201thermal applicationshot gas generatoren
DESCRIPTION
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Thermal Applications
Hot Gas Generators
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For over one hundred years Loesche GmbH has been success-
fully building machines, such as mills, classifiers, hot gas generators,
rotary gates etc., and been involved in plant construction around the
world. Loesche develops, plans and delivers plant components and
complete grinding plants to the cement, iron & steel, power station,
industrial mineral, ore and wood industries and for nonferrous metal-
lurgy applications.
The first Loesche hot gas generators were developed, built and
delivered in 1960, and were available both with and without refrac-
tory linings. Which hot gas generator was used depended on the
desired outlet temperature for the downstream processes and on
the dust content of the process gas to be heated.
Since then these hot gas generators have been subject to continu-
ous further development, always represent the latest know-how and
conform to the current technical standards. They are characterised
by a clean, complete burning process and low emissions.
Loesche hot gas generators are ideally suitable for direct drying
processes and are used for example in conjunction with:
• grinding plants,
• drum-type driers,
• fluidised-bed furnaces/driers,
• flash driers,
• spheroidisers
The hot gas generators can run on a wide range of different fuels:
• Gas (such as e.g. natural gas, biogas, coke gas, blast furnace gas,
lean gas, synthesis gas and LPG)
• Light crude, diesel and heavy oils, and other liquid refinery waste
• Wood dust, pulverised lignite, pulverised hard coal, pulverised
petroleum coke
Loesche combustion chambers come in two different versions:
The LOMA® heater, a combustion chamber made from high-
temperature steel for maximum hot gas outlet temperatures up
to 750 °C. This steel combustion chamber is — thanks to its indus-
trial, economical and ecological advantages — used in most cases.
The LOMA® heater is adapted to the relevant combustion and tech-
nological requirements, i.e. there are design variants depending on
the fuel used and depending on the respective burner type on
account of different flame geometries. This high flexibility on the part
of the Loesche combustion chamber demonstrates the innovative
approach of Loesche and has been utilised around the world in
more than 600 plants with thermal output figures of between 0.1 MW
and 60 MW.
The muffle heater, which is fully lined with refractory material,
for outlet temperatures up to 1200 °C. This muffle heater is used
for special project-specific applications.
Loesche offers complete switchgear assemblies with its own
LOMA®control system for the burner. Loesche is therefore able to
deliver turnkey hot-gas generators.
Loesche technology — always one step ahead
Hot gas generator LOMA®
with steel combustion chamber
① Burner
② Burner muffle
③ Spiral housing
④ Ring slot
⑤ Protective jacket
⑥ Perforated jacket
⑦ Hot gas outlet
Hot gas generator with lined
combustion chamber
① Burner
② Burner muffle
③ Spiral housing
④ Ring slot
⑤ Combustion
chamber housing
⑥ Hot gas outlet
LOMA®control — burner control
LOMA® heater type LF 16 with a heavy oil burner, San Antonio, USA
LOMA® heater type LF 25 for a vertical arrangement in the workshop
LOMA® heater type LF 25 with a natural-gas burner, Dunkirk, France
LOMA® heater type LF 22 with a light oil burner, Settat, Morocco
LOMA® heater type LF 25, view into the perforated jacket
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LOMA® heater
The perforated jacket heater developed by Loesche back in 1960 —
a steel combustion chamber made of high-temperature steel and
a burner muffle — was launched onto the market under the name
LOMA® heater. For decades the LOMA® heater has been used around
the world in a wide range of thermal processes in order to provide
an optimum thermal configuration of the process. It is used to heat:
• Fresh air
• Return gases
• Cleaned exhaust gases
• Hot blast furnace gases
• Process gas with low dust content
These gases to be heated can be introduced at temperatures of up
to 350 °C into the spiral housing.
