Regenerative burner

Types of regenerative burners

A regenerative burner is a device that heats the combustion air by absorbing heat from the flue gases. It is also a type of energy-saving equipment for heating furnaces. Various regenerative burners are used in industrial heating systems to help businesses reduce energy consumption and environmental impact. The following table provides an overview of some typical types of regenerative burners.

• Regenerative Thermal Oxidizer (RTO): It is a type of regenerative burner commonly used in industrial processes for air pollution control and VOC abatement. An RTO consists of a ceramic heat exchanger and a combustion chamber. Polluted air containing VOCs is pre-heated in the ceramic heat exchanger before entering the combustion chamber, where it is raised to a high temperature to break down the pollutants. During this process, the incoming clean air stream is used to absorb heat from the outgoing exhaust gases through the heat exchanger. RTOs achieve high VOC destruction efficiencies by operating at high temperatures (typically above 1,400°F or 760°C) and are considered one of the most efficient and cost-effective emission control technologies.
• Regenerative Thermal Oxidizer (RTO): It is a type of regenerative burner commonly used in industrial processes for air pollution control and VOC abatement. An RTO consists of a ceramic heat exchanger and a combustion chamber. Polluted air containing VOCs is pre-heated in the ceramic heat exchanger before entering the combustion chamber, where it is raised to a high temperature to break down the pollutants. During this process, the incoming clean air stream is used to absorb heat from the outgoing exhaust gases through the heat exchanger. RTOs achieve high VOC destruction efficiencies by operating at high temperatures (typically above 1,400°F or 760°C) and are considered one of the most efficient and cost-effective emission control technologies.
• Regenerative Catalytic Oxidizer: It is a variation of the regenerative thermal oxidizer that uses a catalyst to promote the oxidation of pollutants at lower temperatures. This allows for operation at a lower temperature range (usually between 600-800°F or 315-430°C), which can reduce energy consumption compared to non-catalytic RTOs. Regenerative catalytic oxidizers are suitable for applications with lower VOC concentrations or where a lower operating temperature is desired. The use of a catalyst also enables faster startup times and may provide better destruction efficiency for certain types of VOCs.
• Regenerative Afterburner: It is a type of regenerative burner used for the treatment of exhaust gases from industrial processes. A regenerative afterburner consists of a combustion chamber and a regenerative heat exchanger. The high-temperature exhaust gases from the process are directed into the combustion chamber, where they are ignited to burn off pollutants like VOCs. The regenerative heat exchanger then absorbs heat from the outgoing exhaust gases and transfers it to the incoming process exhaust, preheating it before it enters the combustion chamber. This helps to improve the overall energy efficiency of the system. Regenerative afterburners are effective at achieving high destruction efficiencies for a wide range of pollutants and are commonly used in applications where stringent emission limits must be met.

Specification and maintenance of regenerative burners

The performance of a regenerative burner is closely related to the specifications and maintenance requirements. Here are some of the crucial specifications of the regenerative burner.

• Temperature range: The temperature range of the regenerative burner refers to the range of temperatures that the burner can achieve during operation. This range is usually between 1000 to 2000°C. Different regenerative burners have different temperature ranges. For industrial applications, it is important to select a regenerative burner with an appropriate temperature range to meet specific production requirements.
• Heating capacity: The heating capacity of the regenerative burner refers to the amount of heat it can produce per unit of time, usually expressed in kW. The heating capacity depends on the design and size of the burner. Industrial users need to select a regenerative burner with a suitable heating capacity according to the scale of the production process and the heat demand.
• Fuel type: The regenerative burner can use different types of fuel, such as natural gas, propane, or diesel. Industrial users need to choose the right fuel type for their specific application requirements and fuel availability.

Proper maintenance is important for ensuring the performance and service life of the regenerative burners. Here are some key maintenance requirements:

• Cleaning: Industrial users should regularly clean the regenerative burner to remove the ash, dirt, and other deposits from the combustion chamber, fuel nozzle, and other parts. A clean burner can work efficiently and safely.
• Inspection: Industrial users need to periodically inspect the regenerative burner for wear, damage, or loose parts. If any problems are found, they must be repaired in time to ensure the safety and stability of the burner.
• Lubrication: Some components of the regenerative burner need to be lubricated regularly. Proper lubrication can reduce friction and wear, and improve the efficiency of the burner.

By following the above maintenance tips, the regenerative burner can provide stable and efficient performance.

