bio, bioa, zio - lesman · bio, bioa, zio · edition 05.10 3 bio bioa zio 1 application for...

7.2.14 Edition 05.10Technical Information · GB

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Burners for gas BIO, BIOA, ZIO

• Large capacity range up to 1000 kW• Maintenance-friendly thanks to modular design• Robust burner design• Safe flame control thanks to ionization electrode and reliable electrical ignition• Length increments enable individual adjustment either to new systems or

when modernizing existing systems• Suitable for new systems and modernisation of existing systems thanks to

individual length adjustment• Air preheating to 450°C available as an option• Low polluting level thanks to optimized combustion• For installation as ceiling or side-wall burner• Can be combined with different combustion chamber shapes

BIO, BIOA, ZIO · Edition 05.10

2

t = To be continued

Table of contentsBurners for gas BIO, BIOA, ZIO . . . . . . . . . . . . . . . . . . . . . . 1Table of contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.1 Examples of application. . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.1.1 Continuous control with pneumatic ratio control system . . .51.1.2 Continuous control with pneumatic ratio control system and lance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51.1.3 Cascade control for extended control range . . . . . . . . . . . .61.1.4 Staged control with pneumatic ratio control system . . . . . .6

2 Certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72.1 Approval for Russia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

3 Mechanical construction . . . . . . . . . . . . . . . . . . . . . . . . . . 83.1 Burner housing (furnace flange) . . . . . . . . . . . . . . . . . . . 83.2 Burner insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83.3 Burner tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93.3.1 Burner tube in burner quarl . . . . . . . . . . . . . . . . . . . . . . . . . .93.3.2 Burner tube with attachment tube . . . . . . . . . . . . . . . . . . . .9

4 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115.1 Burner type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115.2 Burner size. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115.3 Burner head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125.4 Field of application . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135.5 Calculating the burner length . . . . . . . . . . . . . . . . . . . 145.5.1 Burners in burner quarls . . . . . . . . . . . . . . . . . . . . . . . . . . . 145.5.2 Burners with burner attachment tube . . . . . . . . . . . . . . . . 17

5.6 Selection table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195.6.1 Type code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

6 Project planning information . . . . . . . . . . . . . . . . . . . . . 216.1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216.2 Recommended ignition transformer . . . . . . . . . . . . . . 216.3 Non-return gas valve . . . . . . . . . . . . . . . . . . . . . . . . . . 216.4 Flame control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

6.5 Hot air compensation . . . . . . . . . . . . . . . . . . . . . . . . . . 216.6 Purging air/cooling air . . . . . . . . . . . . . . . . . . . . . . . . . 226.7 Emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226.8 Gas line connection . . . . . . . . . . . . . . . . . . . . . . . . . . . 236.9 Air line connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236.10 Condition on delivery. . . . . . . . . . . . . . . . . . . . . . . . . . 23

7 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247.1 Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277.2 Ignition lance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

8 Maintenance cycles . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31Contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31


3

BIO

BIOA

ZIO

1 ApplicationFor industrial furnaces and firing systems in the iron and steel industries in the precious, non-ferrous and light metal sector, as well as in the plastics, fibre and paper industries. Other fields of application are thermal incineration installations, as well as driers and hot-air generators.For low temperature applications (e.g. for crucible heating, radiant tube heating or hot-air generation), the burners are equipped with a heat-resistant steel attachment tube.For high temperature applications (e.g. forging furnace), the burners are used in combination with a burner quarl made from refractory concrete. Different flame shapes can be achieved by using burner quarls with a different geometry.The burner may be adapted to the system requirements using different burner lengths.


