For economic andenvironment-consciouscombustion of all liquidand gaseous fuels,i.e. even super-heavyoils.

Combustion and Energy Systems

SKV Burners

No other burner system is able to burn

super-heavy oils so efficiently.

The SAACKE Rotary Cup Ato

Where the combustion of liquid and

gaseous fuels makes high demands on

economy, operational reliability, range of

control, environmental consciousness and

quality, SAACKE burners are first choice

products. The well-proved rotary atomizing

principle is the best condition for a perfect

combustion.

The basis of the SAACKE rotary cup burner

technology is the multi-stage rotation- and

air atomization with thermal support. The

result of this technology is a very fine oil

atomization with a narrow homogeneous

droplet spectrum and a constantly high

quality throughout the entire wide control

range. The combustion process is optimally

controlled by the accurate distribution of the

combustion air as primary, secondary and

tertiary air.

The essential part of the rotary cup atomizer

is its rotating atomizing cup. The liquid fuel

is supplied into this cup almost without any

pressure. The centrifugal forces produced by

rotation draw a wafer-thin homogeneous

and closed film from the entering oil flow.

This film is then uniformly distributed on the

inside of the cup.

When the fuel film leaves the cup rim, the

existing surface tension makes that it is

widened up into an extremely fine film mist.

The primary air emerging with a high kinetic

energy concentrically around the cup rim

now carries out the final and essential part of

the atomization.

The result: optimum combustion.

The Sectional View shows the principleof the multi-stage rotation- andair atomization of the SAACKE rotarycup atomizer.

omizer

The SKV-Low NOx Technolog

With its modular design, the SKV burner which is composed ofoptimally matched components offers not only an operator-friendly concept but also easy service and maintenance andrepresents the actual state-of-the-art in firing technology.

- The product range includes SKV oil burners, SG gas burners and combinedburners of type SKVG

- Capacity range 0.5 - 45 MW- Universally applicable for flame/smoke tube boilers, water tube boilers,

thermal oil boilers, combustors and process engineering plants- Well-proved in land- and marine installations- Reliable, long-life SAACKE quality made in Germany- The modular design allows quick retrofitting for any other liquid or gaseous

fuel. SAACKE burners are, therefore, a future-oriented investment allowingthe operator to feel free and independent from supply- and pricefluctuations on the fuel market.

Windbox / Gas ring burner / Secondary air distributing and feedingsystem with directional vane ring / Internal flue gas recirculation /Tertiary air distributing and feeding system / Outer air annulus ring

- The combustion air guiding system based on many years of experience andrecent research results obtained in the SAACKE fluidics lab allow easy andindividual adaptation to any required plant operating conditions.

- The precise air guiding and distribution system provides for controlledcombustion in staged air streams and guarantees low values of NOx

and solids content.- The adjustable air register consists of heat resistant CrNi-steel. It can

be swung open thus allowing the access to the boiler.- The gas ring burner technology realizes cross-flow mixing with fuel-rich and

fuel-poor zones on a large outlet diameter (low energy density). The result: alow-noise combustion well adapted to the boiler with very low NOx emissions.

y

SAACKE Compound regulation system /Actuating of rotary oilvalve, gas control damper, primary- and secondary air dampers

- By means of precise mechanics, the SAACKE compound regulatorguarantees the reproducible, safe and almost hysteresis-free meteringof fuel and combustion air or other additionalflows.

- All fuel and air flows can be setindependently and modulating over theentire control range.

- Power transmission is made via solidlinkages and high-quality hingedbearings. This assures longtimeconstancy of the settings andhighest liability of operation.

- The electric servomotor(maintenance-free synchronousmotor) with robust gear can beequipped with max. 4 limit switchesand 4 signaling potentiometers for externalfunctions.

