Dual fuel burners - esapyronics.com

1 BurnersDual fuel burnersEXDF - (E3611 rev. 01 - 22/06/2016) - E3611 rev. 01 - 22/06/16 GENERAL WARNINGS: All installation, maintenance, ignition and setting mustbe performed by qualified staff, respecting the normspresent at the time and place of the installation. To avoid damage to people and things, it is essentialto observe all the points indicated in this handbook. Thereported indications do not exonerate the Client/Userfrom observing general or specific laws concerning acci-dents and environmental safeguarding. The operator must wear proper DPI clothing (shoes, ) and respect the general safety, preventionand precaution norms. To avoid the risks of burns or high voltage electrocu-tion, the operator must avoid all contact with the burnerand its control devices during the ignition phase andwhile it is running at high temperatures. All ordinary and extraordinary maintenance must beperformed when the system is stopped. To assure correct and safe use of the combustionplant, it is of extreme importance that the contents of thisdocument be brought to the attention of and be meticu-lously observed by all personnel in charge of controllingand working the devices.

2 The functioning of a combustion plant can be dange-rous and cause injuries to persons or damage to equip-ment. Every burner must be provided with certified com-bustion safety and supervision devices. The burner must be installed correctly to prevent anytype of accidental/undesired heat transmission from theflame to the operator or the equipment. The performances indicated in this technical docu-ment regarding the range of products are a result ofexperimental tests carried out at ESA-PYRONICS. Thetests have been performed using ignition systems, flamedetectors and supervisors developed by ESA-PYRO-NICS. The respect of the above mentioned functioningconditions cannot be guaranteed if equipment, which isnot present in the ESA-PYRONICS catalogue, is / SERVICE:To dispose of the product, abide by the local legislationsregarding :Headquarters:Esa Enrico Fermi 4024035 Curno (BG) - ItalyTel + Sales:Pyronics International Zoning Industriel, 4 me rueB-6040 Jumet - BelgiumTel + Fax NOTES: In accordance to the internal policy of constant quali-ty improvement, ESA-PYRONICS reserves the right tomodify the technical characteristics of the present docu-ment at any time and without warning.

3 It is possible to download technical sheets whichhave been updated to the latest revision from the The EXDF products have been designed, manufactu-red and tested according to the most correct construc-tion practices and following the applicable requirementsdescribed in UNI EN 746-2-2010 Industrial heating pro-cess equipment - Part 2: Safety requirements for com-bustion and for the handling and processing of fuels .We emphasize that the burners described in this datasheet are provided as independent units and areexcluded from the scope of the Machine Directive2006/42/ECnot having any mobile items that are notexclusively manual. Certified in conformity with the UNI EN ISO 9001 Norm by DNV :The products conform to the requests for the Euroasia market(Russia, Belarus and Kazakhstan). - E3611 rev. 01 - 22/06/16 APPLICATIONSThe EXDF burners are dual fuel nozzle mixing burnerswith refractory can burn all types of commer-cial non-corrosive gases or oils with maximum viscosityof 3 E.

4 The fuel and the combustion air are mixed at thepoint of ignition within the refractory cone avoiding thedanger of backfiring. The characteristics of the refractoryblock are such as to allow excellent flame stability andremarkable flow ratio. All the burners of the EXDF seriescan operate with stoichiometric combustion fuel ratios orwith excess air while maintaining a remarkable stability ofthe flame. Kilns for ceramic firing Sanitary firing furnaces Forging furnaces Annealing furnaces Reheating furnaces Melting furnaces Drying furnaces. Incenerators Furnaces for metal, resin and polymer treatment Hot air generatorsF3611I03F3611I04 CHARACTERISTICSGENERAL: Oil functioning capacity: from 100 to 1650 kW Gas functioning capacity: from 90 to1450 kW Functioning with preheated air up to: 450 C Air and gas pressure to the burner : 70 mbar Oil pressure to the burner :2 bar Operation with various types of gases:CH4/LPG/ Functioning with various types of maximum viscosityoils:3 E Flow ratio with gas operation:8 1 Flow ration with oil operation:6 1 Separate air , gas and oil inlets, nozzle mixing, noflash backs.