Features of the LOMA® heater
• Combustion chamber manufactured from high-temperature steels,
no refractory lining necessary (outlet temperatures up to 750 °C)
• Minimal heat losses on startup of the hot gas generator due to the
absence of heating of a refractory lining, therefore startup at full load
possible
• Virtually delay-free adaptation of output in the case of rapid load
changes
• High combustion chamber cooling rate, preventing thermal overload-
ing of downstream components
• There is no need for an EMERGENCY STACK in EMERGENCY
SHUTDOWN SITUATIONS and during startup up and shutdown
• Short-term accessibility for inspections
• Longer service life than plants with refractory linings
• Short installation times, low weight, minimal space requirements, can
be installed in existing plants, complete pre-assembly also for larger
LOMA® heaters
• Horizontal and vertical erection possible
• Combustion chamber virtually adiabatic — more than 99 % of the
heat can be utilised for the process
• Operates both in vacuum and overpressure modes
• No moving parts in the combustion chamber
• Low susceptibility to faults/repairs
• Optical monitoring of perforated jacket temperatures
• Customised plants for individual applications
Operational reliability and economic efficiency considerations play a
major role in layout, design and manufacture.
Methods of operation
The flow of process gas entering via the spiral housing ③ cools the
protective jacket ⑤, the burner muffle ② and the perforated jackets
⑥ as a result of flow control. The process gas passes through the
ring slots ④ and holes in the perforated jacket into the interior of the
combustion chamber, where it mixes with the hot smoke gases from
combustion. The combustion chamber geometry and flow control pro-
tect the perforated jacket against the flame and the hot smoke gases.
The combustion chamber has an overall pressure loss of 2 – 3 mbar.
When process gases with a light dust content and powdery fuels are
used, a vertical arrangement of the LOMA® heater is always chosen.
In processes which require a highly uniform temperature profile,
specially shaped swirl constructions (e.g. baffle plate) with very low
pressure losses (< 1 mbar) are installed in the area of the outlet ⑦ or
at a short distance behind this area. This results in a highly uniform
temperature distribution after only a distance of 1.5 to 2 times the duct
diameter.
① Burner
② Burner muffle
③ Spiral housing
④ Ring slot
⑤ Protective jacket
⑥ Perforated jacket
⑦ Hot gas outlet
① Burner
② Burner muffle
③ Spiral housing
④ Ring slot
⑤ Protective jacket
⑥ Perforated jacket
⑦ Hot gas outlet
Loesche LOMA® type combustion chamberTechnical data
Combustion chamber type
max. combustion chamber output in kWth at 450 °C
Hot gas volumetric flow (outlet)
m3/h (standard conditions)
Dimensions Weightapprox. kgDiameter
(mm)Length (mm)
LF 4 550 3,000 400 1,800 650
LF 5 850 4,800 500 2,200 770
LF 6 1,400 7,600 600 2,500 920
LF 7 1,750 9,700 700 2,800 1,000
LF 8 2,250 12,600 800 3,000 1,500
LF 9 2,800 15,700 900 3,300 1,800
LF 10 3,450 19,100 1,000 3,600 2,200
LF 11 4,200 23,200 1,100 3,900 2,800
LF 12 5,400 30,100 1,200 4,300 3,900
LF 14 6,800 38,000 1,400 4,800 5,200
LF 16 8,700 48,300 1,600 5,300 7,000
LF 18 11,300 62,700 1,800 6,000 8,900
LF 20 13,800 77,000 2,000 6,700 9,200
LF 22 17,500 97,200 2,200 7,400 10,800
LF 25 21,800 121,500 2,500 8,000 12,000
LF 28 26,700 151,800 2,800 8,800 16,000
LF 31 32,200 185,000 3,100 9,600 25,000
LF 36 41,400 238,000 3,600 10,700 34,000
LF 40 55,000 323,000 4,000 12,000 46,000
Ø
Length
Explanation: LF 25
x 100 = outlet diameter of heater in mm
Heaters
LOMA®
The values specified above refer to gas as the fuel and may
differ for a specific project, depending on the fuel used (additional
burner sizes on request).
