CONTRACT INSTRUCTION MANUAL FOR Kiln Burner DBC-323.9-600-8 CUSTOMER : DALMIYA CEMENTS, 4500 TPD PLANT, ARIALUR ‘TAMILNADU INDIA. EQUIPMENT NO. 1431. BU 500 FLSL WORK ORDER NO: PRJO7-002-000 MANUAL NO. :M-120-01 Rev. | By Date Description cvialeefease Date 3: AR Giismivtn By:JAISTABLE OF CONTENTS DESCRIPTION DOCUMENT TAB.NO SECTION A - INSTRUCTION FOR FLSMIDTH PRODUCTS. DUOFLEX KILN BURNER 1 Duoflex Burner, type DBC — Installation, Operation and Maintenance 39651-03 Wear Lining, Deasit- Installation V 3551-01 Refractory, Ceramic Lining Materials - Survey 34201-09 Insulation of Burner Pipe 34721-04 GENERAL 2 General Safety 32031-05 ‘Safety Equipment 34761-03 Key to Lubricants 3650-11 Electrodes 29461-04 General Workshop Instruction Manual 520830(8) BURNER SUSPENSION 3 Bummer Suspension BS 19291-07 SECTION B~ PART LISTS ‘Main Parts ist, 50024723, 4 ‘Duoflex Kiln Burner 50024138, 5 ‘Bumer Suspension BS-2 5517909 6 Adjustment Device 5507293 7DESCRIPTION ‘Trolley supports SECTION C~ GENERAL ARRANGEMENT AND. ASSEMBLY DRAWINGS ‘Outline and load drawing Arrangement drawing Bumer assembly Refractory drawing Centering body asembly Adjustment device assembly drawing Duct suspension assembly Welding and assembly drawing Densit~ Casting mould Welding assembly standard Sealing anangement standard Pressure gauge arrangement draving Assembly of bumes trolley Arrangement of wheel Cable troley EL. diagram ‘Arrangement of cable trolley ‘Trolley support assembly SECTION D~- VENDOR DRAWINGS ‘DN400(16") Pneumatic shut —off damper for PA fan 'DN200(6") Pneumatic shut-off damper for EA fan Geared Motor DOCUMENT 50026488 1012s6s6 ors0sis 013012 10096100 3.700038 2.200015 2200182 20026632 10027683 1123639 2.466112 2.216829 2.216900 3.119606 3.108787 assez 10132132 60042958 60042960 60027647 TAB. NO 10GA of primary ais fan GA df emergency sir fan G.A & Foundation detail of valve stand for startup oil ber G.A & Foundation of oil tank GA of startup ol burner P & 1 Diagram for duplex PF unit, valve stand & start up kiln burer G.A & Foundation detail of pumping and filtering unit for start up burner DESCRIPTION SECTION E - INSTRUCTION AND MAINTENANCE MANUAL Instruction and maintenance Manual for Pneumatic shut - off dampers Instruction, operation and maintenance manual for Primary and Emergency air fans, Operation and Maintenance Manual for Geared motor Catalogue Sheet ~Trellex slurry and storage of SVEDALA slurry hoses Installation, Maintenance and Lubrication Instructions for Machine screw jacs. Installation and Maintenance Manual for Start-up oil bumer 0044494 sous ooas2e2 oou282 ooasne2 onan DOCUMENT Coimbatore flow controls Reitz India Limited IC Bauer Trellex [Nook Industries Ine Singhania ‘Technologists Pvt. Led. TAB.NO n B “4 16INSTRUCTION MANUAL DUOFLEX BURNER, type DBC 39651-03 Installation, operation and maintenance In this manual, reference is made to the following instruction manuals, etc.: Wear lining with Densit V3554 Burner pipe insulation 34721 Oil burner TFSM or OBA fil FE. L.SMIDTH VIGERSLEV ALLE 77. DK-2500 VALBY2 39651-03 fia CONTENTS: PAGE: 1. GENERAL INFORMATION 4 2 CONSTRUCTION AND LE 3. INSTALLATION 8 4. OPERATION 42 5. MAINTENANCE 17 6. KEY TO APPENDICES 24it 39651-09 APPENDICES: Arrangement ' Duoflex burner Adjustment unit Scale, length compensation Replacement of burner pipe Schematic diagram Primary air percentage, diagram Primary air momentum, diagram MGN code: 3K10 | Editedby: NG Translated by: JRo | Approvedby: 1h | Text pages: 224 39651--09, ff NOTE! [The present instruction manual is concemed with the situations| Iwhich, according to the experience of FLS, are the most likely to oc- cur. An exhaustive enumeration of all conceivable situations which| may occur during the installation, maintenance or operation of the| burner unit cannot be provided. Consequently, if a situation should arise, the occurrence of which is |not foreseen in the instruction manual, and which the operator is/or feels unable to handle, we would recommend that FLS is contacted without undue delay for advice on appropriate action. GENERAL INFORMATION The Duoflex burner type DBC is a rotary kiln burner which is used for burning coal dust or for combined burning of coal dust and fuel oil and/or fuel gas. In the case of combined firing, the burner must be used in conjunction with an oil lance and/or gas lance for intro- ducing and atomizing the fuel. See separate instruction manual for such equipment. Only @ part of the airflow required for the combustion Process, i.e. the primary air, is injected through the bumer. Normally, the primary airflow will constitute 7-10% of Lain (the minimum airflow for combustion). To this should be added the conveying air which is injected together with the coal dust. The primary air is injected at a pressure of up to 250 mbar, resulting in a maximum injection rate of approx. 