5 Modular design to facilitate assembly, maintenanceand COMPOSITION: Mixer body and air/gas collector: Cast iron G25 Plate:Cast iron G25 Fuel lance:AISI 304 - E3611 rev. 01 - 22/06/16 IGNITION AND DETECTIONThe EXDF burners must always be ignited with a DSPelectrode or pilot burner in compliance with the EN746 Norm. The pilot burner must be excluded after ignition ofthe main burner and therefore ignition must take place viaa photocell. ModelIgnition with pilot burnerIgnition with electrodeIgnition DetectionIgnitionDetection12 EXDFP64 PBC-FRUV-2 DSP-1UV-216 EXDFP64 PBC-FRUV-2 DSP-2UV-224 EXDFP86 PBC-FRUV-2 DSP-3UV-232 EXDFP86 PBC-FRUV-2 DSP-3UV-248 EXDFP86 PBC-FRUV-2 DSP-4UV-2 Provide a cooling line for ignition electrode (copper pipe 8) and for the photocell in case it is mounted on refrac-tory block housing. The adoption of flame control systemsis strongly recommended in all systems operating at tem-peratures below 750 C (UNI EN746-2).CAPACITY PARAMETERS AND FLAME LENGTHM odelType ofrefractoryblock(1)Capacity[kW]Flamelen gth[mm]Diameterof refrac-tory block[mm]Flue gas outlet speed@1500 C [m/s]a 0ma 0,5ma 1ma 1,5ma 2ma 2,5ma 3m12 EXDFM102300 5001066038191397,56H50904824171297,516 EXDFM203600 80012960522619141110H749058332217141224 EXDFM4071000 1250190 (129)60532720151211H1089074402721171432 EXDFM8141250 150019060522822171412H149906236251915134 8 EXDFM16282000 250028060543227211916H212906338272116144 X48 EXDF*M65122000 25004X28060553428222017 The flame lengths and speeds are approximate, referredto burners fueled by natural gas, placed in open air, wor-king at stoichiometric ratio and at nominal special applications, a mono electrode is used for igni-tion and flame detection or an electrode for ignition and aUV photocell for flame detection.

6 (*) Where higher potential with small flame lengths is needed other multiblock models are available on M: Flame output speed 50 60 m/sH: Flame output speed 80 90 - E3611 rev. 01 - 22/06/16 burner PERFORMANCE Chamber temeprature 1100 C. Diesel oil fuel natural gas OIL CAPACITYMINIMUM OIL CAPACITYP otential, lengths and flame speed are related tonatural gas-fueled burners (8600 kcal / Nm3), placedin the combustion chamber at zero pressure abovesea level, working with the 10% of excess air. burner model12 EXDF16 EXDF24 EXDF32 EXDF48 EXDFB urner capacity[kW]1022034078141628 Combustion air flow[Nm3/h]1001953957901630 Atomizing air flow[Nm3/h]10204080160 Gas flow[Nm3/h]-----Oil flow[IT/h]10204080160 Combustion air pressure[mbar]7070707070 Atomizing air pressure[mbar]200200200200200 Oil pressure[bar]2,12,12,12,12,1 Max Capacity burner model12 EXDF16 EXDF24 EXDF32 EXDF48 EXDFB urner capacity[kW]173468135270 Combustion air flow[Nm3/h]9173468138 Atomizing air flow[Nm3/h]10204080160 Gas flow[Nm3/h]-----Oil flow[IT/h]1,73,46,813,527 Combustion air pressure[mbar]11111 Atomizing air pressure[mbar]200200200200200 Oil pressure[bar]0,060,060,060,060,06 Min.