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Hot gas generators for burning lean gases
The Loesche steel combustion chamber in combination with a
multiple-lance burner (MLB) constitutes a special development for
burning lean gases and is characterised by the following features:
The multiple-lance burner ① comprises a number of individual noz-
zles for lean gas and combustion air, thereby enabling lean gas to be
fully combusted without a supporting flame. Both media strike one
another within the nozzle system at high velocity. This provides for
an intensive mixing of the media, and thereby ensures that the basic
requirement for efficient combustion is achieved. The hot smoke
gases emerging from the burner muffle ⑩ mix in the area of the
perforated jackets ⑫ with the process air to be heated and which is
fed to the LOMA® heater via the spiral housing ⑨. The high propor-
tion of inert gases of sometimes over 75 % in lean gases results in
a low flame temperature. For this reason, a start burner ② installed
coaxially in the main burner is used to start the LOMA® heater. The
function of this start burner (run on natural gas, coke gas, other
burnable gases but also light crude oil) is on the one hand to heat up
the interior wall of the burner muffle to a specific surface temperature
in order to ensure that the lean gas is safely ignited (the ignition tem-
perature of e.g. CO is 605 °C). On the other hand, the start burner is
dimensioned in terms of its output in such a way that the entire plant
can be heated up above the dew point.
The start burner is switched off after the main burner has started.
The output ranges of the main and start burners are designed to
overlap so as to provide continuous operation. The main burner ① has a control range of 1:10, the start burner ② has a control range
of 1:5 to 1:8. Every necessary operating point within the control
range of 1:40 to 1:70 can therefore be easily achieved.
The excellent control performance of the multiple lance burner is a
significant benefit to the downstream processes. More than 50 of
these hot gas generators developed and patented by Loesche are
deployed in conjunction with Loesche vertical roller mills and mills
of other manufacturers around the world in dry-grinding plants (e.g.
PCI plants) and coal gasification plants for preparing coal for the
purpose of smelting iron ore.
Main features of lean gas combustion:• Combustion of lean gases from a calorific value of 2800 kJ/m³
(standard conditions) without a supporting burner• Thermal output of 0.5 MW to 60 MW• Wide control range• Short flame and stable combustion• Low CO and NOx content in the exhaust gas
Fuels:• Blast furnace gas• Exhaust gas, contaminated by hydrocarbons• Biogas• Exhaust gas from the chemical industry• Coke oven gas• Synthesis gas
① Multiple-lance burner
② Start burner
③ Start fuel
④ Combustion air for start fuel
⑤ Lean gas
⑥ Combustion air for lean gas
⑦ Process gas inlet
⑧ Flame monitor
⑨ Spiral housing
⑩ Burner muffle
⑪ Temperature monitor
⑫ Perforated jacket
⑬ Protective jacket
⑭ Hot gas outlet
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3
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2
1 LOMA® type steel combustion chamber
2 Multiple-lance burner
3 Loesche mill
4 Combustion air supply
5 Lean gas regulating station
6 Start gas regulating station
7 Burner control
Flow diagram of a hot gas generator, LOMA® heater with a multiple lance burner for blast furnace gas and a start burner for coke or natural gas
Multiple-lance burner (MLB)
Blast furnace gas hot gas generator, MLB 8 with LOMA® heater type LF 20, Ghent, Belgium, 2004
MLB, viewed towards the nozzle outlet
Fabricated valve and fitting station (gas regulating station) in the workshop
MLB 12, for a PCI plant, Dillingen, Germany, 2009
MLB 13, Typ LF 22, Huckingen, Germany, 2007
temperature
Wobbe index
nominal value
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Since 1986 the Loesche-developed steel combustion chamber
(LOMA® heater) has been successfully used in combination with
multifuel burners of different manufacturers to burn wood dust and
pulverised lignite. This steel combustion chamber is the prototype
of all these combustion chambers which are used for different ther-
mal processes around the world.
