Elster ECOMAX 1C, ECOMAX 4C, ECOMAX 5C, ECOMAX 1M, ECOMAX 2M Technical Information
...
Self recuperative burner ECOMAX® for gas
Technical Information · GB
Edition 02.11
• For direct and indirect heating equipment
• Economical, energy-saving operation by virtue of internal
air preheating up to 700°C
• Great flexibility due to its maintenance-friendly modular design
• Uniform distribution of temperature by means of a high burner impulse
• Low polluting level thanks to staged combustion
• Direct ignition and monitoring
• 7 sizes for a broad output range from 15–500kW
• Highly efficient with a ceramic burled tube recuperator, a cast steel ribbed
tube recuperator or a flat tube recuperator
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Contents
Self recuperative burner ECOMAX® for gas . . . . . . . . . . . . 1
Contents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1 Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.1 Indirect heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.2 Direct heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.3 Examples of application . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.3.1 ECOMAX® in radiant tubes. . . . . . . . . . . . . . . . . . . . . . . . . . .6
1.3.2 ECOMAX
2 Certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.1 Approval for Russia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3 Mechanical construction. . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.1 Burner housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.2 Recuperator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.3 Air guide tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.4 Gas insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.4.1 Versions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4 Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5 Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5.1 Burner type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5.2 Burner design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5.3 Gas types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5.4 Burner length. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5.5 Connection for additional furnace cooling . . . . . . . . . 16
5.6 Differential air pressure measuring kit DA 1 . . . . . . . . 17
5.7 Differential air pressure measuring kit DA2 with
pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5.8 Flue gas monitoring kit DW . . . . . . . . . . . . . . . . . . . . . 18
5.9 Selection table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
5.9.1 Type code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
6 Project planning information . . . . . . . . . . . . . . . . . . . . . 22
6.1 Flame control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
6.2 Purging air and cooling air . . . . . . . . . . . . . . . . . . . . . 23
®
in direct heating systems . . . . . . . . . . . . . . . . . .7
2
6.3 Recommended burner control units . . . . . . . . . . . . . . 24
6.4 Gas connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6.4.1 Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6.4.2 Operation with LPG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6.4.3 Air/gas ratio control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6.5 Air connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6.5.1 Indirect heating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6.5.2 Direct heating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
6.6 Flue gas guide tube FGT for direct heating . . . . . . . . . 29
6.6.1 For ECOMAX..C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6.6.2 For ECOMAX..M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
6.7 Radiant tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
6.7.1 Ceramic radiant tube SER-C for indirect heating . . . . . . . .31
6.7.2 Metallic radiant tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
6.7.3 Radiant tube distances . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
6.7.4 Eductor on burners with metallic single-ended
radiant tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
6.8 Flue gas channelling. . . . . . . . . . . . . . . . . . . . . . . . . . . 34
6.8.1 Indirect heating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
6.8.2 Direct heating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6.9 Burner adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
6.9.1 Differential air pressure measuring kit DA2 with
pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
7 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
7.1 Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
7.1.1 ECOMAX..C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
7.1.2 ECOMAX..M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
7.1.3 ECOMAX..FTR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
7.2 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
7.2.1 ECOMAX..C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
7.2.2 ECOMAX..M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
7.2.3 ECOMAX..FTR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
7.2.4 ECOMAX standard piping . . . . . . . . . . . . . . . . . . . . . . . . . .47
8 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
ECOMAX · Edition 02.11
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= To be continued
9 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
9.1 Flue gas guide tube FGT kit . . . . . . . . . . . . . . . . . . . . . . 49
9.2 Flue gas eductor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
9.3 Ceramic radiant tube SER-C . . . . . . . . . . . . . . . . . . . . . 50
®
9.4 SICAFLEX
segmented flame tube. . . . . . . . . . . . . . . . 50
9.5 P2/P3 set Eco. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
3
ECOMAX · Edition 02.11
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= To be continued
ECOMAX..C ECOMAX..M ECOMAX..FTR
1 Application
The burners with integrated recuperator ECOMAX® are used
for heating on either direct or indirect furnace systems in intermittent mode.
1.1 Indirect heating
ECOMAX® self recuperative burners are used in conjunction
with metallic or ceramic radiant tubes and the segmented
ceramic flame tube SICAFLEX® as indirect heating equipment
whenever the combustion gases are to be separated from
the product.
4
1.2 Direct heating
In conjunction with an eductor to extract the flue gases, the
burner is used to save energy in a direct heating system. Applications include industrial furnaces and firing systems in the
iron and steel industry and in the non-ferrous metal industry.
