M.A.S. KILN BURNERS FIRING SYSTEMS

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1 M.A.S. KILN BURNERS FIRING SYSTEMS

2 TABLE OF CONTENTS The M.A.S. Kiln Burner o Mono Air-duct System - Kiln Burner o How it works o Flame setting with the M.A.S. Kiln Burner o Reproducible Flame Setting o Mixing of Secondary Air into The Flame o Primary air feeding o Burner Accessories o Burner Carriages Secondary waste fuels Fuel Oil Lances o UNIGRESS - ZL o UNIGRESS DDM/X Special features o Burner Automation o Divisible jacket tube for M.A.S. Kiln Burners o Extension of refractory life time o Pneumo Swirl Device for Solid Secondary Fuels Calciner burners Hot Gas Generators Fuel supply systems for Oil Fuel supply systems for Gas Burner Management Systems Thermal oil boilers for fuel oil pre-heating Spares & Maintenance

3 Welcome to UNITHERM CEMCON GmbH Unitherm-Cemcon is a private owned company which its main office located in Vienna Austria. Since the enterprise was established in 1946 Unitherm Cemcon has been working in the cement industry. In the past Unitherm Cemcon produced a large number of traditional rotary kiln burners, installed all over the world. At beginning of the1990 s a long lasting period of engagement in improvement of traditional rotary kiln burner designs ended in an invention of a revolutionary primary air system named M.A.S - Mono-Airduct-System. In September 1993 Unitherm - Cemcon installed the first new generation M.A.S.-burner which has been operated with coal, natural gas and heavy fuel oil. At first time a rotary kiln burner was equipped with one single primary air channel with an integrated flexible swirl setting mechanism for a sophisticated new kind of flame shaping. In December 1993 our Patent (EP ) was introduced to the public in ZKG and Cement review All tests had remarkably good results and the first M.A.S. burner installation revealed as big success. At beginning of 1994 our traditional kiln burner execution has been replaced by the new M.A.S. burner system. Development in the last years aimed in combustion of secondary fuels in solid or liquid condition as secondary fuels. We are fully integrated in this process and have delivered more then the half of our burners with integrated facilities for burning secondary fuels. We are proud to have major cement producers and a large number of private owned cement producers as clients. For detailed information please refer to our reference list. Postal address: Unitherm Cemcon Feuerungsanlagen GmbH Grillgasse 51 A-1110 Vienna / Austria / Europe Phone: Fax: sales@unitherm.co.at Homepage: FIRING TECHNOLOGY FOR THE FUTURE

4 Mono Airduct System - M.A.S. Burner M.A.S-Burner systems are tailor made solutions combining our well proven standard technique with solutions to meet YOUR KILN REQUIREMENTS FUELS Standard fuels: Waste fuel oils: Solid secondary fuels: regular fuel oils, natural gas, high and low caloric coal waste fuel oil with solids, solvents, high viscosity oils. sewage sludge, plastics, seed, wooden chips.. PERFORMANCE 10 MW up to 250 MW (higher firing performance on request) PRIMARY AIR RATE 6% to 12% (higher values on request) LOW NOx EMISSIONS All M.A.S.-burners are designed according to the Low NOx priciple ADVANCED TECHNOLOGY Standard designs - highest level in operational reliability. - easy flame shaping for best clinker quality - maximum burner momentum at each flame shape - best mixing of secondary air into the flame - innovative features for specific requirements - reduced service costs e.g. excellent cooling

