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R & D Centre for Mineral and Coal Technology
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THE USE OF CYCLONE COAL BURNER TO SUBSTITUTE OIL BURNER IN ALUMINUM SMELTER USING REVERBERATORY FURNACE SUMARYONO SUMARYONO
Indonesian Mining Journal Vol 11, No 3 (2008): INDONESIAN MINING JOURNAL Vol. 11 No. 3 October 2008
Publisher : Puslitbang tekMIRA

Show Abstract | Download Original | Original Source | Check in Google Scholar | Full PDF (189.729 KB) | DOI: 10.30556/imj.Vol11.No3.2008.582

Abstract

The increasing of oil price forces the industries to alter their fuel from oil into a cheaper fuel. Undoubt- edly, coal is a promising energy alternative in Indonesia. To save the cost, altering the fuel oil into coal in industries may be accomplished just by altering the oil burner with coal burner, therefore the exist- ing equipment still can be used without much modification. The coal combustor employed should have nearly the same characteristic with the oil combustor, so that the performance of the kiln or other equipment served by the combustor is not change significantly. R & D Centre for Mineral and Coal Technology (TekMIRA) has developed cyclone combustor for coal with particle size of less than 30 mesh. The combustion is stable at the rate of 50 – 180 kg/hr coal with excess combustion air of 22 – 26%. The length of cyclones is ranged from 120 up to 220 cm, the internal diameter is 60 up to 80 cm and the combustion temperature is 1200 up to 1325°C. This combustor characteristics are nearly the same with oil combustor such as: the combustion flame may be directed; high intensity combustion, long flame; and it is not difficult to match the energy output of previous oil combustor. In this experiment the cyclone combustor was used to replace the oil combustor in a reverberatory furnace to refine aluminum from aluminum scrap by melting the material at 1000 – 1060°C. For 500 kg aluminum, the oil consumption was 47.5 litre for 2.5 hour or the average was 19 lt/hr and the energy efficiency was 29.2%. Using high ash bituminous coal with cyclone burner, the coal consumption was 129 kg for 1.8 hour or the average was 71.6 kg/hr and the energy efficiency was 17.9%. A higher efficiency was obtained by using low ash sub bituminous coal, that the coal consumption was 82 kg for 81 minutes or the average was 60 kg/hr and the energy efficiency was 29.0%. Therefore it is a good opportunity for coal to substitute fuel oil in this reverberatory furnace and many other oil fuelled processes such as in boiler, lime calcination, mineral drying etc.
THE USE OF SUB-BITUMINOUS COAL IN COMBINATION FIRING FOR TILE, BRICK AND LIMESTONE BURNING SUMARYONO SUMARYONO
Indonesian Mining Journal Vol 15, No 1 (2012): INDONESIAN MINING JOURNAL Vol. 15 No. 1 February 2012
Publisher : Puslitbang tekMIRA

Show Abstract | Download Original | Original Source | Check in Google Scholar | Full PDF (154.693 KB) | DOI: 10.30556/imj.Vol15.No1.2012.473

Abstract

Combination fi ring of fi rewood and bituminous coal was recommended to reduce fi rewood consumption and to increase energy effi ciency. However, bituminous coal deposit in Indonesia has been depleted, therefore the use of sub-bituminous coal for combination fi ring should be promoted. In this work the use of sub-bituminous coal for combination fi ring was investigated in tile, brick and limestone burning. The calorifi c value of the sub-bituminous coal was only 4.6% lower than the value of bituminous coal. The increase in energy effi ciencies using sub- bituminous coal were lower than that of using bituminous coal. Compared with the use of fi rewood alone the increase in energy effi ciencies using combination fi ring of fi rewood and sub-bituminous coal in tile, brick and limestone burning were 45.7, 53.6 and 28.3% respectively. While, in the use of bituminous coal, the increase were 70.8, 75.1 and 91.9% respectively. In the combination fi ring, the fi rewood substituted by coal using sub-bituminous coal were smaller than the use of bituminous coal, i.e. for tile, brick and limestone burning, using sub- bituminous coal the substituted fi rewood were 47.7, 44.6 and 45.0% respectively while using bituminous coal there were 54.5, 50.0 and 66.0% respectively. It was revealed that the superiority of bituminous coal come from its higher content of high hydrocarbon volatiles which produced higher radiative fl ame resulting more effi cient burning processes.
REPLACING FUEL OIL BURNER IN A ZINC BATH KETTLE FOR GALVANIZATION PROCESS BY COAL CYCLONE ONE SUMARYONO SUMARYONO
Indonesian Mining Journal Vol 9, No 2 (2006): INDONESIAN MINING JOURNAL Vol. 09 No. 2 June 2006
Publisher : Puslitbang tekMIRA