Since 1988 Loesche has supplied a large number of hot gas gen-
erators with outputs of up to 60 MW to burn wood dust from the
chipboard industry. LOMA® heaters run on pulverised lignite are
also successfully used.
In order to burn solid fuels, a vertical arrangement of the combus-
tion chamber should wherever possible be adopted so as to avoid
slag caking.
In view of the increasing scarcity and thus increasing cost of rare
energy sources, such as light crude oil and natural gas, customers
are increasingly expressing a desire to use hard coal, brown coal
or petroleum coke to generate process heat.
Loesche has taken up this challenge by instigating an appropri-
ate research programme in conjunction with university institutes,
since pure steel combustion chambers for burning hard coal and
petroleum coke are barely available on the market. The purpose of
this programme has been to gain initial experience of burning solid
fuels with a 400 kW dust-fired LOMA® heater.
Hot gas generators for solid fuels
Loesche LOMA® type LF 42 steel combustion chamber for burning wood dust
① Dust metering
② Supply of gas and oil
③ Atomisation air
④ Combustion air
⑤ Process gas
⑥ Process gas for
flame cooling
⑦ Hot gas duct with
dust discharge
The Loesche Technology centre also houses an HGG test rig for
solid fuels with a heater output of 1 MW. What is unique about this
test rig is that it is directly coupled to a Loesche mill.
This rig enables Loesche to analyse customer-specific coal of all
kinds and origins under real conditions and to determine the com-
bustion parameters.
On the basis of the positive research results and the ensuing
development of large-scale plants, it has been possible to suc-
cessfully implement in Asia the first LOMA® hot gas generator run
on pulverised hard coal with an output of 30 MW (pulverised hard
coal as the primary fuel, heavy oil as the secondary fuel). Loesche
hot-gas generators for solid fuels are characterised by the follow-
ing features:
• High degree of mixing between dust and combustion air
• Total combustion
• Pulsation-free flame
• Monitored flame temperature
• No caking on the combustion chamber walls
• Gases and oils can be used as the second fuel
• Complete redundancy with secondary fuel
• No heat-up phase required
• Pulsation-free dosing
View into a LOMA® combustion chamber during burning of pulverised hard coal
Coal dust burner with HGG in the Loesche Test Center Loesche test rig (1 MW) for burning solid fuels
Fields of application for Loesche hot gas generators
Process heat for drying plants
Process steam generation
Asphalt mixing plants
Mobile coal grinding plantCoal dry-grinding plant in a steel mill with a HGG for blast furnace gas
Installation variants for hot gas generators in the process
1. Integration in the return gas line (Full-Inline)
In this arrangement the entire process air for the dry-
grinding process is routed through the hot gas generator.
This arrangement provides for maximum energy recovery
and is necessary for example when process air that is low
in oxygen (inert operation) is stipulated for safety reasons
during the comminution of combustible grinding stock.
2. Installation in a bypass to the return gas line
(Semi-Inline)
Here only some of the process air is routed through
the hot gas generator. This variant is chosen if,
on account of large plants, the volumetric flow of
process gas would necessitate very large combus-
tion chambers and high investment costs would be
incurred. The use of only a small proportion of the
process gas means that the combustion chamber has
significantly smaller dimensions.
The use of hot gas generators in industrial plants is char-
acterised by the different ways in which they are inte-
grated in the process. Three variants are shown using
dry-grinding plants with a Loesche mill as the example:
3. Flanged to a return gas line (Flanged)
In this arrangement fresh air (and not process air) is
routed through the hot gas generator. This variant is
chosen primarily when the hot gas generator is only
required for starting the overall system and is then
shut down.
Loesche – worldwide presence
Loesche is an export-oriented company run
by the owner, which was established in 1906
in Berlin. Today the company is internatio-
nally active with subsidiaries, representatives
and agencies worldwide.
Our engineers are constantly developing
new ideas and individual concepts for grin-
ding technologies and preparation processes
for the benefit of our customers. Their com-
petence is mainly due to our worldwide
information management.