5 The most important design criteria for a kiln burner is the way of its P R I M A R Y A I R I N T A K E A N D H A N D L I N G as primary air is mayor responsible for effective flame shaping to place the sintering zone where needed. M.A.S.-Kiln Burner How it works Adjustment of flame shape is performed by means of a flame seting device which is located easily accessible on the burner s cold side. A rod and pinion drive is covered with a housing and equipped with a flame setting device. Actuation is performed by hand operated crank. FLAME SETTING DEVICE with scale FLAME SHAPE LONG FLAME SHORT FLAME An internal twisting mechanism converts a longitudinal motion (transferred by the flame setting device), into a rotary motion (quarter revolution) INTERNAL TWISTING MECHANISM MAS-NOZZLES WITH MAS-HOSE ROTATABLE RING NON-ROTATABLE RING M.A.S.-air (Primary air for flame shaping) is introduced into the kiln through single air jet nozzles (MAS-nozzles) situated at the burner tip. (Picture on the left shows this nozzles mounted on the MAS-hoses, while jacket tube is dismantled) For flame shaping this MAS-nozzles are matter to be deflected around the burner axis from 0 to 40 in tangential direction to create slim or wide flames according adjusted swirl intensity. In this way the entire MAS air is brought into any swirl desired, with the advantage to keep the maximum burner momentum constant at any adjusted swirl and load range. The air jet intake provides best mixing of secondary air into the flame

6 Flame setting with the MAS burner The flame setting device is designed considering the kiln dimensions, it is operated from the burner s cold end. The numbers on the scale of the flame setting device refers directly to the adjusted deflection angle of the MAS-nozzles. This numbers ranging from 1 to 9 are called scale numbers. Scale number adjustment to set 1 the longest possible flame 9 the shortest possible flame any intermediate settings flames from long to short FLAME SHAPE FLAME SHAPE LONG FLAME SHORT FLAME LONG FLAME SHORT FLAME Images beside showing the possible deflection of the MAShoses Air adjustment for a long flame MAS-hose deflection approx. 10 Scale number 1,5 Air adjustment for a short flame MAS-hose deflection approx. 35 Scale number 8,4 The adjustment of the MAS air pressure setting is used to obtain sharp or soft flames. MAS air pressure setting MAS air pressure (e.g. air flow) is controlled by one primary air damper to be adjusted for start up and to obtain: sharp flames (high pressure) or soft flames (low pressure)

7 Reproducible Flame Setting For M.A.S.-Burners the important factors for flame shape adjustment is the setting of : SCALE NUMBER (long or short flames) and the MAS air pressure (sharp or soft flames) In addition, the combustion quality can be influenced by central air flow. Pressure of MAS -air Scale number Pressure of Central air Pressure e.g. Scale number Pressure e.g. flow setting of M.A.S. air on flame setting device flow setting of central. air increase or decrease increase or decrease increase or decrease by valve setting by actuation of a crank by valve setting sharp to soft flame long to short flame combustion quality The simplicity of the adjustment function provides a high degree of reproducibility even when a lot of different fuels are fired or conditions out of any reason would change. The operator only has to adjust: pressure (flow) of MAS air scale number (deflection of MAS-nozzles) on the scale of the flame setting device pressure (flow) of central air