Show Abstract | Download Original | Original Source | Check in Google Scholar | Full PDF (131.628 KB) | DOI: 10.30556/imj.Vol9.No2.2006.646

Abstract

Most galvanizing industries use fuel oil to maintain a zinc bath temperature within the 440 – 455°C range. The oil burner is used in a heating chamber and the flue gas is then passed into the heating space under a zinc bath kettle at a temperature of 600°C. In this works one of the oil burner would be replaced by a coal burner. The kettle dimension is 12 x 1.5 x 1.8 m for its inner length, width and depth respectively. The heating space under the kettle is divided into two sections, each section is heated by a single oil burner of 50 - 80 litres/hour burning capacity. As there is no access into the heating space to remove the accumulated ash, the employed coal combustion technique should not transfer the ash into this chamber. For this purpose a vertical cyclone coal burner is used in a section with combustion capacity of 100 - 200 kg coal/hour. To minimize ash accumulation, a cyclone dust sepa- rator is connected after the cyclone burner, thus a cleaner flue gas enters the heating chamber. The coal used is a low ash sub-bituminous type of 5,500 kcal/kg at with particle sizes less than 30 mesh. Observation of temperature fluctuation in oil heated and coal heated sections during galvanization process showed that the fluctuation in both sections are in balance, indicating that the coal heating matches fuel oil heating in this system. The fuel used are 124 kg/hour for coal and 60 l/hour for fuel oil. To maintain zinc bath temperature around 430 – 455°C within 7 days galvanizing time operation it is found that fuel consumption is 20,300 kg of coal in the coal heated section and 10,080 l fuel oil in the oil heated section. It means that 1 l fuel oil is equivalent to 2 kg of coal or coal efficiency is 18.2% lower than the oil one in this system. The ash produced by the combustion of coal which trapped by both cyclones is 80% which is accumulated in the burner and 20% in the cyclone dust separator. The energy efficiency of coal is lower than that of the fuel oil since the use of fuel oil is directly burned within heating chamber, otherwise the coal is combusted in a cyclone burner and the flue gas enters the heating chamber after a longer journey through a cyclone dust separator.
THE USE OF SUB-BITUMINOUS COAL IN COMBINATION FIRING FOR TILE, BRICK AND LIMESTONE BURNING SUMARYONO SUMARYONO
Indonesian Mining Journal Vol 15 No 1 (2012): INDONESIAN MINING JOURNAL Vol. 15 No. 1 February 2012
Publisher : Balai Besar Pengujian Mineral dan Batubara tekMIRA

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.30556/imj.Vol15.No1.2012.473

Abstract

Combination fi ring of fi rewood and bituminous coal was recommended to reduce fi rewood consumption and to increase energy effi ciency. However, bituminous coal deposit in Indonesia has been depleted, therefore the use of sub-bituminous coal for combination fi ring should be promoted. In this work the use of sub-bituminous coal for combination fi ring was investigated in tile, brick and limestone burning. The calorifi c value of the sub-bituminous coal was only 4.6% lower than the value of bituminous coal. The increase in energy effi ciencies using sub- bituminous coal were lower than that of using bituminous coal. Compared with the use of fi rewood alone the increase in energy effi ciencies using combination fi ring of fi rewood and sub-bituminous coal in tile, brick and limestone burning were 45.7, 53.6 and 28.3% respectively. While, in the use of bituminous coal, the increase were 70.8, 75.1 and 91.9% respectively. In the combination fi ring, the fi rewood substituted by coal using sub-bituminous coal were smaller than the use of bituminous coal, i.e. for tile, brick and limestone burning, using sub- bituminous coal the substituted fi rewood were 47.7, 44.6 and 45.0% respectively while using bituminous coal there were 54.5, 50.0 and 66.0% respectively. It was revealed that the superiority of bituminous coal come from its higher content of high hydrocarbon volatiles which produced higher radiative fl ame resulting more effi cient burning processes.
THE USE OF CYCLONE COAL BURNER TO SUBSTITUTE OIL BURNER IN ALUMINUM SMELTER USING REVERBERATORY FURNACE SUMARYONO SUMARYONO
Indonesian Mining Journal Vol 11 No 3 (2008): INDONESIAN MINING JOURNAL Vol. 11 No. 3 October 2008
Publisher : Balai Besar Pengujian Mineral dan Batubara tekMIRA

