Air lance apparatus, systems, and methods

An apparatus for reducing gas consumption in a rotary kiln comprising:

• an inclined drum having an upper end and a lower end, the drum configured to rotate around an axis and convey a bed of material from the upper end to the lower end along the axis;
• and
• an air lance comprising a wall defining an interior space, a first end, and a second end, the first end of the air lance positioned proximate to the bed of material and effective to inject air from the interior space into the bed of material, the second end positioned distal to the bed of material and effective to transfer air to the interior space;
• wherein the first end of the air lance is about 0 inches to 18 inches from where the coke product discharges from the rotating kiln.

A method of reducing gas consumption of a rotary kiln, the method comprising:

• providing an air lance proximate to an inclined drum,
• wherein the inclined drum comprises an upper end and a lower end and is configured to rotate around an axis to convey a bed of material from the upper end to the lower end along the axis;
• and
• wherein the air lance comprises a wall defining an interior space, a first end, and a second end, the first end of the air lance positioned proximate to the bed of material and effective to inject air from the interior space into the bed of material, the second end positioned distal to the bed of material and effective to transfer air to the interior space, wherein the first end of the air lance is about 0 inches to 18 inches from where the coke product discharges from the rotating kiln;
• and
• injecting air from the air lance into the bed of material while simultaneously rotating the inclined drum to convey the bed of material from the upper end to the lower end along the axis.