8 Mixing of Secondary Air into The Flame The M.A.S- injection system creates single air jets. Between these air jets zones with negative pressure are created. In this way hot secondary air is drawn strongly into the flame. Thus provides a quick and homogenous mixing of secondary air with fuel and combustion gases, a rapid ignition, a hot sharp flame, best heat transfer to the clinker bed and excellent burn out conditions. As Unitherm Cemcon has produced traditional dual channel burners with radial and axial air channels up to end of 1993 we compare the traditional burner with the advanced M.A.S.- system. MAS burner (Multi-jet burner) Outflow of the primary air is divided into 12 to 15 individual air jets Primary air impulse remains always constant at different flame shapes and the point of design Internal recirculation zone and recirculation of the hot secondary air, fuel and exhaust gases The size of the inner recirculation zone remains constant at different flame shapes Primary air flow at the nozzles is swirl free Flame setting is achieved via a different deflection angles of the air jets. Control range of the mixing zone length is approx. 1:3. Thus it is possible to adjust a very sharp hot flame Primary air supply: 315 mbar of primary air pressure is sufficient to burn even hard burnable fuels Burner Nozzle M.A.S. - system Traditional dual channel burner Outflow of the primary air via two coaxial channels (axial air / radial air) Primary air impulse reduced with different flame shapes compared to point of design Internal recirculation zone mixture and recirculation of primary air, fuel and exhaust gases The size of the inner recirculation zone varies with different flame shape settings Primary air flow at the nozzle area has a certain swirl Flame setting is achieved via a changing of the swirl number of the primary air. Control range of the mixing zone is approx. 1:15 Primary air supply: 400 to 600 mbar of primary air pressure is recommendable Burner Nozzle traditional three channel burner (basic) S1 S All primary air for any swirl S Primary air for axial air proportion only a i r c o n d a r y S e S S1 View to nozzle Cross section of air nozzle (approx 6 times the sqare sross section of all single MAS nozzle cross sections) Cross section of single MAS-nozzle Single air jet Gap creating negative pressure d r a i y r a o n c e S S View to nozzle Cross section of air nozzle Air must penetrate the ring shaped hull Intensive mixing of secondary air with fuel and primary air Long penetration depth with single air jet streams Poor mixing of secondary air with fuel Short penetration depth with ring shaped hull m/s MAS design nozzle gap nozzle gap nozzle Conventional burner design with ring shaped air intake >1/3 1/1 length of air penetration into kiln

9 Primary air feeding Primary air is internally divided in MAS-air and Central air. Cooling air for any application (cooling of fuel oil lance, coal or gas channel ) is taken from the burner s central air channel. P R I M A R Y A I R (100%) MAS AIR (approx. 75%) CENTRAL AIR & COOLING AIR(s) (approx. 25%) Standard execution is to equip the burner with one single radial fan for all purposes. (internal splitting of MAS-air, Central air and Cooling air s) MAS-Burners are designed to obtain a specific primary air impulse of 5 12 N/MW. Operation experience with M.A.S.-Burners shows that small air pressure losses and deep air penetration into the kiln does not require a stronger impulse than 5 8 N/MW for best operation result. Nevertheless we supply burners with higher impulses, more than 8 N/MW on request. Such kind of burners are either equipped with radial fans or roots blowers for primary air feeding. Standard and Alternatives Primary air supplied by: No. of sockets Split up Execution Single stage radial fan 1 for all purposes internal Standard Single stage radial fan 1 for MAS air external Alternative Single stage radial fan 1 for Central air Roots blower 1 for all purposes internal Alternative Roots blower and Single stage radial fan 1 for MAS air 1 for Central air external Alternative Standard values for fan sizing depending on certain fuels in use. Fuel to be fired pressure mbar PA % impulse N/MW Natural gas Fuel oil Standard coal Petcoke, Anthracite, Solid secondary waste fuels On request On request (roots blower) > > 8 Air flow m³/hr * Pressure PA impulse Air flow total static pressure of fan in mbar total primary air rate specific primary air momentum * depends on burner performance, altitude, requested primary air rate * depends on requested impulse

10 Burner Accessories IGNITION BURNER For rotary kiln burners the installation of an ignition burner is obligatory according to EN for operation without supervision. Ignition fuel: Natural Gas, Propane Gas or Diesel Kind of ignition: High voltage Flame control: Ignition air: Ionisation rod taken from primary air, no additional fan necessary INTERNAL FLAME SCANNER We provide an internal flame scanning enabling a direct view into the flame. Malfunctions (loss of flame signal) caused by clinker dust is prevented in this way. The optical lance is protected from heat by internal cooling air. The unit consists of: Optical lens with fiber optic cable Flame scanner, mounted on burner Evaluation unit to be installed in a control box. PNEUMATIC LANCE RETRACTIONS To protect fuel lances from overheating it may be useful to equip one or more lance carrier ports with a lance retraction device to retract a lance automatically when operation has been stopped. The unit consists of: Pneumatic cylinder Solenoid valve for actuation Limit switches (retracted/inserted) Guiding bars with lever

