What You Need to Know About Industrial Burners | ACI Controls

What You Need to Know About Industrial Burners: Types, Application, and More

If you’re not already familiar with industrial process equipment, industrial burners might seem otherworldly. You may even picture an old-timey steam-filled boiler room as boilers and burners are often used interchangeably in conversation. However, there are critical differences between the two pieces of industrial equipment.

In this blog, we take a closer look at industrial burners, everything from the different types, their functions, applications, and more – that way you’re better prepared when you need to upgrade your burner system. 

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What are Industrial Burners?

Industrial burners are a key component of every heating system. They provide temperature control throughout entire manufacturing facilities, as well as other heating processes during manufacturing. The mechanical devices mix fuel and air together and use an ignition device to provide a platform for combustion. This means that good reliability, high efficiency, and low emission are the target for both equipment users and machinery manufacturers.

How do Industrial Burners work?

From the exterior, burners might just look like a hunk of metal to an untrained eye. However, inside the burner, there is an array of processes taking place. A burner is designed to produce a flame of a specific length, shape, and capacity. These requirements are driven by the needs of the application. Often, this means the burner is firing into a combustion chamber, perhaps alone, or perhaps with several other burners.

The device is used to mix oxygen with fuel to achieve controlled combustion. Fuel is injected into the system using a burner tip, which is essential to the heating process. The burner produces a specific flame and heat-release pattern that can be controlled within the combustion chamber, making it ideal for heating, melting, manufacturing, and steam production, among other things.

What are the Different Types of Burners?

Most people are familiar with typical cold air burners, which are found most often on residential properties. However, there is a multitude of burner types; the ones most commonly used in residential and commercial applications are:

• Cold air burners: These types of burners are found typically found in residential devices like gas ranges and furnaces.
• Hot air burners: These types of burners preheat incoming air using a central heat-exchanger device.
• Regenerative burners: These burners use a pair of burners to alternate between firing and exhausting, preheating a regenerative heat exchanger box to create hotter preheated air.
• Oxy-fuel burners: These burners use pure oxygen to burn with fuel instead of combustion air.
• Self-recuperative burners: Exhaust hot gases at the same time they are firing. The hot exhaust gas is used to preheat the combustion air, again for greater efficiency and lower emissions.
• Direct-fire burners: Designed to fire directly into the open furnace or oven.
• Indirect-fire burners: Designed to fire into radiant tubes. The heat radiates from the tube to increase the furnace temperature. This method is used in applications where the products of combustion must not come in contact with the work product, or if the work product is liquid or semi-solid.
• Package burners: Typically contain all necessary components for safe operation in one easy-to-install package. The blower is mounted directly to the burner, as is the fuel manifold. The installer mounts the burner, connects the fuel, and should be ready to start.

What Are the Industry Applications of Industrial Burners?

Every industrial heating boiler commonly used in heating processes relies on an industrial burner. Industrial burners allow different types of facilities to control an open flame for a wide range of applications. Burners are most commonly used in industrial settings for heating purposes, as a means to generate steam or supply thermal energy, or applied in manufacturing processes and industries — including automotive, major appliances, food and beverage, petrochemical, power, chemical, and more.

Additionally, they are used for other applications, such as:

• Providing heat to boiler systems
• Welding
• Heating liquids/fluids
• Creating chemical reactions
• Melting metals
• Recycling
• Glass blowing

There are a variety of uses for industrial burners in an industrial setting, and because there is such a wide range of burner types, some work better for specific processes than others. It’s important to review your specific application to understand the kind of industrial burner that will suit your needs.

Benefits and Drawbacks of Industrial Burners

Like any other industrial equipment piece, there are benefits and drawbacks to using industrial burners in your facility. One main reason that their use is so widespread across industries is the power of their performance. Industrial burners allow for the rapid production of heat and energy compared to other heating solutions.

Industrial burners are also great for a broad range of applications because they allow for overarching control of heat levels and production. The type and level of combustion produced by the burner are also able to be controlled. This way, they can be used across a variety of applications within your facility.

Another great thing about industrial burners is that they require very little maintenance over time. The major drawback of the system is that when care is necessary, it can be extremely costly. Facilities should factor in potential unforeseen problems so that the repairs don’t overtake the budget or cause significant downtime.

