLUND JENSEN

CDJ@FLSMIDTH.COM

Success for
the new multi-fuel Baseline tests
Before installation of the JETFLEX burner, a series of baseline tests

kiln burner
were performed on Rohoznik’s existing multichannel burner in
order to obtain performance data. The tests were conducted
using a special high-temperature camera that provided video
footage helping to understand flame and fuel behaviour inside
the flame.
FLSmidth’s new JETFLEX® burner
has helped improve plant operation Figure 1 shows the footage in the visual (#1) and infrared (#2)
spectra, where the cold alternative fuel appears black. The solid
and alternative fuels usage at the alternative fuel was poorly suspended and dropped out of the
Rohoznik Cement Plant. flame into the charge.

At CRH’s Rohoznik Cement Plant in Slovakia, the JETFLEX kiln
burner has now been in operation on the plant’s 3500 tpd clinker
line since early February 2016. The many features built into the
burner for optimising reliability, availability and fuel substitution
have been tested with solid and convincing results. This has
contributed to meeting Rohoznik’s goal of high alternative fuels
substitution, and improved clinker quality and energy efficiency.
The project at Rohoznik was managed by Mads Nielsen from
FLSmidth R&D and Przemek Bochen, Production Manager at
Rohoznik. Thanks to good collaboration between them and their
teams, the project has been highly successful.
A fast start
The JETFLEX burner was started up on 8 February 2016 after
being installed during the plant’s winter shutdown. Re-using many
of the plant’s existing burner parts, the JETFLEX prototype installed
at Rohoznik is designed for 100 percent coal/petcoke and natural
gas firing, though natural gas is mainly used for heating up.
The burner can operate with a high percentage of waste fuels
– up to 100 percent depending on fuel quality. According to the
plant operators, it proved easy to start and gave them excellent
flame control from the very beginning. Changes to burner settings
were observed immediately, and the operators could transition
smoothly from gas to petcoke and then to alternative fuels firing.

FIGURE 1. FLAME FOOTAGE OF ROHOZNIK’S OLD BURNER (1 AND 2) AND THE JETFLEX® BURNER (3). FOOTAGE 1 AND 3 IS SHOWN IN THE VISUAL SPECTRUM
AND NO. 2 IN THE INFRARED SPECTRUM. COLD, UNIGNITED FUEL APPEARS BLACK. ALL FOOTAGE IS TAKEN WITH THE PETCOKE TEMPORARILY SHUT OFF TO
GET A BETTER VIEW OF THE SRF.
Focus on alternative fuels
The Rohoznik plant has an excellent track record in its use of
alternative fuels, such as Solid Recovered Fuel (SRF). Consequently,
alternative fuel substitution is a key performance parameter, in
addition to capacity, clinker quality and energy efficiency. The
operators and the project team spent the first months of
operation testing and optimising the burner and kiln performance,
improving the overall performance.
Improvements in burner performance are shown in Figure 1 (#3),
which shows how well the JETFLEX burner can mix and suspend
the fuel in the flame centre with a strongly reduced tendency for
the fuel to drop into the kiln charge.
Figure 2 indicates the JETFLEX burner fuel flows, the petcoke
substitution (measured as energy share), and the clinker Alite
(C3S) content over a 24-hour period. A substitution of
approximately 80 percent was achieved with a 14-20 MJ/kg SRF
(Solid Recovered Fuel) at 10-24 percent moisture, while
maintaining good clinker strength. At 20 and 22 hours, the SRF
dosing unit experienced a blocking tendency forcing a reduced
SRF flow from approximately 12 tph to 8.5 tph.
FIGURE 2.
ALTERNATIVE FUELS
SUBSTITUTION AND
CLINKER QUALITY
HIGHLIGHTS CEMENT – OCTOBER 2016 31
The average kiln inlet NOx emission was recorded well below 700
mg/Nm3 @ 10% O2 during the same period.
Inspection after first run
The JETFLEX burner was in operation for 106 days without any
issues. The plant was then shut down according to plan for two
days which was ample time for a thorough inspection of the
burner. The front of the burner appeared in excellent condition
and the adjustable air nozzles were in good condition and could
easily be adjusted. Following the inspection, the burner was put
back into operation.
A bright future
Production Manager Przemek Bochen at Rohoznik says: “We
faced an increasing need to bring alternative fuels into our
production, and we saw a good opportunity to do this with a
new burner. We have been pleased with the performance of
the JETFLEX burner.”
The JETFLEX burner is now available for use with any kiln fuel.
This article is based on an article first published in World Cement.