11 Burner Carriages Unitherm Cemcon provides standard burner carriages in suspended and floor mounted design. The burner alignment range is +/- 3 around the front suspension support. Adjustment at front suspension Adjustments at rear suspension Vertically +/- 150 mm Vertically +/-100 mm Horizontally +/- 150 mm For initial burner settings the burner can be adjusted either horizontally or along the kiln axis for hard burnable fuels. The horizontal adjustment at the rear suspension is provided to consider the kiln rotation. Standard actuations Suspended Design Floor Mounted Design Actuation of front suspension manual manual, hydraulic Actuation of rear suspension manual manual, motor Burner carriage frame geared motor geared motor

12 Secondary Waste Fuels Waste fuels fired through the kiln burner Unitherm Cemcon has been one of the first leading companies supplying kiln burners fired with solid secondary fuels since By using secondary waste fuels basic consideration must be taken to: Technical feasibility - chemical influence on the clinker process Economic conditions - fuel regularly supplied quality cost saving Legal regulations - local environmental standards limited substitution Investment to benefit relation - today s and future aspects Liquid secondary waste fuels fired through the kiln burner: Liquid waste fuels are fired by means of special oil lances. The UNIGRESS DDM-X waste oil burner lances are designed to burn a large variety of liquids, ranging from high to low viscosity fuels with abrasive solid components. Solid secondary waste fuels fired through the kiln burner: For pneumatically conveyable solid secondary waste fuels best results are obtained by firing this fuels through the kiln burner. We provide secondary waste fuel channels situated in the burner s central channel, enabling maintenance works on this channels even when the burner remains in operation with standard fuels. Most important is complete combustion of the waste fuel to prevent negative effects like reduced burning. Best burnout behaviour will be achieved with our unique Pneumo-Swirl technique. Equipment for waste fuel firing situated inside the burner s central channel (typical) Internal flame scanner (option) Solid secondary fuel channel equipped with Pneumo Swirl Device Lance port for liquid secondary waste fuel lance UNIGRESS DDM-X Central air channel with flame stabilizer plate Fuel Oil Lance UNIGRESS 4001 ZL

13 Typical solid secondary waste fuels: sewage sludge, sunflower seed, animal meal, pulverised fuel ash, and many others wooden saw dust shredded waste shredded plastics Considerations: Load factor: Load factor ranges basically depending on waste fuel used, bulk density and length of conveying distance. Medium velocity: Velocity should be within the range of 27 m/s up to 45 m/s ( ft/s) Particle sizes: Conveying air: The relation between specific surface and mass of the particles must be taken under consideration for proper burnout time. Conveying air flow should be adjustable by speed controlled motor to obtain optimum injection velocities. Standard pipe dimensions for solid secondary waste fuel firing Standard pipe diameter Conveying air flow +/- 20% Secondary waste flow up to DN 100 / m³/hr / 700 acfm 3500 kg/hr / 7700 lb/hr DN 125 / m³/hr / 950 acfm 6000 kg/hr / lb/hr DN 150 / m³/hr / 1350 acfm 8000 kg/hr / lb/hr Above mentioned flows are basic data only