200-210 mvs.fi 39651--03 5 2. CONSTRUCTION AND OPERATING PRINCIPLE 2.1___Arrangement, Appendix | ‘The burner which is suspended from a carriage (07) - seo separate instruction manual for burner suspension - is fed with primary air from the primary air fan (14). A special cool ing air fan (13) assures cooling of the burner in the event of power failure 22 yendix It The bumer is suspended from the supporting beam (22) which in turn is welded to the supporting pipe (21). ‘The supporting pipe has an air intake for admitting the exter- nal primary airflow, referred to as axial air. {In the centreline of the bumer there is a central duct (83) and, dependent upon the specific application, this duct may have a protective tube for the oil or gas bumer set as well as for an ignition gas bumer. Externally, the duct is equipped with a wear-resistant Densit lining in the zone in which the admis- sion of coal dust takes place. Also, fitted at the inlet end is a pipe connection (26) with a ball valve (17) and hose (16) for feeding cooling air from the primary air fan (14). At the outlet end the duct features a nozzle plate (41) with holes for cool- ing air. A coal pipe (34), radial air pipe (85) and a burner pipe, in the ‘mentioned order, are fitted concentrically around the central duct (83). The coal pipe (34) is centered around the central duct (33) by ‘means of guide fins. At the outlet end, the duct (30) is pro- vided with a machined, cylindrical nozzle (27). At the inlet nd, the duct is fixed via a flanged joint to the coal inlet (25). ‘The coal inlet which is internally lined with a wear-resistant Densit lining is designed so that the inlet extends into the coal pipe on the front section. Also, the coal duct is con- ected via expansion joint (44) to the radial air pipe (35). ‘The radial air pipe (35) extends through the supporting pipe (21), being connected to the latter by means of a flanged joint, Radial air (-swit ait) is admitted through pipe connec- tion (22)39651~03 Bumer pipe (20) is, via a flanged joint, bolted to supporting pipe (21). At the outlet end, the pipe is provided with a coni- cal air nozzle (40). The swirler unit (28) which is fixed by welding inside the burner pipe (20) also features a number of inclined vanes (28) to subject the airflow to swirling action. ‘The swirler unit is also equipped with a turned bushing and a number of spring-loaded means (30) for centering the coal nozzle (27). Externally, the bumer pipe (20) as well as the air nozzle (40) are equipped with a refractory lining (19). Conveying air and coal dust are fed via hose (08) and coal inlet (25) to the coal pipe (34) through which it is injected into the kiln. Immediately after its discharge from the nozzle, the coal dust is mixed with the primary airflow which is injected through the conical air nozzle (40). Normally, the injection rate of the primary air will be much higher than the rate at which coal dust is injected. As a result, there will be an acceleration of the coal dust flow. At the same time, hot secondary air is drawn into the coal flow, as- suring the ignition of the coal. The primary air is supplied by the fan (14) via coupling flange for air (04) and expansion joint (05) to the air distribution pipe (06), where the airflow is distributed into, respectively, axial air and swirl air. The axial air flows via the damper (36) and burner pipe (20) through to the conical air nozzle (40) while the swie air lows through the damper (37) and the radial air pipe (35) on to the ‘swirler unit (29). See Appendix Il. The inclined vanes in the ‘swirler unit subject the airflow to swirling action before it is again mixed with the axial air. The total primary airflow is then discharged through the air nozzle (40). In the event of power failure or if the primary air pressure is too low, the emergency cooling fan (13) will be started auto- matically, with simultaneous opening of the butterfly valve (12). The coal pipe (84) and coal inlet (25) are suspended jointly from the supporting beam (23) via the movable suspension (24) to allow it to be displaced in the longitudinal direction. It will thus be possible to adjust the annular area in the alr noz- zie (40). Adjustment is done by means of the spindle gear unit (38),