Combustion System Improvements

Improved combustion systems aim to optimize the shape of the flame, the mixing of combustion air and fuel and reducing the use of excess air. Different techniques have been developed to this effect. 

For rotary kilns, one of such technique, the Gyro-Therm technology improves gas flame quality while reducing NOx emissions. The technology can be applied to gas or gas/coal dual fuel burners. The Gyro-Therm burner uses a patented "precessing jet" technology. The nozzle design produces a gas jet leaving the burner in a gyroscopic-like processing motion. This stirring action produces rapid large scale mixing in which pockets of air are engulfed within the fuel envelope without using high velocity gas or air jets. Besides reducing energy consumption, the technology is reported to help reduce NOx emissions by 30 to 70%, and increase productivity by more than 5%. 

Indian flag This technology has limited potential for India, as gas as a fuel is not avaialble to cement plants in the country. 

Development Status Products

Combustion System ImprovementsCosts & Benefits

Parent Process: Clinker Making
Energy Savings Potential

Specific fuel savings up to 8% have been realised in plants using Gyro-Therm technology.  

Another technique developed in the UK for flame control resulted in fuel savings of 2 to 10% depending on the kiln type.

CO2 Emission Reduction Potential

The payback times for Gyro-Therm technology is expected to be less than one year. 

Costs are estimated to be around $1.0/annual ton clinker capacity, with estimated payback periods of 2-3 years.

Combustion System Improvements Publications

Energy Efficiency Improvement Opportunities for the Cement Industry

The U.S. Environmental Protection Agency’s (EPA) energy guide, Energy Efficiency Improvement and Cost Saving Opportunities for Cement Making, discusses energy efficiency practices and technologies that can be implemented in cement manufacturing plants. This ENERGY STAR guide provides current real world examples of cement plants saving energy and reducing cost and carbon dioxide emissions.

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Combustion System Improvements Websites