Boiler Burner Selection Guide | How to Choose a Suitable Burner?

The burner is one of the main components of the boiler. Its quality determines whether the boiler can make full use of the fuel to obtain the heat after combustion, reach the rated output and can operate safely, reliably and economically. In order to improve the fuel utilization rate of the boiler and reduce the operating cost of the boiler, it is also critical to select the right burner. Choosing the wrong burner can be a costly mistake.

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So how to choose a suitable boiler burner?

Choosing the right burner for a particular boiler requires constant practice, and a considerable number of variables should be considered to ensure that the burner operates normally. Some are simple, but some require more investment. EPCB summarizes some tips for selecting burners to help you avoid minefields and reduce operating costs.

What is a burner in a boiler?

Burner Classification

Burners can be divided into three categories: pulverized coal burners, oil burners and gas burners according to the different fuels they burn.

According to the object of use, it can be divided into kiln burner and boiler burner.

According to the application field, it can be divided into industrial burners, civil burners and special burners.

Oil burners are divided into light oil (such as diesel) and heavy oil burners (such as waste oil).

Gas burners are divided into natural gas burners, liquefied gas burners, city gas burners, biogas burners, etc.

And what we usually call the burner is the boiler burner.

How to choose a boiler burner?

The selection of a burner is a relatively complex technical issue. Generally, the following factors need to be considered:

7 Factors to Choosing Boiler Burner

Ⅰbrand

Users can choose the burner brand according to their own funds and equipment requirements.

Common boiler burner brands are divided into three series: German series (Weiser, Zach, Ouke, Riello, Paterson), Finland series (Olin, etc.), China (Opel, Baxter), etc.

Ⅱ Fuel

The user must first determine what kind of fuel to choose, and then choose the burner according to the type of fuel.

Common boiler fuels include: pulverized coal, oil (heavy oil, light oil) and gas (natural gas, liquefied gas, city gas, biogas), etc.

Ⅲ Technical parameters of equipment

1. Calorific value

2. Power

3. Furnace temperature and pressure

4. Gas heating value and pressure

Ⅳ Adjustment method

According to the requirements of the temperature accuracy of the equipment used, one-stage fire control, two-stage fire control, progressive and proportional adjustment burners can be selected.

Ⅴ Atomization Way

If you choose heavy oil as the fuel, you can choose mechanical atomizing burners and medium atomizing burners according to the viscosity of the fuel oil.

Ⅵ Region and environment

Different regions and different environments have different requirements for burners.

Ⅶ Special requirements for burner

Users can choose special burners according to equipment or application environment

When choosing a boiler burner, the most important point is that many variables need to be considered. You need to determine the required capacity, flame, temperature requirements, burner ratings, etc.

EPCB experts collected their five most valuable tips for selecting industrial burner.

5 Tips for Choosing a Burner

Burner selection tip 1: Know the burner rating

First, consider the burner rating. You need to look for a burner with a maximum input rating higher than the maximum burning rate of the equipment.

Burner selection tip 2: Determine the combustion load

The turn-down ratio, the ratio of the maximum capacity to the minimum capacity, shows the flexibility of the burner. If you are looking for a burner that can handle a variety of different load curves, look for a burner with a larger turndown ratio.

Burner selection tip 3: Consider installing

When choosing a burner, consider the ease of installation, access, and adjustment. The burner installation should allow the head to be removed and access to other important parts. This way you don't have to completely disassemble the burner, remove the wiring or move other equipment. Some burners require the installation of bulky refractory materials that are difficult to install and maintain.

Burner selection tip 4: Install a variable frequency drive

When installing a new burner, it is the ideal time to install a forced fan with a variable frequency drive (VFD). VFD is a good idea for any burner system, especially those that will not run at full capacity all the time.

Burner selection tip 5: Consult a burner expert

As the selection process becomes more difficult, talk to a boiler expert for advice.

Burner pit avoidance guide   

There are many imitations of well-known brand burners on the market, and it is difficult to distinguish the true from the false. Many unscrupulous merchants will use fakes to replace the real ones, thereby obtaining high profits. So how to distinguish these burners?

QianYue Product Page

1. Riello burners, each burner has a QR code on the body, and there is only one, which is equivalent to everyone’s ID number, verify this anti-counterfeiting code to know the burner you bought Is it genuine?

2. Counterfeiters can only imitate some well-known brand old models of burners, and some of the latest models of burners cannot be imitated because they involve the latest technology. Therefore, buying the latest burners can avoid buying counterfeit and shoddy products.