14 Fuel Oil Lances Oil lance UNIGRESS ZL for kiln firing systems NO NOZZLE CHANGE FROM START UP TO FULL LOAD The UNIGRESS ZL high pressure fuel atomizer lances are designed for regular forward flow but also for the more professional forward / return flow control mode. This enables kiln burner oil operation without nozzle change due to a total control range of 1 : 8 on forward / return flow control mode. Precondition: Also the fuel oil valve train (as control unit) must be designed to be operated in forward / return flow control mode as UNITHERM CEMCON provides. Forward flow operation Adjusting device for internal lance piston mode for normal burner operation with high burner capacity. In this mode the fuel oil enters the oil lance through both the axial oil connection and the radial oil connection, and is thus fed through both channels into the lance nozzle. In forward flow operation the oil is fed parallel to the atomiser nozzle (radial and axial). (When the fuel oil valve train is not designed for return flow operation a nozzle change is necessary for lower load.) Return flow operation special mode for start up and low burner capacity. In this mode the oil lance operates as a return flow lance, i.e. fuel oil only enters the oil lance through the radial oil connection and is fed to the burner nozzle via the radial oil channel. Excess oil is then returned to the axial oil connection of the oil lance via the axial channel. Return flow back to tank separately is controlled with a control valve on valve train. (Return flow operation is only possible when the fuel oil valve train is designed therefore) A special feature of the UNIGRESS ZL oil lance is the manual adjustable piston to shut or open radial slots situated on the nozzle insert for radial oil. This sophisticated design enables: a total control range of 1:15 and a possibility for flame shape adjustment on forward flow mode Scale for adjustable piston Radial oil connection Axial oil connection UNIGRESS - ZL 4001-ZL 8001-ZL ZL ZL Max. flow in kg/hr Max. flow in lb/hr Lance carrier pipe ø 76,1 mm / 2 ½ 88,9 mm / 3 88,9 mm / 3 114,3 mm / 4 Atomising viscosity up to 20 cst Pressure range 9 bar 36 bar 130 psi 522 psi Above flows refer to heavy fuel oil (fuel oil #6). Performance example: Heavy fuel oil, 15 cst at 130 C, l/hr, UNIGRESS 8001 ZL Forward flow operation: l/hr 1:3 (1:3,1) (normal burner operation) Return flow operation: l/hr 1:8 (1:3,2) (start up burner operation) Adjustable piston: l/hr 1:15 (1:2,4) (drying operation) Total control range: l/hr 1:15 without nozzle changing

15 Waste oil lance UNIGRESS DDM/X for kiln firing systems The UNIGRESS DDM/X oil lance series are designed as waste fuel oil lances using compressed air (or steam) for atomisation. The design allows to burn liquid waste fuels with high or low viscosities, with or without solid particles. The lance is to be used on rotary kiln or calciner burners. Construction details Waste oil is supplied via a central pipe which is surrounded by an outer pipe for compressed air feeding (alternatively steam). Oil flows straight through one single nozzle-bore designed with a minimum diameter of 6 mm. Compressed air (or steam) is introduced through bores at a conical part of the nozzle for atomisation. The control range depends on the speed controlled pump installation. This special design has no internal parts. Therefore oil contaminated with solid particles can be fired without particles blocking. Low wear and low pressure losses are additional design benefits. Bores for fuel atomising Straight nozzle-bore to prevent particle blocking UNIGRESS DDM-X DDM-X/1 DDM-X /2 DDM-X /3 Max. flow in kg/hr Max. flow in lb/hr Lance carrier pipe ø 60,3 mm / 2 76,1 mm / 2 ½ 88,9 mm / 3 Waste oil pressure 6-8 bar / 85 psi 115 psi Compressed air 4-6 bar / 60 psi 85 psi Compressed air flow 10 % - 15% referred to oil mass flow Particle size 3-4 mm / 0.15 inch Atomising viscosity up to 120 cst Above flows refer to oil with a specific weight of water. For aggressive medias the UNIGRESS DDM/X lance is available in stainless steel.