4

Shaft melting and holding furnace Bogie hearth forging furnace Incineration installation for thermal regen-erative flue air purification

Application

Strip galvanising plant Rotary table furnace Aluminium tank furnace


5

AKT

GEH

GEH

GEH

EKO

BVAIC 20..E + BVA

M

VAG

60DJZ VG 8

BIO..L, ZIO..L

60DJLZ

EKO

1 .1 Examples of application1 .1 .1 Continuous control with pneumatic ratio control systemThe burner output is controlled in modulating mode by ad-justing the butterfly valve BVA. The air/gas ratio control VAG ensures a constant gas/air flow ratio via the impulse line. This type of control is used in melting furnaces in the aluminium industry or in regenerative incineration installations in the environment industry, for example.

1 .1 .2 Continuous control with pneumatic ratio control system and lanceThe burner’s flexibility is increased thanks to an ignition lance. This type of control is used in heat treatment furnaces in the iron and non-ferrous metal industries and in heating furnaces in the steel industry, for example.

IC 20 + BVA

VAG

M

BVA

VASZIO, BIO, BIOA

EKO

EKOGEHAKT

Three-pointstep

Application


6

M

VAGVAS

ZIO, BIO, BIOAEKO

M

IC 20+ LFC

IC 20 + BVA EKO

AKT

LEH

GEH

VAS

VAG+VBY

BIO, BIOA, ZIOAKT EKO

EKOMB 7 + BVHM

GEH

LEH

Application > Examples of application

1 .1 .3 Cascade control for extended control rangeThe burner is adjusted near-stoichiometrically to a low-fire rate of 10% using a pneumatic ratio control system. Smaller capacities can be adjusted with the IC 20 at a constant low-fire air flow rate by throttling down the gas flow. With cascade control, control ranges of 1:45 can be achieved with excess air.

1 .1 .4 Staged control with pneumatic ratio control systemThe burner capacity is switched cyclically between high fire and low fire by opening and closing the solenoid-operated butterfly valve for air.The pneumatic air/gas ratio control system offers maximum safety by an air deficiency cut-out, with a constant lambda value being maintained while the air pressure varies. The low-fire rate is guaranteed by the bypass valve VBY. The high output impulse at the burner produces a uniform tempera-ture distribution and good circulation of the furnace or kiln atmosphere, e.g. in heat treatment furnaces in the iron and non-ferrous metal industries or kilns for heavy clay and fine ceramics.


7

2 Certification2 .1 Approval for Russia

Certified by Gosstandart pursuant to GOST-R.Approved by Rostekhnadzor (RTN).

http://docuthek.kromschroeder.com/doclib/main.php?language=2&folderid=207050&by_lang=-1&by_class=20


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3 Mechanical constructionThe burners are composed of three modules: burner hous-ing, burner insert and burner tube. This structure allows the burners to be easily adapted to the respective process or to be integrated into existing systems. Maintenance and repair times are reduced, and existing furnace installations can easily be converted.

3 .1 Burner housing (furnace flange)

BIO BIOA ZIO

The burner is secured to the furnace by the burner housing. The burner housing accommodates the burner insert and the burner tube, and routes the combustion air. The combustion air pressure can be measured using an air pressure test nipple.

3 .2 Burner insert

BIO BIOA ZIO

The combustion gas is supplied to the burner head via the gas connection and the gas pipe. The gas connection flange comprises of the gauge glass, ground screw and electrode plugs with plug caps.As of construction stage E, a measuring orifice and flow adjust-ment are integrated in the connection flange to easily measure and adjust the gas flow rate.The ignition and ionization electrodes are screwed into the connection flange and can be replaced without removing the burner insert as of burner size 65.Burners BIO, BIOA and ZIO are nozzle-mixing burners. Gas and air are mixed only once they are in the burner head. This prevents explosive gases from being generated in the pipeline. There are various burner head versions for different flame shapes and gas types.


9Mechanical construction

3 .3 Burner tube

Different overall lengths enable adjustment to the furnace wall thickness of the system.

3 .3 .1 Burner tube in burner quarlThe burner head is positioned inside the burner tube. The burner quarl accommodates the burner tube and simulta-neously acts as the combustion chamber for the complete combustion of the flame. The burner quarls are components of the refractory lining of the furnace and are usually supplied by the furnace manufacturer.