Burner swing-out assembly / Rotary atomizing cup and primary airfan with the common drive / Gas-electric or light oil-electric ignition

- Optimum combustion with low excess air and small emission of solids due to aparticularly fine and homogeneous rotary- and air atomization with thermalsupport = saving fuel costs and reducing the needs of boiler cleaning.

- Constant low excess air, even at boiler loads of less than 20 %, technicallypossible by using the primary air as component of the combustion air with highmixing energy = increase of the boiler efficiency especially in partial loads

- The rotary cup burner’s ability to fire any fuel of variable quality, viscosity andcontamination = increase of reliability in operation.

- Low pressure fuel supply, the central fuel feed to several burner plants throughonly one pump and strainer unit, the insignificant wear as well as easy access tothe most important burner components when swinging the rotary cup atomizeropen = reduction of maintenance cost to a minimum.

- By its separate and monitored flame, the ignition burner for gas or light oilensures absolutely safe, pressure-shock free ignition of the main flame.

Water injection system for the reduction of solids- In order to achieve an even higher burn-out of the heating medium

“heavy fuel oil” and a reduction of the content of solids in the flue gases,water is added to the oil via nozzles before the oil enters the rotary cupatomizer.

- The water finely distributed in the oil evaporates in the hot combustion zoneimmediately downstream of the outlet of the rotary cup which acts as anemulsifier.

- The expanding water vapor makes that the atomized oil droplets are dispersedeven finer so that the fuel oil - due to the larger surface - is burnt optimally andthe content of combustible solids in the flue gas is reduced to a minimum.

- This effect is further optimized by a chemical reaction, the “water-gas-reaction”which supports the burn-out of otherwise hardly combustible fuel components.

Gas ring burner- The gas ring burner technology realizes cross-flow mixing with fuel-rich and

fuel-poor zones on a large outlet diameter (low energy density). The result: alow-noise combustion well adapted to the boiler with very low NOx emissions.

Advantages of therotary atomizingtechnology

Economic

* The large range of control minimizes standstill lossesand extends the service life of the boiler.

* Finest homogeneous atomization results in optimumcombustion and reduces boiler fouling.

* The constant low excess air, even at boiler loads downto 20 %, increases the efficiency of the boiler.

* The speed control system (option) reduces the electricservice costs.

* The O2 control system (option) optimizes the efficiencyof combustion.

Reliable in operation

* For safe “starts from cold”, it is only necessary to provide for electric current as auxiliary energy.* The burner’s ability to fire on any fuel of differing quality, grade, pressure, viscosity, temperature or degree of contamination assures continuous readiness for operation.* The absolutely safe and pressure-shock free ignition

(at low burner load) is always ensured by a separateand monitored ignition flame.

Environmental conscious

* Emission values which are even lower than those specified by the stringent German emission

regulations make proof of highest combustionquality.Oil operation:

Low NOx and low solids content as a result of multi-

stage rotation- and air atomization with thermalsupport.Gas operation:

Low NOx as a result of gas ring burner technology with fuel-rich and fuel-poor zones on a large outlet diameter.* Emission minimizing measures can be integrated without problems.* A water injection system reduces the content of solids in the flue gas further without the need of an additional emulsifier.

The Technical PerformancesThe rotary cup atomizerThe high-precision atomizer has beendesigned on the basis of our latest researchesand is manufactured with the highest possibleaccuracy. Its most characteristic features are:

Rotary atomizing cup• computer-calculated geometry• optimally shaped cup rim• integrated pre-distributor• finest hard-chrome plated surface• inner air guiding• vibration-free running due to alignment to

VDI 2060 Q 2,5• uniform film formation and finest

atomization are even assured for a longoperation time when firing contaminated oil

Primary air fan, shaft and drive• integrated high-performance fan• pressurized primary air, high pulse for

optimum combustion• precision-type shaft with ball- and roller

bearings• long time lubrication even in standard

design, small maintenance needs• in case of re-lubrication: over-greasing

impossible• high-tech Poly-V drive with high efficiency

(low heating), slip-free and long service life• maintenance-free three-phase a.c. motor

which can be sized for all voltages andfrequencies

• the high-pressurized primary air inconnection with the characteristics of therotary atomizing cup results in highcombustion quality even when firing super-heavy fuel oils otherwise never achieved