16 Special Features Burner Automation As the Unitherm M.A.S.-burner stands for simple and safe flame shaping can be easily operated, it is also easy to execute the burner with control equipment for automation. Useful automation steps: Remote controlled: Standard execution: Air pressures on burner pressure transmission visually with gauge Flame shape adjustment motor actuated rack and pinion drive incl. feedback control for setting rack and pinion drive hand operated Primary air butterfly valve executed with an actuator incl. adjustment with lever positioner Central air butterfly valve executed with an actuator incl. adjustment with lever positioner Cooling air valves (different executed with an actuator incl. adjustment with lever settings for fuel in use) positioner Lance retraction(s) if burner is equipped with oil lance(s) pneumatic retraction cylinder manually retracted Automation module 1 With above recommended equipment for automation the burner can be simply operated by [+] [-] setting commands given from the control room via a PLC or other control equipment. A kiln camera and a shell temperature supervision system should be available. Automation module 2 In case the primary air fan is equipped with a flow measurement and/or a variable speed control the degree of automation can further be increased. This is done in combination with a Burner Management System by Unitherm Cemcon. That enables the creation of control loops for burner set-points and semi-automatic operation. The evaluation of burner data like setting feedbacks and an internally calculated burner momentum and swirl number are also provided. Automation module 3 Is the burner equipped with automation module 2 the burner can be operated by AUTOMIZED FLAME CONTROL (process supervision by digital picture processing flame analysis) together with a kiln optimisation (PiT Navigator, LINKman, etc.), artificial intelligence, neural networks, and fuzzi logic. Basically all M.A.S. burners equipped in standard execution can be retrofitted for automation. For further information please contact us.

17 Special Features Divisible Burner Jacket Tube for M.A.S. Kiln Burners Frequently re-lining works on kiln burner jacket tubes must be performed by pulling off the jacket tube from the burner. For this procedure the burner must be moved backwards until the necessary space for pulling off is available. Often the burner must be removed from its carriage to perform this work when proper space is unavailable. Unitherm can offer a special option - the jacket tube in divisible execution, to improve the service work for burner insulation essentially. The jacket tube is divided into a front and a rear part, connected with an burner-internal locking mechanism. Locking or unlocking is simply operated from the cold side of the burner. Unfastening of the locking mechanism Pulling off the front part of the divisible jacket tube Changing of used by readily prepared tube The execution as divisible jacket tube offers several advantages in investment and quicker service: The locking mechanism situated at burner s cold side lower investment for spare outer jacket tube in case of wear at the lower part of the burner tip insulation the front part of the jacket tube can be turned 180 easier relining service works of the outer jacket tube less space requirement on the burner platform as only the front part of the jacket tube has to be pulled off for new lining!! correct preparing of lining (sintering, drying) easily possible due to smaller dimensions

18 Special Features Extension of burner refractory life time As M.A.S.-burners uses the primary air for flame shaping without air splitting its flow remains basically constant over the entire load range. In this way constant cooling of the burner jacket pipe is ensured. Nevertheless abrasion caused by clinker dust, high heat impact and chemical influences causes problems in a way that kiln burner refractory often has to be repaired after a short time in use. The direct consequence thereof are production loss and high costs for lining material and works. - Heat impact Heat impacts the burner tip directly by radiation from the flame. High heat radiation destructs even heat resistant refractory materials in combination with chemical influences. - Abrasion Different to heat impact abrasion destructs refractory from burner tip s bottom. Clinker dust with high velocity rises up from the cooler reaching the bottom side of the burner tip sliding along the surface. Due to increasing of secondary air temperature (volume flow increase by temperature) the clinker dust is extremely accelerated and may wear the tip-edge of the burner strongly. To increase refractory lifetime we are in the position to offer particular solutions, like cast-ribs located on front of burner s jacket pipe (reducing thermal stress), even an execution with ceramic bricks (reducing abrasion, high temperature resistance) is possible. Nevertheless such designs have to be selected carefully according to the present kiln conditions to prolong refractory lifetime. As chemical influences (basically sulphur, alkalis and chlorides) are major responsible for lining destruction detailed information about kiln atmospheres and a hot meal analysis is essential.