Applications of regenerative burners

Regenerative burners are used in several industries and applications. Some of the most popular include:

• Heat treating and annealing

Metal heat treatment and annealing processes require precise temperature control and uniform heating to achieve the desired material properties. Regenerative burners provide efficient and high-temperature heat sources, making them ideal for use in heat treating furnaces, annealing furnaces, and other heat treatment equipment. They facilitate processes like hardening, tempering, solution annealing, and stress relieving, among others.

• Ceramics and glass processing

Regenerative burners' ability to maintain stable high temperatures makes them very suitable for glass and ceramic production. The burners are used in glass melting furnaces, glass annealing lehrs, and ceramic kilns. They help to create the high temperatures necessary for melting raw materials and forming glass and ceramic products. Additionally, they enable precise temperature control to achieve the desired product characteristics.

• Incinerators and thermal oxidizers

Regenerative burners are also used in waste incinerators and thermal oxidizers. They help to achieve complete combustion of waste materials or pollutants, ensuring efficient and clean destruction. The burners also play key roles in maintaining high temperatures and reducing emissions in environmental remediation applications.

• Industrial drying and roasting

Regenerative burners are used in industrial ovens, dryers, and roasters for materials such as food, paper, textiles, and wood. They help to provide efficient and uniform heating, which is suitable for drying, baking, roasting, and other thermal processing operations. They also increase energy efficiency and production capacity.

• Metals processing

Regenerative burners are used in non-ferrous metals melting, such as aluminum, copper, and zinc. They help to provide efficient and high-temperature heat sources for melting operations, thus improving energy efficiency and reducing operating costs.

• Chemical processing

Regenerative burners are used in chemical processing equipment like reactors and distillation columns. They help to provide precise and controlled heat sources for exothermic reactions, distillation, and other chemical processes. Additionally, they offer high efficiency and emission control features to meet the stringent requirements of chemical production.

How to choose regenerative burners

When selecting the ideal regenerative burner, it is important to consider the following factors:

• Fuel type

This is one of the most important factors to consider when choosing a regenerative burner for a specific application. Some regenerative burners are designed to work with natural gas, while others are compatible with various liquid fuels. Select a regenerative burner that is compatible with the preferred fuel type to ensure seamless integration and optimal performance.

• Heating capacity

Regenerative burners come in different sizes and specifications, each with a specific heating capacity. It is important to select a regenerative burner with a suitable heating capacity for the intended application to ensure efficient energy utilization and adequate heat generation.

• Control system

It is important to choose a regenerative burner with an advanced control system that offers precise temperature control, programmable settings, and remote monitoring and adjustment capabilities. A sophisticated control system can improve operational efficiency, optimize energy usage, and enable easy integration with existing systems.

• Installation requirements

Consider the installation requirements of the regenerative burner, including space constraints, ventilation needs, and compatibility with existing infrastructure. Ensure that the selected regenerative burner can be safely and easily installed in the desired location with proper support and maintenance access.

• Energy efficiency

When selecting a regenerative burner, it is important to consider its energy efficiency performance. Choose a regenerative burner with a high efficiency rating and advanced heat recovery technology to minimize fuel consumption, reduce greenhouse gas emissions, and lower operating costs.

• Maintenance and service

It is important to choose a regenerative burner from a reputable manufacturer with a track record of quality products and reliable customer support. Select a supplier that offers comprehensive maintenance and service support to ensure the regenerative burner operates optimally and can promptly address any technical issues or system maintenance requirements.

Regenerative burner FAQ

Q1: How does a regenerative burner work?

A1: Regenerative burners use preheated combustion air. They have heat exchangers that transfer heat from exhaust gases to incoming combustion air. They store some heat from the last combustion cycle. The stored heat preheats the incoming air.

Q2: What are the advantages of regenerative burners?

A2: Regenerative burners have high energy efficiency. They can achieve heat recovery rates above 70%. The high efficiency helps to reduce fuel consumption and operating costs. Regenerative burners also produce low nitrogen oxide emissions. They are suitable for use in environmentally sensitive areas.

Q3: How do regenerative burners reduce NOx emissions?

A3: Regenerative burners operate at high combustion efficiency. In a well-controlled combustion process, the fuel burns completely. The high temperature and longer residence time allow for complete fuel oxidation. As a result, there is minimal formation of nitrogen oxides (NOx). When NOx is formed, the burner design and operation minimize its release into the atmosphere.

Q4: What is the lifespan of a regenerative burner?

A4: The lifespan of a regenerative burner depends on its design, quality of construction, and maintenance. A well-maintained regenerative burner can last for fifteen to twenty years before it requires replacement.