Oil guiding system, oil valves• heated up to the oil outlet thus assuring safe

start from cold• oil circulation up to the compound regulator,

even in case of burner standstill• low-pressure system, only low oil pressure

and low pre-heating temperature required• no hoses, only solid pipings• burner can be swung in open position

without disconnecting the oil system, cleanhandling

• labyrinth packing ring avoids surplus flow ofoil

• only one oil meter (low-pressure) required inthe supply piping

• oil valves TÜV-approved in compliance withDIN-EN regulations

• robust, compact design of SAACKE valves oftype ESV (optional), directly actuated, axialsealing, without control drillings

• high pull-up capacity, no holding capacity,safe even in case of voltage drop down to85 %

• can be heated electrically

The SAACKE know-how systematicallydeveloped and collected during decadesmakes proof especially in certain details whichare not considered in other burner makes. Theconsequent attention given to all relevant factsensures that SKV plants are firing systems withhighest possible availability and reliability.

Compound regulator

The compound regulator is a SAACKEinvention that is well-known since decadesand is continuously optimized:

• made of fluid- and wear-resistant special cast• oil flows for full load and small load can be

set independently from each other• the oil flow for full load can be set individually

by axial setting of the rotary valve whenmaking full use of the setting angle thusmaking the compound regulator a valve withvariable nominal bore !

• multilayer cam strips made of CrV-springsteel, cam blocks made of precision-fine cast

• cam followers with needle bearings,clearance- and maintenance-free

• radial adjustment of the cam followers to thecam strip by rotary seat, no mechanicaloverload

• can be disconnected from the servomotor forcommissioning purposes, with locking device

• equipment with up to 3 cams of same design,e.g. for 2 air dampers and 1 gas damper

Gas burner• possibility to burn gas of almost all grades,

such as natural gas, propane or butane gasand even process gases and waste gases, etc.

• combustion of gases having a very low heatvalue, furthermore co-combustion of wastegases is possible when main firing is assuredwith liquid fuel

• simultaneous combustion of 2 gases• designed for large control range• absolutely flashback-proof thanks to the

special design of the gas nozzles• requires only low gas pressure; operation,

however, also possible with high gas pressure• design and equipment to German regulations

DIN and DVGW• suitable for normal boiler brickwork, small

mounting depth• gas ring made of steel of special resistance,

cooled by the combustion air• front part lined with refractory material,

Al2O3- content > 70 %, thus protected againstflame radiation

Gas train• variably adapted compact gas trains, mounted

ready for operation• in compliance with German Standards DIN

and DVGW• assuring high safety: 2 safety shut-off valves• installation of the gas train adaptable to the

local space conditions at and near the boiler• quality-assured, approved components• leak test system in connection with the

SAACKE automatic sequence control system• design also possible for compatibility with

automatic control systems of othermanufacturers

Fan, windbox

Fan• precise energy-saving design of volume and

pressure in relation to the individual capacityrequirements of the plant

• efficiency of even more than 80 %• optimized course of characteristic curves

adapted for large control ranges• stable, low-vibration design• reduction of vibrations by burner mounting

on vibration dampers and vibration de-coupling by means of separately deliveredelastic connections to the windbox

• selected special fan impellers and casingswith well adapted design allow direct fittingto various windbox types

• variable constructive types make it possible toassure the most favorable location in theplant, e.g. on the boiler, underfloor, separateinstallation place or room

• compact, price-efficient design with disk-typesound absorber

• corresponding to the most stringent noisereduction regulations

• available with sound cabins or suction- ordischarge-side sound absorbers (optional)

• adaptation to all control-engineeringvariations such as swirl controller or speedcontrol (optional)