3 .3 .2 Burner tube with attachment tubeThe burner head is positioned inside the burner tube. An at-tachment tube made of heat-resistant steel acts as the com-bustion chamber for the complete combustion of the flame for low- and medium-temperature applications.


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4 FunctionThe burner control unit opens the gas and air control valves. Gas flows through the gas connection flange and air flows through the burner housing as far as the nozzle-mixing burner head.The combustible gas/air mixture is produced downstream of the burner head. Slots and holes in the air disc vary the degree and manner of twisting of the combustion air and determine the flame geometry. Depending on the gas type, the geometry of the gas nozzle varies.The gas/air mixture is electrically ignited directly by an igni-tion electrode or an ignition lance. A flame forms which is monitored using an ionization electrode or optionally using the UV sensor.The choice of the respective combustion chamber material and geometry is primarily determined by the process.Using burner quarls, almost any flame shape and outlet ve-locity can be achieved.For low-temperature applications, a combustion chamber made of heat-resistant steel can be used. The flame burns inside the metal burner attachment tube.

Burner insertBurner housing

Burner head

GasAir Burner tube

BIO, BIOA

Burner insertBurner housing Burner head

Gas

Air

Burner tube

ZIO

Ignition electrode Ionization electrode

Gas nozzle

Burner head


11

5 Selection5 .1 Burner type

5 .2 Burner size

Type HousingAir temperature Furnace temperature

°C °CBIO GG 20 to 450 50 to 1600BIOA AlSi 20 to 200 50 to 1400ZIO ST 20 to 450 50 to 1600

* For furnace temperatures of > 1450°C, special burner versions are available on request.

Burner size Burner capacity[kW]

BIO 50 40 BIO, BIOA 65 90BIO 80 150BIO 100 230BIO 125 320BIO 140 450ZIO 165 630ZIO 200 1000


12

5 .3 Burner headThe choice of burner head depends on the flame shape, gas type and variant.

Flame shape Burner head code letter Control range Low fi re l λ1) Furnace temperature

[°C]Air temperature2)

[°C]Continuous Staged

Normal R 1:10 1:10 > 1.05 0.8 to 1.3 50 to 350 20 to 1504)

Long H 1:10 1:10 > 1.3 0.8 to 1.5 500 to 16005) 20 to 450Flat K3) – 1:10 > 1.05 0.9 to 1.2 50 to 1004) 20 to 504)

1) Indicates the rough range for the max. connection rating. For precise values for the individual versions, see burner diagrams. The ranges were determined for an ionization current of ≥ 5 µA. Extension of the working range using a UV sensor.

2) The gas fl ow rate should be reduced in accordance with the enthalpy gain of the preheated combustion air.3) In conjunction with a burner quarl, for use as a radiant burner.4) Higher temperatures available on request.5) From a furnace temperature of > 1450°C, the control range is limited.

Selection

Gas type Code letter Calorifi c value range[kWh/m3(n)]

Density ρ[kg/m3]

Natural gas L and H quality B 8 to 12 0.7 to 0.9Propane, propane/butane, butane M 25 to 35 2.0 to 2.7Propane, propane/butane, butane G1) 25 to 35 2.0 to 2.7Coke oven gas, town gas D 4 to 5 0.4 to 0.6Low calorifi c value gas L2) 1.7 3 to 3 0.9 to 1.15

1) For λ < 0.9 or when using the BIO 50.2) Not for all burner sizes. Burner capacity is limited to 50 % of the rated capacity.3) Calorifi c value range < 1.7 on request.

Variant Code letter Output[kW]

Ignition lance L approx. 1.5Reduced max. connection rating R –


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5 .4 Field of applicationFor optimal operation, the combustion chamber and flame shapes are combined according to the field of application.