19 Special Features Pneumo-Swirl-Device for solid secondary fuels Solid secondary waste fuels are conveyed by compressed air through a piping system to the burner. The waste fuel channel inside the burner is basically a pipe of same diameter. At the hot end of this pipe the Pneumo-Swirl-Device is installed, used to set the fuel flow into a defined rotation. Air necessary to create this rotation is taken from the burner s primary air pipe system, compressed air is not necessary. How it works A low swirl intensity results in a large throwing range while a high swirl intensity increase the retention time in a way that waste fuel is deflected into the flame, time for burnout is prolonged as well. Low swirl intensity (little air flow provided for pneumo swirl device) results in a large throwing High swirl intensity (much air provided for the pneumo swirl device) results is a large throwing angle Construction details: The Pneumo-Swirl-Device is located at the front part of the waste fuel pipe, executed with slots arranged around the circumference of this pipe. The slots are deflected in a way that swirl air flows inside the pipe circumference to set the axial fuel flow into rotation. This system is encased by an additional pipe to support swirl air. The swirl intensity is adjusted by valve setting (flow regulation), this equipment is situated at the burner s primary air piping.

20 Calciner Burners The UNICAL calciner burners are designed to be operated with traditional and different alternative fuels. Burners are available for every performance range, for single or multi fuel operation. Side fired calciner: fired. For example: 60 MW Coal Petcoke Natural gas (drying) The fuel is injected in the calciner at 2 or 4 points at the shell of the calciner. The design of the burner depends on the number and kind of fuels References: Lucky Cement Ado Cement Lafarge Selva Alegre Top fired calciner: The fuel is injected in the combustion chamber at the top. The burner is designed in three channel design with axial air and swirl air to ensure good fuel distribution, optimum control of the flame and complete combustion. For example: 165 MW Coal Petcoke Natural gas References: Lehigh Union Bridge Dewan Cement Inland Cement Important factors for the design of a calciner burner: Good mixing of the fuel: optimum fuel dispersion into the gas flow is essential for complete combustion of the fired fuels Retention time for the combustion has to be sufficient: the combustion must be completed in the precalciner, otherwise it will continue in the next stage where the temperature is not optimum for calcination. This can lead to not optimum utilization of the heat and higher fuel consumption Suitability for a wide range of fuels: depending on the availability of alternative fuels, the burner should be suitable to fire different fuels when they are available Low NOx emissions Beside for rotary kiln burners, Unitherm Cemcon is using CFD modelling also for calciner burners to find the optimum point of injection, air rates, etc. for complete combustion of different fuels.

21 Hot Gas Generators Hot gas generators fabricated by Unitherm Cemcon are designed for direct air heating performed by a firing system. Air to be heated is either supplied by a dilution air fan or is delivered from process with high or low temperatures or combinations of both. Unitherm provides: Hot Gas Generator engineering for supply or local manufacturing Brick lining material Burner (mono block or special designs) incl. operation valve train and fuel supply system Dilution air fan HGG field instruments for performance and safety control HGG control cubicle Hot Gas Generator type HG Hot Gas Generator type HR Execution steel structure with inside brick lining steel structure with 3 layers of heat resistant steel Air outlet temperature 350 C C 100 C 350 C Range of performance 0,7 MW 60 MW 0,7 MW 12 MW Fuels to be fired liquid and gaseous fuels and liquid and gaseous fuels coal or petcoke Installation vertical and horizontal vertical and horizontal Installation coal operation - vertical ---- Heat capacity (storage) high low Horizontal HG-design fired with HFO and Natural Gas ver HGG for gas / oil operation Vertical HG-design fired with Gas/Coal operated with process air and dilution air

22 Fuel supply systems for Oil Fuel oil valve trains for kiln- and calciner burner operation: Unloading pump stations Tank suction heater Transfer pump stations High pressure pump stations High pressure preheating stations Thermo oil boiler systems

23 Fuel supply systems for Gas Gas valve trains for kiln- and calciner burner operation: Pressure reducing stations Burner regulating valve train

