Burners - Low NOx industrial combustion technologies and ...

1 Burners Flat flame Burners ESW (E3500 rev. 01 - 19/04/2016). ESW - E3500 rev. 01 - 19/04/16. GENERAL WARNINGS: GENERAL NOTES: All installation, maintenance, ignition and setting must In accordance to the internal policy of constant quali- be performed by qualified staff, respecting the norms ty improvement, ESA-PYRONICS reserves the right to present at the time and place of the installation. modify the technical characteristics of the present docu- ment at any time and without warning. To avoid damage to people and things, it is essential It is possible to download technical sheets which to observe all the points indicated in this handbook. The have been updated to the latest revision from the reported indications do not exonerate the Client/User website.

2 From observing general or specific laws concerning acci- dents and environmental safeguarding. The ESW products have been designed, manufactu- red and tested according to the most correct construc- The operator must wear proper DPI clothing (shoes, tion practices and following the applicable requirements ) and respect the general safety, prevention described in UNI EN 746-2-2010 industrial heating pro- and precaution norms. cess equipment - Part 2: Safety requirements for com- bustion and for the handling and processing of fuels'. To avoid the risks of burns or high voltage electrocu- We emphasize that the Burners described in this data sheet are provided as independent units and are tion, the operator must avoid all contact with the burner excluded from the scope of the Machine Directive and its control devices during the ignition phase and 2006/42/EC not having any mobile items that are not while it is running at high temperatures.

3 Exclusively manual. All ordinary and extraordinary maintenance must be Certified in conformity with the UNI EN ISO 9001. performed when the system is stopped. Norm by DNV GL. To assure correct and safe use of the combustion plant, it is of extreme importance that the contents of this document be brought to the attention of and be meticu- lously observed by all personnel in charge of controlling For ESA-PYRONICS, the NxT symbol has the follo- and working the devices. wing two meanings which are connected to each other: NEXT GENERATION, or new generation Burners that The functioning of a combustion plant can be dange- maintain functionality, reliability and performance. rous and cause injuries to persons or damage to equip- NOx TECHNOLOGY energy saving and low polluting ment.

4 Every burner must be provided with certified com- emissions. bustion safety and supervision devices. CERTIFICATIONS: The burner must be installed correctly to prevent any type of accidental/undesired heat transmission from the flame to the operator or the equipment. The products conform to the requests for the Euroasia market The perfomances indicated in this technical document (Russia, Belarus and Kazakhstan). regarding the range of products are a result of experi- mental tests carried out at ESA-PYRONICS. The tests have been performed using ignition systems, flame CONTACTS / SERVICE: detectors and supervisors developed by ESA-PYRO- NICS. The respect of the above mentioned functioning conditions cannot be guaranteed if equipment, which is not present in the ESA-PYRONICS catalogue, is used.

5 Headquarters: International Sales: Esa Pyronics International DISPOSAL: Via Enrico Fermi 40 Zoning Industriel, 4 me rue 24035 Curno (BG) - Italy B-6040 Jumet - Belgium Tel + Tel + Fax + Fax + To dispose of the product, abide by the local legislations regarding it. 2. ESW - E3500 rev. 01 - 19/04/16. The ESW series identifies a family of flat flame Burners called nozzle mix : the high velocity combustion air flow produces a vortex inside the refractory block where the gas mixes producing high combustion . The parabolic shape of the block and the centrifugal force generated by the rotating movement of the air spread the flame against the cone wall and against that of the surrounding furnace transferring heat only radially to the refractory block.

6 APPLICATIONS. Annealing furnaces Melting basins in reverb Aluminum melting and holding furnaces Zinc melting furnaces. Bell furnaces. Pit furnaces. Billet heating furnaces F3500I03. CHARACTERISTICS. GENERAL: Capacity: from 90 to 1400kW. Preheated air up to: 450 C. Air pressure to the burner: 70mbar Gas pressure to the burner: 80mbar Turn down: 1:8. Maximum temperature used: 1400 C. MATERIAL COMPOSITION: Burner body: Cast iron G25. Plate: Cast iron G25. Gas tube: AISI304. Pre-heated air up to: 450 C. Gas group: Class 1/2/3. F3500I04. 3. ESW - E3500 rev. 01 - 19/04/16. CAPACITY PARAMETERS AND FLAME LENGTH. The ignition of the ESW Burners takes place via an elec- The adoption of flame control systems is highly recom- trode, whilst the detection is done via a UV-2 scanner.