Field of application Illustration Combustion chamber Control Flame

shapeMax.

capacity Remarks

Industrial furnaces, open combustion chambers A Open cone High/Low

Continuous R 100 %Recommended for cold-air operating

mode only, otherwise the nitric oxide val-ues are too high

Industrial furnaces, open combustion chambers B Cylindrical

High/LowHigh/Low/OffContinuous

R, H 100 % Normal to medium fl ow velocity

Industrial furnaces, open combustion chambers C Tapered

High/LowHigh/Low/OffContinuous

R, H approx. 80%

Medium to high velocity, capacity de-pending on the diameter

Industrial furnaces, open combustion chambers D Flat fl ame

quarl

High/LowHigh/Low/Off(Continuous)

K 100 % With continuous control, limited control range (≥ 40%)

Radiant tube heating E

Burner with attachment

tube and purging air bore holes

On/Off H 100 %

For cold-air only. Note the capacity of the radiant tube in accordance with the man-

ufacturer’s specifi cations.A draught blocker must be fi tted on the

fl ue gas side.

Hot-air generation F

Burner attach-ment tube

with purging air bore holes,

protective fl ame tube

FPT

High/LowHigh/Low/Off

continuousR 100 %

Protection of the fl ame from cooling is en-sured by using a protective fl ame tube

FPT at fl ow velocities of > 15 m/s). Only where the furnace temperature is

< 600°C.

Selection


14

L2 LO

BKL

L1

5 .5 Calculating the burner length5 .5 .1 Burners in burner quarlsThe position of the burner head (L2) should be appropriately selected, so that the burner head extends into the burner quarl.The position of the burner head is available in the following lengths: 35, 135, 235, 335 mm, etc.The burner chamber length BKL for ensuring optimum flame formation and stable burner operation can be found in the [Data table – p. 15].Determine the position of the burner head: L2 = LO - BKLThe burner tube length (L1) is predefined, depending on the flame shape R, K or H: R, K burner head: L1 = L2 + 15 mm, H burner head: L1 = L2 + 65 mm

ExampleDesired burner quarl type = B, desired flame shape = R (normal).Selected burner with 90 kW capacity = BIO 65, suitable for burner chamber length (BKL) = 115 – 265 mm.Furnace wall thickness LO = 340 mm.Calculate shortest length L2: Select maximum burner chamber length: BKL = 265 mm.L2 = LO - BKL = 340 mm - 265 mm = 75 mm.Compare L2 (here 75 mm) with standard lengths (35, 135, 235, 335 mm, etc.).Select next longest standard length L2: L2 = 135 mm.Test whether the burner chamber length BKL fits: LO - L2 = BKL ➔ 340 mm - 135 mm = 205 mm.205 mm falls into the burner chamber length range for burners BIO 65: 115 – 265 mm – see [Data table – p. 15].

LegendL1 = Burner tube length L2 = Position of burner head LO = Furnace wall thicknessBKL = Burner chamber length (L10)

Selection


15

BKL

6°

BKL

∅

BKL

BKL

B

C

D

A

Data table

BIO, BIOA, ZIO Burner quarl type Flame shapeBurner head*

Burner chamber length BKL (L10)

[mm]50 A R 215 to 26550 B, C R 115 to 26550 B, C H 115 to 26550 D KB, KG 130 to 13565 A R 215 to 26565 B, C R 115 to 26565 B, C H 115 to 26565 D KB, KM, KD 155 to 17580 A R 215 to 26580 B, C R 165 to 26580 B, C H 165 to 26580 D KB, KM 205 to 225

100 A R 215 to 315100 B, C R 165 to 265100 B, C H 165 to 315100 D KB, KM 230 to 250100 D KD 170 to 190125 A R 265 to 365125 B, C R 215 to 315125 B, C H 215 to 365125 D KB 190 to 210

* Flame shape: R = normal, H = long, K = fl at.Gas type: B = natural gas, M, G = propane, butane/propane, butane, D = coke oven gas, town gas.