24 Burner Management Systems A burner management system is one of the most important equipment to optimise burner and kiln line operation. UNITHERM CEMCON provides solutions according long lasting experience in kiln firing system operation, assuring control at safest level and highest flexibility for your (specific) application. Control cubicles are completely wired up for operation and undergoes a detailed function test prior of delivery. Design of the management system is performed according latest VDE and EN regulations. Shop test BMS directly mounted on oil valve train BMS located in MCC-room The used hardware for the BMS is preferably of brand SIEMENS S7 or Allen Bradely, other brands to be used on request. A free programmable control unit is provided for monitoring and control tasks of burner and fuel supply systems. Communication between BMS and superior management system is performed by an internal communication processor (Profibus DP, Ethernet or others) enabling remote controlled and local operation. An operation panel with LCD-display as multi purpose screen is used as operating surface for local operation (HMI). Different operation pictures with indicated process data, release conditions, system and control parameter can be viewed by using defined function keys. This keys are also used to set actions like set point adjustment, fuel selection and for specific tasks. System handling is menu-supported. (Standard language English conversion into other languages

25 Thermal oil boilers for fuel oil heating UNITHERM CEMCON provides THERMAL OIL BOILERS as heating facility for the fuel oil preheating, especially designed for applications in the cement and lime industry. GMBH The thermal oil boiler is a tubular heater constructed for the use of both organic and synthetic heat transfer fluids and for hot water. Its large combustion chamber provides best combustion results and guarantees thereby ideal emission rates. The horizontal position of the thermal oil boiler has the advantage that the burner is easily accessible for adjustments, inspection and maintenance purposes. All our appliances comply with the DIN 4754 regulations for boiler plants. They can be used in many different applications, not only because of their advantage of being in operation up to temperatures of 300 C. The thermal oil boiler can be fired directly by the use of light fuel oil, medium fuel oil, heavy fuel oil or natural gas. The use of heat transfer fluids guarantees a long durability of the system without the problem of pipe corrosion. As the boiler is cooled by the tubular heating surface, fireproof coating is not necessary. This results in a minor wear of the material. One of the most important safety devices is a flow safety device which makes sure that the circulation quantity of the heat transfer fluid in the boiler is never below the required minimum. Thermal oil boilers can be delivered ready for installation, e.g. in a standard container or on a common frame so that the skid can be instantly installed at the respective place. UNITHERM-CEMCON Firingsystems GmbH Vienna Austria Head Office The single thermal oil boiler capacity is available from 500 kw up to kw. The normal operating range is 3:1 and can be enlarged up to 6:1 by a special burner design.

26 Spares & Maintenance All M.A.S.-burners are designed to keep maintenance costs low, maintenance and even repair works can be performed by plant maintenance personnel, specialists or personnel from Unitherm Cemcon is not necessary for this works. Equipment Execution: Fuel nozzles on burner tip all air and fuel nozzles are equipped with threats Baffle plate mounted tension free (no bulging by heat ) Coal cannel at intake section coal pipe is covered with high wear resistant ceramic tiles Solid secondary fuel insert exchangeable while burner remains in operation (option) Front of burner jacket pipe made of high heat resistant cast iron steel (800 mm long) Lance cooling any lance carrier pipe is equipped with a cooling facility Burner refractory enlarged lifetime by optimum cooling Flame setting mechanism heavy duty design, save operation The burner s internal twisting mechanism with it s MAS-hoses, MAS-nozzles and the flame setting device is a well proven design which is under regular operation conditions not matter to be particularly maintained. The M.A.S.-burner is designed to be dismantled without any cutting, for all connections flanges (or pieces with threats) are provided. Welding works are only necessary on the burner jacket pipe. Picture on left side shows a M.A.S Burner with dismantled jacket pipe and screwed off fuel nozzles. Outside air nozzle to be welded on jacket pipe (designed with ribs), and nozzle wrenches to unscrew the fuel nozzles