Training Services

Burners

FH/7-1

Section Outline

Pilot
Gas
Combination
Low NOx
Emissions

FH/7-2

Pilot - ST-1S Assembly

301

302
306

307

303
305

301
302
303
304
305
306
307

Pilot Tip
Pilot Nipple
Pilot Mixer
Orifice Spud
Air Door
Pilot Hub
Port Cover

304
HTR-R00-58

FH/7-3

Pilot

UOP specifies continuous pilots for safety

concerns
Natural gas is recommended fuel
John Zink ST-1S or equal
Pilot is a small inspirated gas burner with
glow plug head
Works at lower fuel pressure than standard
gas burners
Air adjusted at inspirator to maintain good
air mixing
FH/7-4

Pilot Burner Problems

Long Yellow Flames

Prone to Blowout

Insufficient Primary Air

Open Air Register

FH/7-5

Pilot Burners

Zink ST-1S

Ignition Source

Safety Device

90% Premix Burner

Short Blue Flame

Orange Color Tip

Blue Flame Spikes on

Side

FH/7-6

Premix Gas

Inspirated Air Burners (Premix)

Advantages

Little fouling/plugging in tips

High efficiency air-fuel mixing

Disadvantages

Flashback (flame speed exceeds mixing

speed)

FH/7-7

Premix Gas Burner

3

Secondary Air

Air
2
3

Primary Air
Gas
HTR-R00-59

Air
Pilot Gas
FH/7-8

Premix Gas Burner

Oldest Burner Design

Inspirates 30-50% of
Combustion Air

Self Correcting on Excess Air

with Gas Pressure

Large Gas Orifice - No Fouling

High Noise

Potential Flashback (Flame

Speed Exceeds Mixing Speed)

Secondary
Air

Air

Primary
Air

Air
Gas

Pilot Gas

High NOX
FH/7-9

Premix Gas Burner

John Zink HEDV Burner

Round Flame Premix

Glowing Tile Indicates Improper

Tip Position

Gas Tips Should be 25/20 Cr/Ni

FH/7-10

Premix Gas Burner

John Zink PFH

Flat Flame Premix

Improper Round Tile

Early 1970s Design

FH/7-11

Premix Gas Burner

John Zink PFH

Flat Flame Premix

Proper Rectangular Tile

1990s Revamp

FH/7-12

Raw Gas

Raw Gas or Nozzle Mix Burners

Advantages

High turndown ratio

No possibility of flashback
Can burn wide variety of fuels
Disadvantages
Fouling/plugging in tips
Lower efficiency air-fuel mixing

FH/7-13

Raw Gas Burner

1

3
4

Air

Air

Gas
HTR-R00-60

Pilot Gas

FH/7-14

Raw Gas Burner

Simple Construction

Can Burn Wide Range of

Fuels

Short Flames

High Turndown Ratio

No Possibility of
Flashback

Potential Fouling of Tips

Air

Air

Gas
Pilot Gas

FH/7-15

Raw Gas Burner

110 ppm NOX

Slight Haze on End of

Flame

Low Excess Air (2%)

Hot Flame Temperature

Bright Refractory Color

FH/7-16

Raw Gas Burner

Improper Tile Installation

High Air Close to Pilot

FH/7-17

Raw Gas Burner

Flame Cone Located too

Low

FH/7-18

Combination Burner

Air

Pilot Gas
HTR-R00-62

Damper
Gas Control
Steam
Oil
FH/7-19

Oil Burners

Oil gun atomizes oil to fine spray of oil

droplets that approximate gas firing

Atomization done with steam, air, or

mechanically (high pressure)

FH/7-20

Oil Burner

FH/7-21

Dual Tube Oil Gun

Used for light oils

Prevents flashing and

pressure fluctuation with
light oils and naphtha

FH/7-22

Combination Burner

Combines Raw Gas and Oil

Burner

Use Either Fuel When in

Service

Air

Not Recommended to Run

Both Fuels at Same Time

Light Oil Gun Off Main

Gas - Not Pilot

Gas

Damper Control

Steam

Pilot Gas
Oil

Startup on Gas Until

Firebox is Hot
FH/7-23

Combination Burner

Oil Gun in Center of

Primary Tile, 1 (25 mm)
Below Tile Ledge

Gas Tips Located Between

Primary and Secondary
Tiles

FH/7-24

Combination Burner

Oil Firing on Right Burner

High Emissivity Oil Flame

Gas Firing on Left Burner

Low Emissivity Gas Flame

FH/7-25

Oil Gun Location

Proper position is critical to proper spray

pattern and air mixing

Proper location

HTR-R00-97

Too far in

Too far back

FH/7-26

Combination Burner

Looking at Oil Flame

Through Primary Tile

Flame Recirculation

FH/7-27

Combination Burner

Looking at Oil Flame

Through Primary Tile

Flame Recirculation with

No.2 Oil with Staged Air
Burner

FH/7-28

Combination Burner

Oil Ash (Sodium Vanadates)

Attack Refractory

Use 94% Alumina on

Primary Tile

FH/7-29

Combination Burner

94% Alumina on Primary

Tile

60% Alumina on Secondary

Tile

Use Plywood Template to

Align Secondary Tile Pieces

FH/7-30

Burner Excess Air Adjustment

Opening/closing air register or damper

Registers - large clearances - will pass 50% of
design air when fully closed
Dampers - tighter clearances - will pass 1225% of design air when fully closed
Keep all burners lit if possible
Minimum pressure drop 0.10-0.15 in H2O
80% of burner pressure drop in throat - 20%
in damper/register

FH/7-31

Burner Air Controls

Concentric Register

Prone to Sticking

Difficult to Adjust

Leaks 50% Air when

Closed

FH/7-32

Burner Air Controls

Damper Control

Tight Shutoff

Positive Position

Good Excess Air

Control

FH/7-33

Burner Excess Air Adjustment

% Excess Air in Flue Gas

100

75
Register Type Burner

50
Burner w/ Inlet Damper

25

HTR-R00-65

Burner Air Register

Completely Closed
at this Point

Burner Air
Register Completely
Closed at this Point

25

75
50
% of Burner Design Firing Rate

100
FH/7-34

Emissions

National/local governments restrict emissions

of:
NOx
SOx
CO
Particulate
Unburned hydrocarbons
Heavy metals
Others

FH/7-35