Combustion Catalog | Fives North American

The Fives North American Product Catalog serves as a functional and technical guide to the current products and services provided. Need assistance or have questions? Call +1 800 626 3477

COMBUSTION CATALOG _ Fives North American Combustion, Inc. Innovative Solutions in Combustion

03 /20 2 5

Energy | Combustion

Since 1917, we've partnered with leading industrial manufacturers from around the world, providing them with the most efficient combustion systems available. These partnerships have led to a greater understanding of what can be achieved through optimizing the combustion system. And through the results we've delivered, our customers have come to know Fives North American as one of the most trusted names in combustion worldwide. Fives North American Combustion, Inc. YOUR PARTNER IN COMBUSTION

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TABLE OF CONTENTS Product Literature

BULLETINS, BROCHURES, SUPPLEMENTS, SPECIFICATIONS, CAPACITIES

—Gas Burners

—TwinBed - Regenerative Burners

—Dual-fuel Burners

—Oil Burners

—Oxygen Burners

—Burner Management

—Combustion Control and Analyzers

—Packaged Systems

— Blowers

— Regulators

— Valves

— Accessories

Copyright © 2020 - Fives - All rights reserved. Fives North American Combustion, Inc. assumes no responsibility for any errors or omissions; nor is any liability assumed for damages resulting from the use or misuse of any of the data contained in this catalog. Further, Fives North American reserves the right to make changes to the data in this catalog at any time without notice.

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USA OFFICES

NORTHEAST USA NORTH EAST PA, CT, ME, MA, NJ, NY, VT Buffalo, NY 216 373 8469 - Sales 216 373 8466 - Orders NORTHWEST USA AK, HI, OR, WA, UT, WY, MT, CO, NM Marysville, WA 425 530 0096 - Sales 216 373 8354 - Orders SOUTH USA TX, LA, OK Houston, TX 216 373 8472 - Sales 216 373 8465 - Orders SOUTH CENTRAL USA SOUTH GA, AL, FL, MS, TN Birmingham, AL 216 373 8613 - Sales 216 373 8465 - Orders

MID-ATLANTIC USA NC, VA, WV, MD 216 373 8351 - Sales 216 373 8466 - Orders MIDWEST USA CENTRAL IN, SOUTHERN IL,

SOUTHEAST USA NORTH GA, SC Atlanta, GA 216 373 8468 - Sales 216 373 8465 - Orders WEST COAST USA CA, AZ, NV Los Angeles, CA 216 373 8468 - Sales 216 373 8359 - Orders THERMAL PROCESS CONSTRUCTION SERVICES/FURNACE PARTS Birmingham, AL 205 956 8191 - Sales/ Orders

BAKERSFIELD (Oil Field) USA Cleveland, OH 216 373 8388 - Sales 216 3737 8354 - Orders CORPORATE HEADQUARTERS Cleveland, OH 216 271 6000 - Co. Main 800 626 3477 - Sales 216 373 8366 - Service CLEVELAND/WEST OH, EAST CENTRAL PA Cleveland, OH 216 373 8463 - Sales 216 373 8608 - Orders GREAT LAKES USA, EAST & CENTRAL OH EAST MI Cleveland, OH

MO, AR, KY, KS Crown Point, IN 216 373 8611 - Sales 216 373 8489 - Orders

MIDWEST USA NORTHERN IN, CENTRAL IL, IA, NE, SD, ND Crown Point, IN 216 373 8475 - Sales 216 373 8489 - Orders MIDWEST USA NORTHERN IL, EASTERN & NORTHERN MI, WI, MN Crown Point, IN 216 373 8475 - Sales 216 373 8489 - Orders

