Each FCT Turbu-Jet burner delivers peak performance because it is fully optimised using FCT proprietary physical and mathematical modelling techniques. Each burner is custom designed to suit not only the kiln firing rate, but to suit the heat flux, flame shape and length requirments for that process. FCT modelling engineers evaluate the kiln aerodynamics and fuel properties when designing a burner with the required flame properties.

FCT designs and supplies burner ancilliary equipment including, fuel handling systems, gas and oil valve trains and burner management systems to comply with any safety standard.

Gas can be a difficult fuel to burn efficiently in kilns because of its narrower flammability limits (ignition and stability), low flame emissivity (lower rates of heat transfer), and higher combustion gas volume than oil or coal. This can adversely affect product quality, production rates and fuel consumption unless special precautions are taken.

FCT Gas Burner Applications:

• Lime
• Lime sludge
• Cement
• Alumina calcination
• Petroleum coke calcination
• Dolomite
• Titanium dioxide
• Chromium
• Incineration applications
• Minerals processing
• Metals processing
• Refractories
• Mineral sands
• Reduction kilns

FCT burners can be designed to use virtually any gaseous fuel including the various biogases.

FCT gas burners can be supplied with an auxiliary or main load carrying oil sprayer. Auxiliary waste liquid or gaseous waste lances can be supplied for incineration or emission control.

Oil is an excellent fuel for kilns owing to it's high emissivity, which results in high rates of heat transfer to the charge. However to burn it efficiently it must be atomized and sprayed in to the kiln in a controlled manner FCT offers a range of oil burners utilising our unique CM high performance atomiser.

FCT Oil Burner Applications:

• Lime
• Lime sludge
• Cement
• Alumina calcination
• Petroleum coke calcination
• Dolomite
• Titanium dioxide
• Chromium
• Incineration applications
• Minerals processing
• Metals processing
• Refractories
• Mineral sands
• Reduction Kilns

FCT oil burners can be supplied with light up oil or gas guns, and waste liquid or gaseous waste lances for incineration or emission control purposes.

Coal is an excellent fuel for kilns owing to it's high emissivity. Coal is, however, rather more difficult to handle than oil or gas since it is a solid material of varying composition and calorific value. The variable nature of coal requires a flexibility of burner design to allow the use of different grades of fuel.

FCT Kiln Coal Burner Applications:

• Lime
• Lime sludge
• Cement
• Alumina calcination
• Petroleum coke calcination
• Dolomite
• Titanium dioxide
• Chromium
• Gypsum
• Incineration applications
• Minerals processing
• Metals processing
• Refractories
• Mineral sands
• Reduction kilns

Each of the above products requires a different heat transfer pattern for optimum product quality, production rate and fuel efficiency.

FCT coal burners can be supplied with light up oil or gas guns, and waste liquid or gaseous waste lances for incineration or emission control purposes.

Instability in world fuel prices makes prediction of fuel costs very difficult. A true multi-fuel installation allows the kiln to utilise the most economical fuel currently available. In many cases by-product fuels may be used in place of, or in addition to, the primary fuel.

FCT Multi-Fuel Kiln Burner applications:

• Lime
• Lime sludge
• Cement
• Alumina calcination
• Dolomite
• Titanium dioxide
• Chromium
• Petroleum coke calcination
• Incineration applications
• Minerals processing
• Metals processing
• Refractories
• Mineral sands
• Reduction kilns

Each of the above products requires a different heat transfer pattern for optimum product quality, production rate and fuel efficiency. Each fuel has different burning characteristics. For example the peak heat transfer with gas firing tends to be much further up the kiln compared to oil or coal firing

Oxides of nitrogen (NOx) are air pollutants that cause chemiluminescent smog. Rotary kilns emit relatively high levels of thermal NOx and kiln operators are under increasing pressure to reduce NOx, even though their contribution to the overall level in the atmosphere is small. Hence kiln operators have to meet ever more stringent emissions regulations.

NOx forms by oxidation of the nitrogen in the air and from the organic nitrogen compounds in the fuel. Three formation mechanisms exist; Thermal NOx, Fuel NOx and Prompt NOx. Since thermal NOx is the dominant mechanism of NOx formation in kiln flames, NOx reduction techniques commonly adopted concentrate on reducing both flame temperature and oxygen in the flame by simply reducing the fuel/air mixing rates. Although this can be effective at reducing NOx it can also substantially reduce the heat transfer to the product, resulting in reduced production rates and/or poor product quality.

NOx usually is formed in the high temperature zone close to the burner nozzle. A good knowledge of the aerodynamics is used by FCT to ensure reduced oxygen concentrations and temperatures in this region whilst maintaining the overall fuel/air mixing and heat transfer rates. Thus NOx is minimised but production rates and product quality maintained.