• for light oil/gas burners with flue gasrecirculation for NOx reduction

• flue gas recirculation fans in space-savingdesign with heat- and sound insulation

• recirculation fans designed for highestthermal loads

Windbox• windbox for most favorable air directing with

flow optimization• configurable for all plant specific requirements• durable surface protection by powder

coating with well-defined coat thickness• integrated air dampers, both-side precisely

supported without clearance, with optimumcharacteristic curve

Automatic sequence control system,control cabinet• oil-, gas- or combined oil/gas operation• approval to DIN EN 230 and DIN EN 298,

CE approval no. to “Gas AppliancesGuideline”

• 72-hour operation without attendanceaccording to TRD 604, Sheets 1 and 2,Section 5.4

• ignition by means of an ignition burner ordirect ignition with ignition spark monitoringpossible with suitable burner design

• separately integrated safety circuits withconnection terminals for safety elements“General”, “Oil” and “Gas”

• integrated testing of the combustion airpressure monitor

• integrated program- and start-up timemonitoring

• adjustable purge time• fully automatic control of the servodrive

during the purge period• selectable running time of the servodrive• memory of collective trouble• integrated automatic leak testing system for

the gas valves• interlock by external fault signal possible

• self-monitoring• thanks to the constructive design of the

control system and various settingpossibilities, the automatic sequence controlsystem is suitable for almost all applications

• plug-connections

Flame detection• type-certified flame detector, self-monitoring• high safety and long service life• 100 % inspected, especially for SAACKE• option: intensity indicator

Ancillary products, options

Oil supply equipment

Pumps and strainer group• low-pressure design, low noise, economic

due to small current consumption and longservice life

• screw-type pump with integrated safety valve• compact unit with strainer or change-over

strainer and valves and fittings• maintenance-free three-phase a.c. motor

Preheater• efficient heat transmission to the counterflow

principle• electric heating element (option) provides for

a safe start of the burner plant if no steam orhot water are available as heating medium

• TÜV-certified quality for highest operationalreliability and service life

• completely equipped with valves and fittingsand control devices

• extremely low power consumption thanks tothe SAACKE rotary atomizing principle

Pressure controller• available as inlet pressure controller (spill flow

controller) or outlet pressure controller(pressure reducer), i.e. optimum design forthe individual plant conditions

• good control accuracy, low hysteresis• oil-hydraulically calculated special shaping of

the control valves for large control ranges

Water - fuel mixing system for solids-poorcombustion MEFWhen firing “heavy” fuel oil, the injection of amaximum of 10 % water upstream of theburner inlet provides for a higher burn-out. Atthe same time, the content of solids in the fluegases is considerably reduced.The water finely distributed in the oilevaporates in the hot combustion zoneimmediately behind the outlet of the rotarycup.By the expansion of the water vapor, the oildroplets are decomposed even finer. Theheavy fuel oil burns optimally due to thedeveloped larger surface so that the content ofcombustible solids in the flue gases is reducedto a minimum.In most cases, MEF replaces cost-extensivefiltering equipment thus representing the morecost-effective and maintenance-friendlysolution.

Further advantages are:• unrestricted use of heavy fuel oils• injection of the water immediately upstream

of the burner, controlled via 4 magneticvalves in dependence of the load demand

• simple and reliable mode of operation• easy retro-fitting in existing plants possible• no costly emulsifiers required• simple commissioning, maintenance-friendly

Separate water feed unit with pressure vesseland water centrifugal pump, completely pipedon a base plate together with all necessaryvalves and fittings, with double protectionagainst a possible return of fuel oil into thewater supply system.