Selection > Calculating the burner length > Burners in burner quarls

Burner quarl type


16

BKL

6°

BKL

∅

BKL

BKL

B

C

D

A

BIO, BIOA, ZIO Burner quarl type Flame shapeBurner head*

Burner chamber length BKL (L10)

[mm]140 A R 315 to 415140 B, C R 265 to 365140 B, C H 265 to 415140 D KB, KM 215 to 235165 A R 315 to 465165 B R 265 to 415165 B, C H 265 to 465165 D KB, KM 240 to 260200 A R 415 to 565200 B R 315 to 465200 B, C H 315 to 565200 D KB 255 to 275

* Flame shape: R = normal, H = long, K = fl at.Gas type: B = natural gas, M, G = propane, butane/propane, butane, D = coke oven gas, town gas.

For further information on burner quarls – see www.docuthek.com

Selection > Calculating the burner length > Burners in burner quarls

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17

E

F

Selection > Calculating the burner length

5 .5 .2 Burners with burner attachment tubeExamples for fields of application

Radiant tube heatingWhen using the burner in radiant tubes or protective flame tubes, the extended burner tube (attachment tube) acts as the combustion chamber. Burners for this field of application are supplied with purging air bore holes for optimal flame stability.The outlet diameter of the radiant tube must be reduced to the point where a pressure loss of approx. 10 mbar occurs at the burner’s rated capacity.

Hot-air generationTo generate hot air at a furnace temperature of < 600°C, burn-ers with an attachment tube and purging air bore holes are used.At flow velocities of > 15 m/s, the protective flame tube FPT is used to protect the flame from being cooled. At flow veloci-ties of < 15 m/s, the protective flame tube FPT is not needed.


18

L2

LO

L1-2

L1

Calculation exampleAttachment tube lengths (L1-2):

BIO, BIOA, ZIOH burner head R burner head

[mm] [mm] 50 115 115 65 115 115 80 165 165 100 165 165 125 215 215 140 265 265 165 265 165200 315 215

Position of the burner head (near the interior furnace wall): L2 = LO ± 50 mmThe burner tube length (L1) is calculated by adding the position of the burner head (L2) to the attachment tube length (L1-2):L1 = L2 + L1-2

ExampleDesired flame shape = H (long) – see [Field of application – p. 13].Selected burner with 90 kW capacity = BIO 65.Attachment tube length (L1-2) = 115 mm.Furnace wall thickness LO = 300 mm.Calculate shortest length L2: L2 = LO - 50 mm = 300 - 50 mm = 250 mm.Compare L2 (here 250 mm) with standard lengths (35, 135, 235, 335 mm, etc.).Select next longest standard length L2: L2 = 335 mm.Calculate the related burner tube length (L1): L1 = L2 + L1-2 = 335 mm + 115 mm = 450 mm.

LegendL1 = Burner tube lengthL2 = Position of burner headLO = Furnace wall thicknessL1-2 = Attachment tube length (distance

from burner head to burner tube end)

Selection > Calculating the burner length > Burners with burner attachment tube


19Selection

5 .6 Selection table50 65 80 100 125 140 165 200 H R K B G M L D L R - 50 –… /35 – … -(1) – -(99) A – Z B

BIO � � � � � � � � � � � � � � � � � � � � �

BIOA � � � � � � � � � � � � � � � �

ZIO � � � � � � � � � � � � � � � � �

� = standard, � = available

Order exampleZIO 165RB-50/35-(17)D


20Selection > Selection table

5 .6 .1 Type codeCode DescriptionBIOBIOAZIO

Burner for gasBurner for gas with aluminium housing

Burner for gas50 to 200 Burner size

HRK

Flame shape:long

normalfl at

BG, MLD

Gas type:natural gas

propane, propane/butane, butanelow calorifi c value gas

coke oven gas, town gas

LR

Variant:with ignition lance

with reduced max. connection rating–50*–100**–150*–200**–250*–300**…

Burner tube length (L1) [mm]

/35–/135–/235–…

Position of burner head (L2)

-(1) to - (99) Burner head identifi erD to F Construction stageB With purging air bore holes

* R, K burner head** H burner head


21

6 Project planning information6 .1 InstallationInstallation position: any.Gas and air connection: can be rotated in 90° steps.Install and insulate the burner in order to avoid any overheat-ing of the components during operation. Where applicable, purging air must be used to prevent ingress of aggressive gases and thermal overload of components.