There is a wide range of reasons to upgrade your current industrial burner equipment, but one of the most critical considerations is productivity levels. It’s often cited that increased heat levels allow for maximized production, mainly when your facility’s processes include melting different metals. By installing efficient, industry-leading process equipment in your facility, you can quickly increase productivity levels and significantly reduce your bottom line.

Selecting the Right Industrial Burner

When it comes down to it, your burner is an essential part of your facility’s operations. If it’s no longer operating up to par, it is probably time to consider replacing your existing burner equipment.

During the selection process, you have to ask yourself: What am I trying to achieve using my new industrial burner? Are you aiming to increase production, reduce fuel consumption and emissions, improve the machinery’s reliability, or mitigate maintenance costs? There are several ways to apply the benefits of an industrial burner to your facility’s processes.

Once you have a clear understanding of your industrial burner’s application within your facility, you can select the right industrial burner to improve your processes significantly. When choosing your next industrial burner, consider the following components:

• Capacity
• Turndown performance
• Flame geometry
• Temperature
• Mounting
• Ignition

It’s also incredibly important to understand the key differences between various burner types – one type might work better for your needs than others. For example, an oxy-fuel firing burner has high efficiency and low emissions but is incredibly costly to operate due to the cost of supplying oxygen.

This means that working with a professional process equipment manufacturer or provider, like ACI Controls, can help you understand which burner type is best for your facility.

Selecting the perfect industrial burner for your facility’s needs can be a challenging task. However, our team of process equipment experts can help you select exactly what you need. An excellent burner system is the best way to positively impact your productivity levels and bottom line, but it’s a long-lasting investment if appropriately selected. Reach out to ACI Controls today to get started!

When selecting an oil, gas, or dual fuel burner, precise specifications are crucial to achieving optimal performance and compliance. It’s crucial to provide detailed specifications to ensure that the burner meets the client’s needs and is compatible with the boiler or heating system it will serve. The specifications should cover various aspects, including fuel type, capacity, control systems, and emissions requirements.

Below is a comprehensive list of the important specifications required to quote for an oil, gas, or dual-fuel burner

1. Fuel Type and Requirements

• Primary Fuel: Specify whether the burner will use natural gas, LPG, diesel, heavy oil, or other fuels.
• Secondary Fuel (for Dual-Fuel Burners): Indicate the secondary fuel type (e.g., gas/oil).
• Fuel Supply Pressure: Required fuel supply pressure for proper operation, typically measured in psi or bar.
• Fuel Viscosity (for oil): The viscosity of the oil fuel, which affects atomization and combustion.
• Fuel Calorific Value: The heating value of the fuel, which impacts burner sizing.

2. Burner Capacity

• Heat Output: The burner’s heat output, typically measured in kilowatts (kW) or British Thermal Units per hour (BTU/hr).
• Firing Rate: The range of firing rates (turndown ratio) the burner can operate at, which impacts efficiency and flexibility.
• Boiler/Burner Compatibility: Ensure the burner’s capacity matches the boiler or heating system it will serve.

3. Emissions Requirements

• NOx Emissions: Specify the maximum allowable nitrogen oxide (NOx) emissions, usually in ppm (parts per million).
• CO Emissions: Carbon monoxide emissions limits.
• SOx Emissions: For oil burners, sulfur oxide (SOx) emissions may need to be specified.
• Compliance with Regulations: Indicate any specific environmental regulations the burner must meet (e.g., UL, CE, local standards).

4. Burner Type and Configuration

• Monoblock or Duoblock: Monoblock burners integrate all components into one unit, while duoblock burners have separate components (e.g., fan, fuel supply).
• Pressure or Atmospheric Burner: Pressure burners use fans to supply air, while atmospheric burners rely on natural draft.
• Single-Stage, Two-Stage, or Modulating: Indicates whether the burner operates at a single output level, multiple stages, or modulates to meet varying demands.
• Horizontal or Vertical Mounting: Specify the orientation of the burner based on installation needs.

5. Control and Monitoring Systems

• Burner Control System: Specify the type of control system, such as mechanical, electronic, or PLC-based control.
• Flame Detection: Details on the flame detection system (e.g., UV scanner, ionization rod) for safety and reliability.
• Ignition System: Type of ignition system, such as electric spark, pilot flame, or direct ignition.
• Safety Interlocks: Include specifications for safety interlocks, emergency shutoffs, and fault alarms.
• Remote Monitoring and BMS Integration: If the burner needs to integrate with a Building Management System (BMS) or remote monitoring platforms.