7 - E3611 rev. 01 - 22/06/16 burner PERFORMANCEMAXIMUM natural GAS CAPACITYMINIMUM natural GAS CAPACITYB urner model12 EXDF16 EXDF24 EXDF32 EXDF48 EXDFB urner capacity[kW]921833667331465 Combustion air flow[Nm3/h]1012014028061610 Atomizing air flow[Nm3/h]-----Gas flow[Nm3/h]9,218,336,673,3147 Oil flow[IT/h]-----Combustion air pressure[mbar]7070707070 Atomizing air pressure[mbar]-----Oil pressure[bar]-----gas p [mbar]1010101010 Max. Capacity burner model12 EXDF16 EXDF24 EXDF32 EXDF48 EXDFB urner capacity[kW]12234592185 Combustion air flow[Nm3/h]132550102203 Atomizing air flow[Nm3/h]-----Gas flow[Nm3/h]1,22,34,59,218,5 Oil flow[IT/h]-----Combustion air pressure[mbar]1,11,11,11,11,1 Atomizing air pressure[mbar]-----Oil pressure[bar]-----gas p [mbar]0,20,20,20,20,2 Min. Capacity AIR INLETMFCV12TO OTHER BURNERSBE15BD14BI16 BMS17BT18 ATOMIZING AIR INLETHV10 FCV11TO OTHER BURNERSF02 SSV04HV01 PCV03 OIL INLETTO OTHER BURNERSHV06 PCV07 SSV08TO OTHER BURNERSGAS INLETSSV08 SSV04 FCV13 FCV09 FCV05 APPLICATION includedHV 01 Oil interception valveXF 02 Oil filterXPCV 03 Oil pressure regulatorXSV 04 Oil safety valveXFCV 05 Oil interception valveXHV 06 Gas interception valveXPCV 07 Zero governorXSV 08 Gas safety valveXFCV 09 Gas adjusterXHV 10 Atomizing air interception valveXFCV 11 Atomizing air regulation valveXFCV 12 Combustion air regulation valveXFCV 13 Manual air regulation valveXBD 14 Flame detection XBE 15 BurnerXBI 16 burner ignition XBMS 17 Flame controlXBT 18 Ignition transformerXEXDF - E3611 rev.

8 01 - 22/06 - E3611 rev. 01 - 22/06/16 WARNINGS The burners of EXDF series are intended for use infixed installation. If mobile installations are needed (bellfurnaces, etc ..) it is necessary to evaluate the possibi-lity of any damages determined by the movement of theactual furnace burner ignition must be always performed at minimumpower, then modulating towards the maximum, facilita-ting ignition and reducing outlet overpressure. Moving from minimum to maximum power, and viceversa, should be gradual and not instantaneous. For all low-temperature applications (up to 750 C), burner ignition and the control of the fuel gas solenoidvalves must be performed by a certified burner controldevice. It is always necessary to use flexible couplings in thepresence of preheated air. To avoid possible damage to burners , make sure thatthe blower does not send them air that may be fouled bycombustion products, oils, solvents or other. To avoidthese phenomena from taking place, possibly install theblower or the suction duct outside the establishment andfar from the exhaust pipes.

9 Check the correct connection of the feeding lines afterinstallation. Before switching the burner on, check thatthe combustion air and fuel gas pressure values are cor-rect. The burner can only function within the indicatedpower range. Functioning at lower or higher power couldcompromise the burner performance as well as its lifespan. In which case, the general warranty conditions willautomatically expire and ESA will not be held responsi-ble for any damage to persons or objects. If there is trouble with other devices during the burnerstart up phase, use the connector with anti disturbancefilter for the high-tension (HT) cable connection of theignition electrode. Avoid burner ignition close to each other so as not toheat the ignition command system devices (solenoidvalves and transformers). Prewash time lapse + firstsafety time lapse + min. of 5 sec. = time lapse betweenone ignition and another. (however, do not attempt morethan 2 ignitions during a 30sec. time lapse).

10 Make sure the power supply is TURNED OFF whenintervening on the burner and its devices. In case of bur-ner malfunctioning, follow the indications in the'Maintenance' chapter of the present manual or contactESA-PYRONICS assistance. Any modification or repair done by third parties cancompromise the application safety and automaticallycauses the general warranty conditions to - E3611 rev. 01 - 22/06/16 INSTALLATIONThe EXDF burners are generally installed on the furnacewalls. Roof mounting is unadvisable; in any case, if it isnecessary, please specify during the order light needed for the burner housing must have suffi-cient open space around the refractory block for the cera-mic fibre insulation (which is already supplied with theburner). Please refer to the OVERALL DIMENSIONS chapter for this use of flexible hoses and / or compensators for con-nection of the air and gas lines is mandatory. The air andgas inlets have flanges (threaded or to be welded) andcan freely rotate at a 90 recommend you install the refractory block with theholes for the pilot burner and flame detection photocell onthe upper FIBERINSULATIONDO NOT REMOVE!