6 .2 Recommended ignition transformer

≥ 7.5 kV, ≥ 12 mA, e.g. TZI 7,5-12/100 or TGI 7,5-12/100.

6 .3 Non-return gas valveNon-return gas valves are not required, since the burners are of the nozzle-mixing type.

6 .4 Flame controlFlame control is performed using an ionization electrode or optionally using a UV sensor.

6 .5 Hot air compensationIn order to maintain the λ constant in hot-air operating mode, the combustion air pressure is increased. The gas pressure increases in hot-air operating mode (450°C) by approx. 5 mbar for BIO..K and by approx. 10 mbar for BIO..H. The total capacity (gas capacity + hot air capacity) must not exceed the maximum possible burner capacity (see also burner operating charac-teristic diagrams at www.docuthek.com):

0 50 100 150 200 250 300 350 400 450 0

10

20

Hot air [°C]

Hot

air

capa

city

[%]

The air pressure is increased for a constant λ.

0 50 100 150 200 250 300 350 400 450 0

50

100

150

200

250

Hot air [°C]

Air

pres

sure

[%]

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22

6 .6 Purging air/cooling air

While the burner is switched off and depending on the furnace temperature, there must be a certain air flow in order to ensure safe ignition and monitoring of the burners, and for cooling the burner components.The relative air volume in percentage values, based on the air volume for the rated capacity of the relevant size, is given in the Purging/cooling air volume for burners diagram. For hot air, the values on the right-hand axis are based on the standard air volume for the relevant rated capacity.The air fan must remain switched on until the furnace has cooled down completely.

6 .7 Emissions

Emissions for cold-air operating mode do not exceed the limits stipulated by the German Clean Air Directive.NOX values depend on the temperature, burner head, com-bustion chamber, furnace chamber, λ value and output (NOX values on request).If operated with LPG, NOX values are approx. 25% higher.

700 800 900 1000 1100 1200 1300 14000

6

4

2

5

3

1

0

12

8

4

10

6

2

BIO, ZIO

BIO/ZIO..KB..E

BIO/ZIO..K

Purging/cooling air volume for burners

Kiln temperature °C

Cool

ing

air a

t 20°

CA

ir vo

lum

e at

rate

d ca

paci

ty [

%]

Cool

ing

air a

t 450

°CA

ir vo

lum

e* a

t rat

ed c

apac

ity [

%]

* The cooling air volumes measured in standard cubic metres are converted into percentage values.

NOX[mg/m3]

5% O2

R, K (20 °C)

H (20 °C)

10 50 100

100

200

300

400500600

50

70

H (450 °C)

K (450 °C)

Capacity [%]

Flame shape:R = NormalH = LongK = Flat

TFurnace = 1000°C

Project planning information


23

6 .8 Gas line connectionTo ensure accurate measurements of the pressure differential on the integrated gas measuring orifice, the following applies for the design of the gas connection:

– Ensure undisturbed flow to the gas connection on the burner for a distance of ≥ 5 DN.

– Use a bellows unit with the same nominal dimensions as the gas connection on the burner.

– Use a pipe bend up to an angle of 90° with the same nominal dimensions as the gas connection on the burner.

– Only use reducing nipples with an external thread at both ends in order to reduce the nominal diameter on the burner (e.g. from 1” to ¾”).

To ensure optimum flow, to avoid incorrect measurements and to enable burner operation with excess gas, we recommend the following:

– Do not screw the manual valve directly into the burner.

