REGENERATIVE BURNERS

 Exceptionally high furnace efficiency – unthinkable with normal burners & recuperators
 Offer fuel savings opportunity of 15-50%
 Reduction of CO2 emissions as less fuel is use
 Higher production from same furnace or smaller furnace for the same production
 Suitable for all fuels – producer gas (including hot/dirty), FO, LPG, natural gas, LDO
 Offer opportunity of using low cost / low CV fuels (like producer gas or BF gas) even for high temperature applications like melting or forging

WORKING PRINCIPLE

Regenerative Burners work in pairs in a cyclic manner. When one of the burners of the pair is firing, the flue gases pass through the other burner. The burner contains a ‘heat storage media’ consisting of refractory material. When the flue gases pass through the refractory media, heat of the flue gases is stored in this media. After a short interval of pre-set cycling time (30-60 seconds), the firing of the pair of burners is switched. The burner that was firing is ‘switched off’ and the burner with heated media starts firing. By doing so, heat stored in the refractory media is recovered by combustion air and conveyed back to the furnace. Therefore, very high air preheat temperatures (150-2500C below furnace temperature) and hence very good furnace efficiencies are achieved.

   

WHY IS IT BETTER THAN RECUPERATOR?

In recuperators, heat of flue gases is transferred to combustion air through a heat transfer surface. Therefore, materials of heat transfer tubes tend to fail beyond a certain temperature putting a limit on the maximum achievable combustion air preheat temperatures. In regenerative burners, there is no such limit as heat is absorbed and then released through a refractory media. For example, if a forging furnace operates at 13000C, combustion air can be preheated to 1000-11000C using regenerative burners, which is unthinkable with recuperators.


HOW FURNACE PRODUCTION CAN BE INCREASED?


With regenerative burners, entire furnace can be maintained at a nearly flat temperature profile without losing excessive heat to exhaust gases. Hence, material being heated requires lower retention time and so yielding higher production. In the case of a new installation, smaller furnace would serve the purpose with savings in capex as well!


REDUCTION IN CO2 EMISSIONS


CO2 emissions are directly proportional to fuel consumption. Since regenerative burners enable 15-50% reduction in fuel consumption, corresponding reduction in CO2 emissions are achieved.


REVERSING CYCLE TIME


Normally, burners reversing cycle is set to 30-60 seconds. In special cases, burners can be designed for specific cycle times as per requirement.


ROBUST & RELIABLE REVERSING VALVES


COSMO’s proprietary reversing valves (used for cyclic operation of burners) are of robust design – free from complicated electronics. These are made so as to be easily maintainable by average technicians.


CUSTOM ENGINEERED COMBUSTION SYSTEM


We understand that each furnace / application has a unique requirement. Therefore, we study your existing or proposed furnace, appropriately design the entire combustion system and offer you custom engineered solution (consisting of appropriate number & size of regenerative burners, reversing valves, interconnecting piping, fans, etc.).


HOW MUCH FUEL CAN BE SAVED


Quantity of fuel that can be saved would depend upon the present level of efficiency, temperature of furnace, temperature of exhaust gases and fuel being used. The expected savings could be in the range of 15-50%. In high temperature applications like forging or melting, savings of the order of 40% can be expected in most cases.

IN MOST CASES, PAYBACK PERIODS ARE EXPECTED TO BE LESS THAN 1 YEAR