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6. Combustion Air Supply

• Air Supply System: Specify whether the burner will have an integrated fan or require external combustion air supply.
• Air/Fuel Ratio Control: Details on how the air/fuel ratio will be controlled for efficient combustion.
• Air Temperature Requirements: If preheated air is required, specify the temperature range.

7. Fuel Supply and Piping

• Fuel Pump (for Oil Burners): Specifications for the fuel pump, including pressure, capacity, and type.
• Fuel Metering: Details on fuel metering components for accurate fuel delivery.
• Fuel Piping: Materials and sizing of the fuel supply lines, including any specific requirements for corrosion resistance.

8. Noise Level

• Sound Pressure Level: Maximum allowable noise level of the burner, typically measured in decibels (dB) at a specific distance.

9. Physical Dimensions and Installation Requirements

• Burner Dimensions: Overall size, including length, width, and height, to ensure it fits within the available space.
• Weight: The total weight of the burner, which may affect installation.
• Clearance Requirements: Space needed around the burner for maintenance and operation.
• Mounting Requirements: Specifications for how the burner will be mounted, including flange sizes and bolt patterns.

10. Electrical Requirements

• Voltage and Frequency: The electrical supply requirements, such as 230V/50Hz, 400V/60Hz, etc.
• Power Consumption: The total electrical power consumption of the burner, usually expressed in kilowatts (kW).
• Control Wiring: Specifications for control and safety wiring, including any specific requirements for explosion-proof or hazardous areas.

11. Maintenance and Service Requirements

• Access for Maintenance: Provisions for access doors, inspection ports, and removable panels for easy maintenance.
• Service Life: The expected operational lifespan and any warranties offered.
• Maintenance Intervals: Recommended maintenance schedule, including specific requirements for fuel and air components.

12. Material and Construction Specifications

• Burner Materials: Details on materials used in the construction of the burner components, such as stainless steel for high-temperature areas.
• Corrosion Protection: Any coatings or treatments to prevent corrosion, especially in humid or harsh environments.
• Insulation: Type and thickness of insulation used in the burner to reduce heat loss and improve efficiency.

13. Compliance with Standards and Codes

• ASME Code Compliance: Whether the burner meets ASME standards for pressure and safety.
• ISO Standards: Compliance with ISO standards related to quality, safety, and environmental management.
• UL/CE Certification: Certifications that indicate compliance with safety standards for electrical and mechanical components.
• Local Building Codes: Any additional local or regional building and safety codes that must be met.

14. Customization and Special Requirements

• Custom Designs: Any specific design modifications or custom features required by the client, such as specific burner shapes, sizes, or materials.
• Special Certifications: Requirements for certifications like PED or others, depending on the region or application.
• Redundancy Requirements: If multiple burners are needed for redundancy or load sharing.

15. Delivery and Installation Considerations

• Lead Time: Expected delivery time from order placement to commissioning.
• Shipping Requirements: Any special requirements for shipping, packaging, or overseas transport.
• Installation Services: Whether installation and commissioning services are included in the quote.

16. Budget and Cost Considerations

• Initial Cost: The base price of the burner and associated equipment.
• Operating Costs: Estimates for fuel consumption, electricity usage, and maintenance.
• Return on Investment (ROI): Calculations or justifications for the investment based on efficiency and operating costs.

17. Documentation and Support

• Operating Manuals: Detailed manuals for operation and maintenance.
• Training: Any training services offered for operators and maintenance personnel.
• Technical Support: Availability of technical support and spare parts.

18. Warranty and After-Sales Service

• Warranty Period: Coverage duration for parts and labor.
• Extended Warranties: Options for extended warranties and service contracts.
• After-Sales Support: Details on service plans, regular inspections, and emergency support.

These specifications ensure that the oil, gas, or dual-fuel burner selected is appropriate for the client's needs, installation conditions, and operational requirements. Providing accurate and detailed information will help prevent potential issues and ensure long-term, efficient operation of the burner system.

Here is a brief checklist to summarize :