ECOMAX · Edition 02.11
Application
Roller hearth furnace Bogie hearth furnace Batch furnace
5
ECOMAX · Edition 02.11
Application
6
1.3 Examples of application
1.3.1 ECOMAX® in radiant tubes
The high outlet velocity of the combustion gases generates a
pressure at the outlet of the ceramic burner tube, resulting in
the recirculation of the flue gases. This leads to the following:
– a reduction in NOx emissions,
– a uniform radiant tube temperature.
The hot flue gases are fed through the ceramic or metallic heat
exchanger, heating the additional supply of cold combustion
air flowing in the opposite direction. The maximum achievable
air preheat temperature amounts to approx. 700°C, depending on the application.
Flue gas
Gas Cold air
Flue gas
Metallic radiant tube
®
Sicaflex
Ceramic radiant tube
SER-C
SICAFLEX® segmented flame tubes must be fitted in the singleended (metallic or ceramic) radiant tube to guide the hot flue
gases.
Flue gas
P radiant tube
Gas Cold air
Flue gas
Gas Cold air
Twin P
radiant tube
Gas Cold air
ECOMAX · Edition 02.11
Flame tube
Application > Examples of application
1.3.2 ECOMAX® in direct heating systems
Flue gas
Gas Cold air
ECOMAX® self recuperative burner in a direct heating system with an eductor for extracting the flue gases from the
furnace. The eductor generates a vacuum with a centrally
positioned nozzle and thus draws the flue gases out of the
furnace chamber through the burner’s heat exchanger. The
maximum achievable air preheat temperature amounts to
approx. 700°C, depending on the application.
7
ECOMAX · Edition 02.11
ECOMAX® with eductor and burner control unit BCU
2 Certification
2.1 Approval for Russia
Certified by Gosstandart pursuant to GOST-R.
Approved by Rostekhnadzor (RTN).
8
ECOMAX · Edition 02.11
9
3 Mechanical construction
The ECOMAX® burner unit is composed of four modules:
burner housing, recuperator, air guide tube and gas insert.
The modular design facilitates adapting the burners to the
respective application or integrating them into an existing
furnace system. Maintenance and repair times are reduced,
and existing furnace installations can easily be converted.
3.1 Burner housing
The burner housing accomodates the connections for the
combustion air, gas, cooling air and flue gas channelling. It
also secures the burner insert. It is made of cast aluminium,
which means it has a low weight. The housing has a doublewall design. The combustion air is fed into the burner via the
outer annular gap. This cools the burner housing und reduces
emissions.
3.2 Recuperator
All-ceramic
The surface of the all-ceramic recuperator, which is made
of SiSiC for high thermal stress, is burled in order to achieve
high efficiency.
Cast steel
The ribs on the cast steel recuperator offer a large surface area,
allowing it to achieve high efficiency even at low temperatures.
Flat tube
The flat tube recuperator has a smooth surface. It is a cost-
effective alternative at a lower efficiency level and is suitable
for lower application temperatures.
ECOMAX · Edition 02.11
Mechanical construction
10
3.3 Air guide tube
Burners Ecomax..C have a ceramic air guide tube that for sizes
0 to 3 also serves as the combustion chamber.
Burners Ecomax..M and Ecomax..FTR have an air guide tube
made of heat-resistant steel.
3.4 Gas insert
The gas insert consists of the gas connection flange, the gas
lance with mixer unit and the ignition electrode (also serves
as monitoring electrode). For operation with LCV gas, the gas
insert is equipped with a special mixing system.
Gas insert with combustion chamber for Ecomax M and Ecomax FTR
ECOMAX · Edition 02.11
Gas insert without combustion chamber for Ecomax C (sizes 1 to 3)
Mechanical construction > Gas insert
3.4.1 Versions
Burner Size Gas insert Air guide tube
Ceramic,
ECOMAX..C
ECOMAX..M
ECOMAX..FTR
0 – 3
4 – 5
1 – 3
4 – 6
1 – 3
4 – 5
With mixing
funnel
With swirl plate
and ceramic
combustion
chamber
With mixing funnel and ceramic
combustion
chamber
With swirl plate
and ceramic
combustion
chamber
With mixing funnel and ceramic
combustion
chamber
With swirl plate
and ceramic
combustion
chamber
with integrated
combustion
chamber
Ceramic
Metallic
Metallic
Metallic
Metallic
11
ECOMAX · Edition 02.11
4 Function
Combustion air
12
Flue gas
Combustion gas
Air guide tube
Recuperator
Gas insert
Combustion chamber
Housing
The self recuperative burner ECOMAX® uses the heat from the
flue gases to preheat the combustion air. The heat exchanger
(recuperator) required for this is part of the burner.