6 .9 Air line connectionEnsure there is a bellows unit and an air adjusting cock up-stream of the burner. It is recommended to install a measuring orifice FLS to determine the air flow rate.

6 .10 Condition on deliveryGas and air connections are fitted opposite one another at the factory.

Project planning information


24

7 Technical dataGas supply pressure: approx. 20 to 50 mbar, Air supply pressure: approx. 25 to 40 mbar, each depending on flame shape and gas type (gas and air pressures – see burner diagrams at www.docuthek.com).Burner length increments: 100 mm.Gas types: natural gas, LPG (gaseous) and coke oven gas; other gases on request.Heating: direct using a burner quarl or an attachment tube, indirect using a burner attachment tube inside the radiant tube.Control type: staged: On/Off, High/Low/Off, continuous: constant λ value.Most of the burner components are made of corrosion-re-sistant stainless steel.Housing: BIO: cast steel, BIOA: AlSi, ZIO: ST.Flame control: with ionization electrode (UV sensor as an option).Ignition: direct, electrical, lance as an option.Maximum furnace temperature: BIO/ZIO in burner quarl: up to 1600°C, with K burner head: up to 1100°C (higher temperatures on request), BIO/ZIO with burner attachment tube: up to 600°C (higher temperatures on request).

Maximum air temperature: BIO, ZIO: 450°C, BIOA: 200°C.

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25Technical data

Burners Rated capacity1) Burner quarl type Flame shape code letter Flame length2) Flame outlet velocity3)

kW cm m/sBIO 50 40 A R 25 15BIO 50 40 B R 30 55BIO 50 40 B H 35 50BIO 50 40 D K – –BIO(A) 65 90 A R 40 20BIO(A) 65 90 B R 50 70BIO(A) 65 90 B H 60 65BIO(A) 65 90 D K – –BIO 80 150 A R 45 20BIO 80 150 B R 60 75BIO 80 150 B H 70 70BIO 80 150 D K – –BIO 100 230 A R 55 20BIO 100 230 B R 70 75BIO 100 230 B H 80 70BIO 100 230 D K –BIO 125 320 A R 60 20BIO 125 320 B R 100 65BIO 125 320 B H 115 60BIO 125 320 D K – –BIO 140 450 A R 80 20BIO 140 450 B R 120 75BIO 140 450 B H 140 70BIO 140 450 D K – –ZIO 165 630 A R 90 20ZIO 165 630 B R 110 75ZIO 165 630 B H 160 70ZIO 165 630 D K – –

1) Higher capacities are possible – either on request or see burner diagrams at www.docuthek.com.2) Measured in the burner quarl from the front edge of the burner quarl. The fl ame diameter is approx. one to two times that of the burner tube or burner

quarl outlet.3) Refers to rated capacity, with a fl ame temperature of 1600°C for R burner head and 1500°C for H burner head. The fl ow velocity is increased when the

outlet diameter of the burner quarl is reduced. The rated capacity must then be adjusted to the outlet diameter.


26

Burners Rated capacity1) Burner quarl type Flame shape code letter Flame length2) Flame outlet velocity3)

kW cm m/sZIO 200 1000 A R 100 25ZIO 200 1000 B R 130 85ZIO 200 1000 B H 200 80ZIO 200 1000 D K – –

1) Higher capacities are possible – either on request or see burner diagrams at www.docuthek.com.2) Measured in the burner quarl from the front edge of the burner quarl. The fl ame diameter is approx. one to two times that of the burner tube or burner

quarl outlet.3) Refers to rated capacity, with a fl ame temperature of 1600°C for R burner head and 1500°C for H burner head. The fl ow velocity is increased when the

outlet diameter of the burner quarl is reduced. The rated capacity must then be adjusted to the outlet diameter.