Concluding

Purchasing a burner is a prudent choice. The quality of the burner is directly related to the thermal efficiency of the boiler. Sometimes, the price of a good burner is equivalent to the price of a boiler or even higher, so you must find a professional boiler system expert to buy a boiler supporting burner. If you encounter any problems when buying or using the boiler, please contact EPCB, and we will provide you with free consulting services.

EPCB, your private boiler system expert!

Related Reading:

Boiler Technical Guide|General Guidance on Industrial Boiler's Operation

What is boiler？Detailed introduction Boiler Composition, Classification and Work Process

When selecting an oil, gas, or dual fuel burner, precise specifications are crucial to achieving optimal performance and compliance. It’s crucial to provide detailed specifications to ensure that the burner meets the client’s needs and is compatible with the boiler or heating system it will serve. The specifications should cover various aspects, including fuel type, capacity, control systems, and emissions requirements.

Below is a comprehensive list of the important specifications required to quote for an oil, gas, or dual-fuel burner

1. Fuel Type and Requirements

• Primary Fuel: Specify whether the burner will use natural gas, LPG, diesel, heavy oil, or other fuels.
• Secondary Fuel (for Dual-Fuel Burners): Indicate the secondary fuel type (e.g., gas/oil).
• Fuel Supply Pressure: Required fuel supply pressure for proper operation, typically measured in psi or bar.
• Fuel Viscosity (for oil): The viscosity of the oil fuel, which affects atomization and combustion.
• Fuel Calorific Value: The heating value of the fuel, which impacts burner sizing.

2. Burner Capacity

• Heat Output: The burner’s heat output, typically measured in kilowatts (kW) or British Thermal Units per hour (BTU/hr).
• Firing Rate: The range of firing rates (turndown ratio) the burner can operate at, which impacts efficiency and flexibility.
• Boiler/Burner Compatibility: Ensure the burner’s capacity matches the boiler or heating system it will serve.

3. Emissions Requirements

• NOx Emissions: Specify the maximum allowable nitrogen oxide (NOx) emissions, usually in ppm (parts per million).
• CO Emissions: Carbon monoxide emissions limits.
• SOx Emissions: For oil burners, sulfur oxide (SOx) emissions may need to be specified.
• Compliance with Regulations: Indicate any specific environmental regulations the burner must meet (e.g., UL, CE, local standards).

4. Burner Type and Configuration

• Monoblock or Duoblock: Monoblock burners integrate all components into one unit, while duoblock burners have separate components (e.g., fan, fuel supply).
• Pressure or Atmospheric Burner: Pressure burners use fans to supply air, while atmospheric burners rely on natural draft.
• Single-Stage, Two-Stage, or Modulating: Indicates whether the burner operates at a single output level, multiple stages, or modulates to meet varying demands.
• Horizontal or Vertical Mounting: Specify the orientation of the burner based on installation needs.

5. Control and Monitoring Systems

• Burner Control System: Specify the type of control system, such as mechanical, electronic, or PLC-based control.
• Flame Detection: Details on the flame detection system (e.g., UV scanner, ionization rod) for safety and reliability.
• Ignition System: Type of ignition system, such as electric spark, pilot flame, or direct ignition.
• Safety Interlocks: Include specifications for safety interlocks, emergency shutoffs, and fault alarms.
• Remote Monitoring and BMS Integration: If the burner needs to integrate with a Building Management System (BMS) or remote monitoring platforms.

6. Combustion Air Supply

• Air Supply System: Specify whether the burner will have an integrated fan or require external combustion air supply.
• Air/Fuel Ratio Control: Details on how the air/fuel ratio will be controlled for efficient combustion.
• Air Temperature Requirements: If preheated air is required, specify the temperature range.

7. Fuel Supply and Piping

• Fuel Pump (for Oil Burners): Specifications for the fuel pump, including pressure, capacity, and type.
• Fuel Metering: Details on fuel metering components for accurate fuel delivery.
• Fuel Piping: Materials and sizing of the fuel supply lines, including any specific requirements for corrosion resistance.

8. Noise Level

• Sound Pressure Level: Maximum allowable noise level of the burner, typically measured in decibels (dB) at a specific distance.