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.30556/imj.Vol11.No3.2008.582

Abstract

The increasing of oil price forces the industries to alter their fuel from oil into a cheaper fuel. Undoubt- edly, coal is a promising energy alternative in Indonesia. To save the cost, altering the fuel oil into coal in industries may be accomplished just by altering the oil burner with coal burner, therefore the exist- ing equipment still can be used without much modification. The coal combustor employed should have nearly the same characteristic with the oil combustor, so that the performance of the kiln or other equipment served by the combustor is not change significantly. R & D Centre for Mineral and Coal Technology (TekMIRA) has developed cyclone combustor for coal with particle size of less than 30 mesh. The combustion is stable at the rate of 50 – 180 kg/hr coal with excess combustion air of 22 – 26%. The length of cyclones is ranged from 120 up to 220 cm, the internal diameter is 60 up to 80 cm and the combustion temperature is 1200 up to 1325°C. This combustor characteristics are nearly the same with oil combustor such as: the combustion flame may be directed; high intensity combustion, long flame; and it is not difficult to match the energy output of previous oil combustor. In this experiment the cyclone combustor was used to replace the oil combustor in a reverberatory furnace to refine aluminum from aluminum scrap by melting the material at 1000 – 1060°C. For 500 kg aluminum, the oil consumption was 47.5 litre for 2.5 hour or the average was 19 lt/hr and the energy efficiency was 29.2%. Using high ash bituminous coal with cyclone burner, the coal consumption was 129 kg for 1.8 hour or the average was 71.6 kg/hr and the energy efficiency was 17.9%. A higher efficiency was obtained by using low ash sub bituminous coal, that the coal consumption was 82 kg for 81 minutes or the average was 60 kg/hr and the energy efficiency was 29.0%. Therefore it is a good opportunity for coal to substitute fuel oil in this reverberatory furnace and many other oil fuelled processes such as in boiler, lime calcination, mineral drying etc.
REPLACING FUEL OIL BURNER IN A ZINC BATH KETTLE FOR GALVANIZATION PROCESS BY COAL CYCLONE ONE SUMARYONO SUMARYONO
Indonesian Mining Journal Vol 9 No 2 (2006): INDONESIAN MINING JOURNAL Vol. 09 No. 2 June 2006
Publisher : Balai Besar Pengujian Mineral dan Batubara tekMIRA

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.30556/imj.Vol9.No2.2006.646

Abstract

Most galvanizing industries use fuel oil to maintain a zinc bath temperature within the 440 – 455°C range. The oil burner is used in a heating chamber and the flue gas is then passed into the heating space under a zinc bath kettle at a temperature of 600°C. In this works one of the oil burner would be replaced by a coal burner. The kettle dimension is 12 x 1.5 x 1.8 m for its inner length, width and depth respectively. The heating space under the kettle is divided into two sections, each section is heated by a single oil burner of 50 - 80 litres/hour burning capacity. As there is no access into the heating space to remove the accumulated ash, the employed coal combustion technique should not transfer the ash into this chamber. For this purpose a vertical cyclone coal burner is used in a section with combustion capacity of 100 - 200 kg coal/hour. To minimize ash accumulation, a cyclone dust sepa- rator is connected after the cyclone burner, thus a cleaner flue gas enters the heating chamber. The coal used is a low ash sub-bituminous type of 5,500 kcal/kg at with particle sizes less than 30 mesh. Observation of temperature fluctuation in oil heated and coal heated sections during galvanization process showed that the fluctuation in both sections are in balance, indicating that the coal heating matches fuel oil heating in this system. The fuel used are 124 kg/hour for coal and 60 l/hour for fuel oil. To maintain zinc bath temperature around 430 – 455°C within 7 days galvanizing time operation it is found that fuel consumption is 20,300 kg of coal in the coal heated section and 10,080 l fuel oil in the oil heated section. It means that 1 l fuel oil is equivalent to 2 kg of coal or coal efficiency is 18.2% lower than the oil one in this system. The ash produced by the combustion of coal which trapped by both cyclones is 80% which is accumulated in the burner and 20% in the cyclone dust separator. The energy efficiency of coal is lower than that of the fuel oil since the use of fuel oil is directly burned within heating chamber, otherwise the coal is combusted in a cyclone burner and the flue gas enters the heating chamber after a longer journey through a cyclone dust separator.
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