Electric control plants• land installations• marine installations• SAACKE-own manufacture of electric control

plants• own final inspection facilities• development and realization of user-defined

solutions in electric and control engineering

Options• Wiring of the burners on a common terminal

box with high-temperature resistant cable

Integrated Management System IMS(Initial value signalling system for burnercontrol systems)• freely configurable inputs 230 V a.c. for initial

value-, fault- and operational messages aswell as operating mode presettings

• relay outputs for control-, pushbutton- andspecial functions (e.g. collective fault output)

• all message texts are freely configurable• instructive texts (What to do ?) and

measuring point designations (KKS standardor similar) can be allocated to the text ofeach message

• freely configurable time display for everymessage (actual time, instant, timer function,without time)

• the messages can also be issued, in parallelwith the clear text display, to a PC, printer orvia modem

• the last 250 messages are stored• freely user-configurable LEDs as “flashing”,

“continuous light” or “off”• control and diagnostic functions can be

selected via convenient software menus• the inputs can be projected in operating

current or closed-circuit current mode• initial value messages are acknowledged via

the control keyboard or optionally via inputs -also automatically

• remote data transmission of the messages viamodem is possible

Burner control with a fail-safeProgrammable Logic Control (PLC)Type HIMA / Siemens• oil-, gas- or combined oil/gas operation• operation of up to 4 burners• one- or two-burner parallel operation• hardware inspected by TÜV

(Class 1-6 to DIN V 19250)• software in compliance with the binding

regulations to DIN, TRD and VDE• integrated evaluation of initial value fault

messages• initial values monitored on IMS display

Fuel

Heavy oil

Light oil

Gas

Heavy oil/gas

Light oil/gas

2 gases

Heavy oil/2 gases

Light oil/2 gases

Capacity range(MW)

Burner size

Burner type

SKV

SKV

SG

SKVG

SKVG

SGD

SKVGD

SKVGD

0.455 0.57 0.57 0.68 0.74 1.13 1.13 1.36 1.81 2.26 2.60 2.83 3.62 3.96 4.53� � � � � � � � � � � � � � �1.7 2.26 3.39 4.53 5.66 6.79 9.055 11.32 16.98 20.4 22.6 28.3 33.9 39.6 45.3

15 20 30 40 50 60 80 100 150 180 200 250 300 350 400

Oil burner SKV

The SKV is ableto burn any

liquid orgaseous fuel

Safe investmentsby modular

design The SAACKE SKV burner represents a

future-oriented investment because

even the standard burner can be

applied universally and adapted to

various individual operating conditions.

Its modular design further allows quick

conversion to any other liquid or gaseous

fuel: even liquid or gaseous waste fuels or

other problematic fuels can be burnt.

The burner’s ability to fire on any fuel of

differing quality, viscosity or contamination

assures operational reliability at any time.

In addition, SAACKE rotary cup burners

give you the possibility to burn different

liquid and gaseous fuels simultaneously.

It is also possible to provide for operation

with preheated combustion air thus

reducing service costs considerably.

The SAACKE SKV makes you

independent from fuel supply

problems or abrupt changes of

the energy markets.

Gas burner SG

Count on this Service

SAACKE production sites and service stations in 22 countriesworldwide, additional 70 international SAACKE contactoffices, supply of spare parts in 24-hour service, repairand replacement around the clock...We help competently and immediately – wherever youneed us.

Diagnostics via thight-knit, worldwide Tele Support & Service andextensive capacities in maintenance, repair and spare partslogistics enable us to ensure your burners‘ trouble-free operationslong after assembly and commissioning at site.

SAACKE‘s customers worldwide can rely on fast availabilityregarding repair and replacement of all SAACKE burners.SAACKE‘s service partnership includes at the same time –depending on the individual agreement – maintenance andoperational optimisation of your burners, training of boilerroom personnel, safety inspections according to TRD or completeboiler room management by our specialists.

In line with our burner systems, we offer a wide choice ofservices to choose from at any time, according to your specialrequirements.

Our service is geared to on aim: to secure the functioning ofyour burners for many years – economic, eco-friendly, reliable!

Tele Support & Service

replaces external

servicing in many cases.