This ensures that current knowledge and
developments can also be used immediately
for our own projects.
The services of our subsidiaries and agen-
cies are of key importance for analysis,
processing and solving specific project
problems for our customers.
Please visit our homepage at
www.loesche.com for up-to-date
information on our overseas companies.
Loesche GmbHHansaallee 24340549 DüsseldorfTel. +49 - 211 - 53 53 - 0Fax +49 - 211 - 53 53 - 500Email: [email protected]
BrazilLoesche Equipamentos Ltda.Rua México 119 sl. 190820031-145 Rio de Janeiro, BrazilTel. +55 - 21 - 22 40 79 00Fax +55 - 21 - 22 20 94 40Email: [email protected]
GermanyLoesche Automatisierungstechnik GmbHZum Pier 5244536 LünenTel. +49 - 231 - 98 70 10Fax +49 - 231 - 98 70 10 - 20E-mail: [email protected]
Loesche ThermoProzess GmbHUechtingstraße 19 / Gebäude D945881 GelsenkirchenTel. +49 - 209 - 36 17 22 - 0Fax: +49 - 209 - 36 17 22 - 180www.loesche-tp.de
IndiaLoesche India Pvt. Ltd.D - 83, Sector - 2Noida - 201301U.P., India Tel. +91 - 120 - 40 18 500 +91 - 120 - 24 44 205 - 207Fax +91 - 120 - 40 18 590 - 91 +91 - 120 - 24 43 327Email: [email protected]
People’s Republic of China Loesche Mills (Shanghai) Co., Ltd.No. 568, Jinhong Road(near No. 555, Chunhe Road)Baoshan District,201901 Shanghai, P. R. ChinaTel. +86 - 21 - 5180 6100Fax +86 - 21 - 5180 6101Email: [email protected]/zh
Loesche Mills (Shanghai) Co. Ltd.5 Dongzhimen South Street Room 817-818, CYTS Plaza Dongcheng District, 100007 Beijing, P. R. ChinaTel. +86 - 10 - 5815 6205Fax +86 - 10 - 5815 6220 Email: [email protected]/zh
RussiaOOO LoescheBerezhkovskaya Naberezhnaya 16a/2P.O. Box 97, 121059 MoscowRussian FederationTel. +7 - 495 - 988 50 81Fax +7 - 495 - 988 60 86Email: [email protected]
Socialist Republic of VietnamLoesche GmbH Viet Nam Representative office60 Nguyen Dinh Chieu Str.Dakao Ward, Dist. 1HCM - Ho-Chi-Minh City,Tel. +84 - 8 - 39 10 45 62Fax +84 - 8 - 39 10 45 26 E-Mail: [email protected]
South AfricaLoesche South Africa (Pty.) Ltd.55 Empire Road, Empire Park, Block C2193 Parktown, South AfricaTel. +27 - 11 - 482 29 33Fax +27 - 11 - 482 29 40Email: [email protected]
SpainLoesche Latinoamericana S.A.U.Condesa de Venadito 1, Planta 428027 Madrid, SpainTel. +34 - 91 - 458 99 80Fax +34 - 91 - 457 10 17Email: [email protected]
United Arab EmiratesLoesche Middle East FZEP.O. Box 262 622Jebel Ali, Dubai, U.A.E.Tel. +971 - 4 - 886 59 11 Fax +971 - 4 - 886 59 22Email: [email protected]
United KingdomLoesche Energy Systems Ltd.2, Horsham GatesNorth StreetHorsham, RH135PJ, United KingdomTel. +44 - 1403 - 223 101 Fax +44 - 1403 - 223 102 Email: [email protected]/uk
USALoesche America, Inc.20170 Pines Boulevard, Suite 301Pembroke PinesFlorida 33029, USATel. +1 - 954 - 602 14 24Fax +1 - 954 - 602 14 23Email: [email protected]
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