7 Mended in all plants operating at temperatures below Neither of these elements are provided with the supply. 750 C (UNI EN746-2 Norm). Model Capacity kW Ignition Detection ESW-3 90 DSP UV-2. ESW-4 180 DSP UV-2. ESW-5 290 DSP UV-2. ESW-6 350 DSP UV-2. ESW-7 700 DSP UV-2. ESW-8 1400 DSP UV-2. The flame sizes are approximate and refer to a natual gas assembled next to each other a minimum distance fed burner placed in open air, operating in stochiomentric expected for the larger burner must be kept between ratio at nominal capacity. When two burner models are them. Estimated flame Minimum distances Mx pilot mixtu- diameter (mm). (stoichiometric combustion ). re pressure Max % at maximum capacity Model with max air to excess air the burner 70 mbar between Burners between Burners and (mbar) =1 = 0,75.

8 Material (mm). (mm). ESW-3 6,3 600 600 800 910 200. ESW-4 6,3 900 650 920 1000 300. ESW-5 7,5 700 750 1200 1150 300. ESW-6 8,7 540 900 1400 1400 350. ESW-7 15 700 1500 2300 1800 350. ESW-8 15 400 1800 - 2100 450. DESCRIPTION. The ESW Burners are suitable for those applications in which the flame does not have to be transferred axially inside the chamber. In this way the load that is inserted in front of the burner is preserved. They create a very high heat exchange between furnace and load due to the high flame tubulence of the flat flame and to its radiant compo- nent. F3500I05. 4. ESW - E3500 rev. 01 - 19/04/16. BURNER PERFOMANCE. The air and gas flow capacities refer to a natural gas stion chamber at zero pressure above sea level and fed burner (8600 Kcal/Nm3) placed inside the combu- operating with 15% ecxess air.

9 MIN/MAX (ON/OFF) Functioning Chamber temeprature1000 C. Ambient air temperature 30 C. MAXIMUM CAPACITY. Burner model Parameter ESW-3 ESW-4 ESW-5 ESW-6 ESW-7 ESW-8. Burner capacity (3% O2) [kW] 90 180 290 350 700 1400. Max. capacity combustion air flow [Nm3/h] 104 207 334 403 805 1610. Gas flow [Nm3/h] 9 18 29 35 70 140. Burner inlet air pressure [mbar] 70. Line inlet gas pressure [mbar] 80. MINIMUM CAPACITY. Burner model Parameter ESW-3 ESW-4 ESW-5 ESW-6 ESW-7 ESW-8. Burner capacity (2% O2) [kW] 9 18 29 35 70 140. Min. capacity combustion air flow [Nm3/h] 11 21 34 41 81 161. Gas flow [Nm3/h] 7 14. Burner inlet air pressure [mbar] Line inlet gas pressure [mbar] 80. 5. ESW - E3500 rev. 01 - 19/04/16. NOx EMISSIONS TABLE. 450. NOx [mg/Nm3] O2 ref 3%.

10 NOx - Tair=450 C. 400 NOx - Tair=250 C. NOx - Tair=30 C. 350. 300. 250. 200. 150. 100. 50. 0. 450 550 650 750 850 950 1050 1150 1250. T furnace [ C]. G3500I01. 6. ESW - E3500 rev. 01 - 19/04/16. METHANE GAS FLOW CHART - ESW. ESW-8. ESW-3. ESW-5. ESW-4. ESW-7. ESW-6. 10. Differential pressure at calibrated flange [mbar]. 1. 0,1. 1 10 100. Natural gas flow @ 20 C ,6 [Nm3/h]. G3500i01. AIR FLOW CHART - ESW. ESW-8. ESW-3. ESW-5. ESW-4. ESW-7. ESW-6. 100. Burner inlet pressure [mbar]. 10. 1. 0,1. 10 100 1000. Natural gas flow @ 30 C 1 [Nm3/h]. G3500I02. 7. ESW - E3500 rev. 01 - 19/04/16. BURNER CAPACITY ACCORDING TO THE PREHEATED AIR TEMPERATURE. Tair Capacity [kW]. [ ]. ESW-3 ESW-4 ESW-5 ESW-6 ESW-7 ESW-8. 30 90 180 290 350 700 1400.