After entering the burner, the combustion air flows in the gap
between the air guide tube and the inside of the recuperator
towards the tip of the burner. Some of this air is fed into the
inside of the burner, where it combusts in the first combustion
stage. The rest of the combustion air flows out through the gap
between the combustion chamber and the recuperator head
at high speed before combustion takes place in the second
combustion stage here. This process means that fewer pollutant emissions are produced.
ECOMAX · Edition 02.11
The hot flue gases, flowing in the opposite direction, leave the
furnace chamber on the outside of the recuperator. Heat is exchanged between the hot flue gases and the cold combustion
air through the recuperator wall. The burner is directly ignited.
5 Selection
5.1 Burner type
The burner ECOMAX is available with a ceramic burled
tube recuperator (Ecomax..C), a cast steel ribbed tube recuperator (Ecomax..M) or a metallic flat tube recuperator
(Ecomax..FTR). Selection is dependent on the type of heating
and the furnace temperature.
Furnace temperature [°C]
Burner
direct indirect*
Ecomax..C 1300 approx. 1200
Ecomax..M 1150 approx. 1000
Ecomax..FTR 950 approx. 850
* The max. allowable temperature of the radiant tube must
be observed.
Heating
13
ECOMAX..C
ECOMAX..M
ECOMAX · Edition 02.11
ECOMAX..FTR
Firing efficiency η
Selection
14
5.2 Burner design
Selection of the burner size is dependent on the net heat output.
From this, the required burner output is calculated using the
firing efficiency value.
Net heat output [kW]
Firing
efficiency η
Determine the firing efficiency for the desired furnace temperature using the diagram.
1
0,9
0,8
0,7
0,6
0,5
0,4
0,3
0,2
0,1
0
400 500 600 700 800 900 1000 1100
Flue gas temperature on recuperator inlet [°C]
= Burner output [kW]
M
FTR
Cold air burner
1200
1300
C
1400
Burner
Recuperator Output*
Size
ceramic
C
Ecomax 0
Ecomax 1
Ecomax 2
Ecomax 3
Ecomax 4
Ecomax 5
Ecomax 6 –
= available.
* For operation with natural gas. For operation with coke oven gas,
the output is approx. 80%, for operation with LCV gas, approx.
65%.
metallic
M
metallic,
flat tube
FTR
– – 25
– 500
[kW]
36
60
100
180
250
Precise dimensioning is available on request using the
ECOMAX calculation tool. For this, the following information
is required:
– Type of heating
– Furnace temperature
– Required net heat output
– Gas type
– Geometric furnace data (wall thickness, furnace extension,
clear width)
ECOMAX · Edition 02.11
Selection
15
5.3 Gas types
Calorific value
Gas type Code letter
Natural gas L
and H quality
Propane, propane/butane,
butane
Town gas,
coke oven
gas
LCV gas L 1.7 – 3.9 0.9 –1.15
The output of the burners – see page 14 (Burner design) – refers
to natural gas and LPG.
In the case of coke oven gas, the output of the burners is
reduced to about 80%; higher outputs are only possible with
higher supply pressure.
In the case of LCV gas, the output of the burners is reduced
to about 65% of the rated output.
B 8 – 12 0.7– 0.9
G 25 – 35 2.0 – 2.7
D 4 – 6 0.4 – 0.6
range
[kWh/m3(n)]
Density ρ
[kg/m3]
5.4 Burner length
The burner length G should be selected so that the burner is
flush with the inside edge of the furnace lining (S1 = 0 ± 20 mm).
P1
N1
M1
G
K1
L1
S1
ECOMAX · Edition 02.11
Selection
16
5.5 Connection for additional furnace cooling
The air volume supplied to the burner in cooling mode can
be increased using an optional intermediate flange with an
additional cooling air connection on the burner ECOMAX.
L1, N, PE
DI
P
PLC
DI
32
6
3
33
12
A
P
5
23
22 4
19
BCU 465..C
18
17
16
µC
26
Depending on the technical requirements for the process, cooling can be implemented in two stages. Actuating the air valve
for the burner (terminal 22) initiates “normal” cooling; actuating
a second air valve for the additional cooling air connection
initiates additional cooling. The additional cooling air valve is
actuated separately by the process control system. For wiring
on site, we recommend using a BCU..C with a supplementary
terminal strip (e.g. terminals 32/33 for additional air valve).
VG..L
GEH
VR..N
ECOMAX · Edition 02.11
EKO
Additional purging air connection on the ECOMAX® burner
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