Technical data


27

S d2

D2k2

FLA

GA

hH

D

L3

k3D3

L5

L6

L4 L1

L2

d3

n2

n3

d2

D2k2

FLA

GA

S

h30

H

D

L3L5

L6L4 L1

L2

n2

BIO BIOA

7 .1 Dimensions

L1 (burner tube length) and L2 (position of burner head) are variable (see Calculating the burner tube length)

Technical data

Burner Max. capacity*

Dimensions [mm]Weight

Gas connection Air connection[kW] D** GA LA H h S L3 L4 L5 L6 D2 k2 d2 n2 F D3 k3 d3 n3 [kg]

BIO 50 40 50 Rp 1/2 Rp 11/2 50 38 12 73 149 240 127 181 151 12 4 75 – – – – 5.4BIO 65 90 65 Rp 3/4 Rp 11/2 62 48 12 73 156 246 127 195 165 12 4 95 – – – – 7.2BIOA 65 90 65 Rp 1/2 ∅ 48 80 44 16 95 170 261 149 195 165 13 4 88 – – – – 3.6BIO 80 150 82 Rp 3/4 Rp 2 112 55 14 90 172 272 140 240 210 14 4 110 – – – – 11.2BIO 100 230 100 Rp 1 Rp 2 100 60 16 103 185 285 153 240 200 14 4 120 – – – – 12.6BIO 125 320 127 Rp 11/2 DN 65 135 73 16 120 254 350 212 270 240 14 4 145 185 145 18 4 21.7BIO 140 450 140 Rp 11/2 DN 80 150 80 18 130 271 381 232 300 265 14 4 160 200 160 18 8 29* Cold-air connection, open fl ame, λ = 1,1** Approx. 10 cm larger in the case of a deviation from the standard length, as a weld seam is applied.


28

S

L6

Z I

D

k3D3

L3

L4

LA

L1

H

L2d3

GA

d2

D2k2

F

n2

ZIO

Technical data > Dimensions

Burner Max. capacity*

Dimensions [mm]Weight

Gas connection Air connection[kW] D** GA LA H h S L3 L4 L5 L6 D2 k2 d2 n2 F D3 k3 d3 n3 [kg]

ZIO 165 630 165 R 11/2 DN 100 213 – 20 150 359 – 230 285 240 14 4 ∅ 220 220 180 18 8 26ZIO 200 1000 194 R 2 DN 150 220 – 20 220 469 – 340 330 295 22 8 ∅ 255 285 240 22 8 37

* Cold-air connection, open fl ame, λ = 1,1** Approx. 10 cm larger in the case of a deviation from the standard length, as a weld seam is applied.


29Technical data

7 .2 Ignition lanceBIOGas connection: Rp ¼.Air connection: Rp 3/8.Gas pressure: 30 to 50 mbar.Air pressure: 30 to 50 mbar.

CE2

B

E1

ZI

L7

W2

W1

gas

air

Burner Gas connection

Air connection Dimensions

B C E1 E2 L7 W1 W2mm mm mm mm mm ∠ ° ∠ °

BIO 80..L 57 54 7 10 177 36 45BIO 100..L 57 54 7 10 190 36 45BIO 125..L 69 65 8 8 261 30 30BIO 140..L 63 62 16 18 276 42 45

ZIOGas connection: Rp ¼.Air connection: Rp ½.Gas pressure: 30 to 50 mbar.Air pressure: 30 to 50 mbar.

I

ZI

L7

E2B

E1C

Gas

Air

Burner Gas connection

Air connection Dimensions

B C E1 E2 L7mm mm mm mm mm

ZIO 165..L 118 77 27 71 382ZIO 200..L 137 77 27 89 482


30

8 Maintenance cyclesTwice per year, but if the media are highly contaminated, this interval should be reduced.


31

Kromschröder, a product brand of the Elster Group

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1 Elster GmbH Postfach 2809 · 49018 Osnabrück Strotheweg 1 · 49504 Lotte (Büren) GermanyT +49 541 1214-0 F +49 541 1214-370 [email protected] www.elster.com

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