9. Physical Dimensions and Installation Requirements

• Burner Dimensions: Overall size, including length, width, and height, to ensure it fits within the available space.
• Weight: The total weight of the burner, which may affect installation.
• Clearance Requirements: Space needed around the burner for maintenance and operation.
• Mounting Requirements: Specifications for how the burner will be mounted, including flange sizes and bolt patterns.

10. Electrical Requirements

• Voltage and Frequency: The electrical supply requirements, such as 230V/50Hz, 400V/60Hz, etc.
• Power Consumption: The total electrical power consumption of the burner, usually expressed in kilowatts (kW).
• Control Wiring: Specifications for control and safety wiring, including any specific requirements for explosion-proof or hazardous areas.

11. Maintenance and Service Requirements

• Access for Maintenance: Provisions for access doors, inspection ports, and removable panels for easy maintenance.
• Service Life: The expected operational lifespan and any warranties offered.
• Maintenance Intervals: Recommended maintenance schedule, including specific requirements for fuel and air components.

12. Material and Construction Specifications

• Burner Materials: Details on materials used in the construction of the burner components, such as stainless steel for high-temperature areas.
• Corrosion Protection: Any coatings or treatments to prevent corrosion, especially in humid or harsh environments.
• Insulation: Type and thickness of insulation used in the burner to reduce heat loss and improve efficiency.

13. Compliance with Standards and Codes

• ASME Code Compliance: Whether the burner meets ASME standards for pressure and safety.
• ISO Standards: Compliance with ISO standards related to quality, safety, and environmental management.
• UL/CE Certification: Certifications that indicate compliance with safety standards for electrical and mechanical components.
• Local Building Codes: Any additional local or regional building and safety codes that must be met.

14. Customization and Special Requirements

• Custom Designs: Any specific design modifications or custom features required by the client, such as specific burner shapes, sizes, or materials.
• Special Certifications: Requirements for certifications like PED or others, depending on the region or application.
• Redundancy Requirements: If multiple burners are needed for redundancy or load sharing.

15. Delivery and Installation Considerations

• Lead Time: Expected delivery time from order placement to commissioning.
• Shipping Requirements: Any special requirements for shipping, packaging, or overseas transport.
• Installation Services: Whether installation and commissioning services are included in the quote.

16. Budget and Cost Considerations

• Initial Cost: The base price of the burner and associated equipment.
• Operating Costs: Estimates for fuel consumption, electricity usage, and maintenance.
• Return on Investment (ROI): Calculations or justifications for the investment based on efficiency and operating costs.

17. Documentation and Support

• Operating Manuals: Detailed manuals for operation and maintenance.
• Training: Any training services offered for operators and maintenance personnel.
• Technical Support: Availability of technical support and spare parts.

18. Warranty and After-Sales Service

• Warranty Period: Coverage duration for parts and labor.
• Extended Warranties: Options for extended warranties and service contracts.
• After-Sales Support: Details on service plans, regular inspections, and emergency support.

These specifications ensure that the oil, gas, or dual-fuel burner selected is appropriate for the client's needs, installation conditions, and operational requirements. Providing accurate and detailed information will help prevent potential issues and ensure long-term, efficient operation of the burner system.

Here is a brief checklist to summarize :

• ???? Fuel Compatibility: Supports natural gas, #2 oil, propane, or dual-fuel configurations.
• ⚙️ Thermal Output: Delivers between 1 million and 100 million BTU/hr.
• ????️ Burner Type and Configuration: Options include forced draft, natural draft, low-NOx, and ultra-low-NOx.
• ???? Burner Staging: Available in Single-Stage, Two-Stage, or Modulating for precise control.
• ???? Emissions Compliance: NOx emissions below 30 ppm, CO levels closely controlled.
• ✅ Standards Compliance: Meets ASME, NFPA, and local environmental regulations.
• ⚡ Electrical Requirements: Compatible with 120V, 240V, 480V, and varying power demands.
• ???? System Integration: Seamless integration with SCADA, PLCs, and safety interlocks.
• ???? Turndown Ratio: High turndown ratios (e.g., 10:1) for flexible operation.
• ???? Maintenance: Easy access design with strong service support.
• ???? Safety Features: Advanced safeguards like flame monitoring and automatic shutoff valves.

At ASTEC (Powerflame), we integrate these critical specifications into every burner solution, delivering performance, efficiency, and compliance tailored to your unique requirements.

???? Explore how Powerflame can enhance your industrial heating solutions at Powerflame.

Contact us to discuss your requirements of Industrial Burners. Our experienced sales team can help you identify the options that best suit your needs.