Natural Gas Regenerative Burner System 3500Kw Regenerative Burners Nano Energy Saving

Nano energy saving regenerative combustion system for aluminum melting furnace

Product technologies

1. Air -gas ratio; the air and natual gas are mixed by suitable proportion in the gun and sprayed out to burn, no excessive combustion, no pull back to the heat storage resulting in a short life of heat storage barrels and heat storage balls. (Most of the existing traditional insufficient combustion cannot completely recycle the heat. What's worse, it is unsafe if mixing the air and natural gas after the gun in the furnace chamber.)

2. Waste heat recovery; the normal temperature in the furnace is 1150 ℃. After our technical recycling, the smoke exhaust temperature is below 180℃, and the remaining thermal energy is recovered into the heat storage drum to warm up the air. (The key: fully use the waste heat) (The traditional smoke exhaust temperature is above 250℃, and the temperature of the outer wall of the heat storage drum is too high to touch it with your hands).

3. Furnace pressure control; during the waste heat recovery process, due of the full burning of reasonable ratio air-gas mixture, and all fans with transformed frequency, when the furnace pressure becomes too high, the unduced draft will be increased automatically to draw the excess pressure back into the regenerative heat storage drum for preheating. Therefore, there will be no flame spraying or black smoke,  and there is no need to leave a pressure relief vent on the furnace door.

4. Three-way valve technology; utilizing high-temperature resistant steel for the opening and closing cylinder, ensuring no air leakage and a very low maintenance rate.

5. Safety performance: Safety is not trivial. Our safety coefficient configuration is of utmost importance. Our valve components are more than others (two sets of shut-off valves and one set of natural gas filter valve), and they come with an automatic safety detection function. When the machine is turned on, it automatically detects within three seconds. If there is an abnormality, it will immediately cut off the gas and the alarm will sound immediately, while the problem location will be displayed on the PLC microcomputer.

Parameters:

FAQ
1. The reason of high energy consumption, slow temperature rise, and low thermal efficiency?

Reasons: Poor insulation of the furnace body, heat leakage due to poor sealing, aging of the burner/incomplete combustion, ash accumulation inside the furnace, and aging of equipment.

Solution:
Insulation: Inspect and repair the insulation layer of the furnace body to reduce heat loss.
Sealing: Replace the seals of the furnace door/observation window to prevent air and heat leakage.Combustion: Regularly clean the carbon deposits from the burner, calibrate the air-fuel ratio, and ensure complete combustion; maintain stable gas pressure (natural gas 0.4–0.6 MPa).
Operation: Reduce unnecessary boiler shutdowns and maintain continuous production; avoid frequent melting in small batches.

2. Melting furnace ignition failed, is the furnace with flame out alarm?
Reasons: Erosion of the ignition gun, non-discharge of the electrode, deviation of the flame detection position, fluctuation of the combustion air, instability of the gas pressure, and damage to the burner brick.
Solution:
Check the ignition system: replace the ignition gun/electrode, and adjust the position of the flame detection probe.
Gas / Combustion Air: Stabilize gas pressure, clean the combustion air pipeline filter screen, and reduce pressure fluctuations.
Burner brick: Replace damaged burner bricks to enhance flame rigidity.

3. What are the key points of daily inspection?
Temperature/furnace pressure, gas pressure/combustion status, furnace lining/sealing, degassing system, cooling water.

4. What is the regular maintenance cycle?
Daily: Clean the slag from the furnace mouth/flow channel; inspect the burner, ignition system, and seals.
Weekly: verify thermocouples/temperature control instruments; clean the scale in the water gap of the crystallizer; check the integrity of the filter plate.
Monthly: Conduct a comprehensive inspection of the lining thickness/cracks; calibrate the casting speed and traction synchronization; replace aged sealing rings/gaskets.
Every year: overhaul the furnace body (repair/reline the furnace lining); conduct a comprehensive inspection and maintenance of the casting machinery and electronic control system.

5. Safety precautions?
High temperature protection: Wear high temperature resistant clothing, protective face masks, and heat-insulating gloves to avoid burns.
Explosion protection: Leakage is strictly prohibited in gas furnaces, and regular leak detection is required; moist materials are prohibited inside the furnace to prevent explosions caused by water encountering aluminum liquid.
Emergency response: Equip with dry powder fire extinguishers and dry sand.