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Burner and boiler technology

Introduction

Trying to minimise industrial energy consumption but to retain the same level of effectiveness? Modern burner and boiler technology is what you are looking for. Find out more!

Image Copyright: Fotalia

© Fotalia

The largest share of energy consumed in industry and manufacturing is accounted for by the generation of process heat. In Germany alone, companies expend 400 terawatt-hours of final energy on thermal processes (see German Energy Agency, in German). Efficient heating technology therefore represents an important instrument in reducing energy costs and increasing competitiveness.

Burners and boilers are key elements of heating supply systems. Particularly in outdated systems, it is usually worth replacing these – both in industrial operations and in residential buildings. In recent years in particular, huge technological progress has been made in this area, with the result that a wide range of cutting-edge burner and boiler technology is now available – including condensing boilers, waste heat recovery boilers and multi-fuel burner systems. To ensure efficient operation, it is also essential that burners and boilers have the correct dimensions and are coordinated as closely as possible with one another.

Industrial customers worldwide are happy to place their trust in German expertise for the installation and maintenance of efficient heating systems.

A closer look: Burners and boilers

The installation of energy-efficient burner and boiler technology offers energy-saving opportunities in heat supply systems. Burner and boiler applications are used both on a small scale in the private sector and on a very large scale in the industrial sector.

Unlike conventional boilers, condensing gas boilers recover the heat contained in waste gases using additional heat transfer surfaces. The hot water vapour contained in the exhaust gas after combustion of the gas-air mixture is used for this purpose. Cold feedwater is passed over the heat transfer surfaces through the hot water vapour. The feedwater is thus preheated, while the steam is cooled so that it condenses. Condensing boilers have a much lower exhaust gas temperature and energy content than conventional gas boilers, which accounts for their greater efficiency.

How a condensing boiler works

Waste heat recovery boilers use heat from waste gases, or exhaust gases as they are also known. The exhaust gases from combustion processes or hot exhaust air flows are used to generate hot water or steam. For this purpose, the hot exhaust gas is passed through a tube bundle which transfers its heat to the water in the boiler.

The following burners and processes are especially relevant for furnaces:

  • Flameless oxidation (FLOX) is a highly efficient burner technology that allows compliance with strict nitrogen oxide (NOX) limits, even at high combustion air-preheating temperatures.

  • Due to the high exhaust velocity of the combustion gases, these high-speed or high-momentum burners ensure that the combustion chamber gases are internally recirculated in the combustion chambers, thus achieving uniform distribution of temperature. These burners are therefore more efficient than conventional burners.

  • Combustion with pure oxygen in furnaces offers some advantages over combustion with air: The combustion temperature and combustion efficiency are significantly higher using this process: combustion with pure oxygen reduces the waste gas volume flow and also results in a considerable decrease in exhaust gas losses.

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