Model-based burner
optimization and
oxygen injection
ABOUT US
aixergee is your competent partner when it comes to process optimization in
the cement industry. Due to the high energy demand and caused by the ever-
changing side conditions, the cement industry has a permanent requirement to
optimize their technical processes. In order to solve your problems effectively,
we draw from our long-spanning experience in cement just as much as from
our modern high-performance tools like e.g. CFD (computational fluid
dynamics) and process simulation. We marry theory to reality for the benefit of
our clients.
Take profit from the unique combination of cement experience and modern
engineering tools, specialised for your needs!
WHEN TO USE OXYGEN?
• Secondary Fuel (SF) rate is limited by burnout of lumpy fuels in the main
burner at a high substitution rate level
• Further increase of substitution rate leads to
Cold sintering zone / off-spec clinker
Brown clinker formation
Delayed ignition / unstable kiln
Weak kiln operation
• Conventional approaches by adapting
Process settings
Burner orientation and position
Feed channel selection for SF injection
do not improve the situation anymore.
OUR APPROACH
• Analysis and evaluation of the detailed combustion, heat transfer and
material conversion phenomena through application of process and CFD-
modelling
• Consideration of the mechanical
and thermo-chemical properties of
the locally fired fuels in the models
• Availability of comprehensive
databases for multi-channel-burner
geometries and fuel analyses
• Target-oriented enhancement of
fuel substitution solutions for each
kiln specifically
OUR SERVICES
• Techno-economical evaluation of
oxygen injection under consideration of
the site specific equipment/process
conditions
• Engineering of the optimal position for
oxygen injection
• Design and Engineering of dedicated
nozzles for optimal use of the oxygen
injection
• Estimation of SF rate enhancement by means of comprehensive modelling
YOUR BENEFIT
• Techno-economical evaluation of oxygen injection under minimization of
oxygen costs through an intelligent engineering
• A-priori evaluation of payback times during planning phase
• Typical enhancement of substitution rates up to 25% possible, when
applying intelligent oxygen injection
100%
no oxygen injection
90%
oxygen injection
80%
70%
Char burnout progress* [-]
60%
50%
40%
30%
20%
10%
0%
90 530 980 1560 1970 3960 10030
equivalent particle diameter [µm]
REFERENCES
„As-Is“-Analysis Process Engineering of
Optimization oxygen injection
CEMEX, Beckum, GER
CEMEX, Rüdersdorf, GER
PUBLICATIONS
[Link], [Link], Oxygen-enhanced combustion of alternative fuels, Global
Cement Magazine, 2, 2012, pp. 33-36