216 373 8390 - Sales 216 373 8608 - Orders

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INTERNATIONAL CONTACTS

Alberta, British Columbia, Manitoba, Saskatchewan (D) Process Combustion Systems, Inc. #120-270 Exploration Ave. SE Calgary, Alberta T3S 0C3 CANADA T +1 403 250 1075 F +1 403 250 1076 info@processcombustion.com CHINA (D) Shanghai EN-FA Combustion Equip. Co. Ltd. Room C16, South Zone of Building #8 No.619 Longchang Road Shanghai, P.R.C. CANADA Fives North American Combustion Canada Inc. 540 Piercey Rd. Bolton, Ontario L7E 5B4 CANADA T +1 905 857 3337 F +1 905 857 0304 fna.salesCanada@fivesgroup.com FRANCE Fives North American Combustion France SAS 15 rue Marc Donadille ZAC Château Gombert Les Baronnies Batiment C - 2EME étage 13013 Marseille, FRANCE

SPAIN Fives North American Combustion Spain S.L. Plaza Sagrado-Corazon 4 Sub 2, 48011 Bilbao SPAIN T +34 944 347 200 F +34 944 347 204 fna.salesSP@fivesgroup.com

SOUTH AMERICA Fives North American Combustion Brazil Alameda Mamoré, 911 - cj 802 Barueri, SP, 06454-050 BRAZIL T +55 (11) 4195 3098 celio.takeda@fivesgroup.com

JAPAN (D) Shinko Shoji Company Ltd. 3-27-3 Yushima Bunkyo-ku, Tokyo 113-0034 JAPAN T +81 (03) 3502 6241 F +81 (03) 6284 4336 k.koji@shinko-shoji.jp MEXICO (D) Nutec Bickley Carretera Saltillo-Monterrey KM 62.5 #100 Spare Parts: spares@nutec.com Technical Services: techsupport@ nutec.com www.nutecbickely.com (nutebickley.com) (D) Nutec Bickley Santa Catarina, NL MEXICO CP 66359 T +52 (81) 8151 0800 GERMANY Fives Combustion GmbH Kelterstrasse 73 D 73265 Dettingen unter Teck, Deutschland, GERMANY T +49 (0) 1522 491 42 46 stefan.raffler@fivesgroup.com NETHERLANDS Fives North American Combustion Netherlands B.V. Parellaan 6, 2132 WS Hoofddorp NETHERLANDS T +31 (0) 297 380401 F +31 (0) 297 380438 fna.salesNL@fivesgroup.com

DISTRIBUTORS (D) CANADA - West T +33 (4) 912 140 40 F +33 (4) 912 140 44 fna.salesFR@fivesgroup.com

NEW ZEALAND (D) Windsor Engineering Group Ltd. P.O. Box 13 348 Johnsonville 6440 Wellington NEW ZEALAND T +64 (0) 4 232 8080 F +64 (0) 4 232 5929 windor.sales@windsor.co.nz PERU (D) Insercomgas SAC Santa Amelia 751 Lima 36 PERU T +51 1 286 6357 F +51 1 286 6226 Insercomgas@Insercomgas.com SOUTH AFRICA (D) The Combustion Group PTY Ltd. 4 Mopedi Road Sebenza, Edenvale 1610 SOUTH AFRICA

SOUTH KOREA (D) Kyung In Corp. #1-1508, ACE Hightech City, 775, Gyeongin-ro, Yeongdeungpo-gu, Seoul REPUBLIC of KOREA 07299 T +82 (02) 6309 5188 F +82 (02) 6309 5161 alee@kicorp.co.kr TAIWAN (D) Fred & Jean Engineering Company, Ltd. 12F-2, No. 99, Sec. 1, Hsin Tai Wu Road Hsi-Chih District, New Taipei City ROC 221 TAIWAN T +886 2 2697 2297 F +886 2 2697 2295 fredjean@ms16.hinet.net or info@fredjean.com

T +86 21 6568 1261 F +86 21 6568 1603 jingsheng.qiao@en-fa.cn ITALY Agent for Italy, Greece, Switzerland DEAR s.a.s. Corso Dante, 203 14100 Asti, ITALIA T +39 0141 21 55 99 F +39 0141 21 55 99 C +39 335 81 90 132 DinoCosta@dearsas.co

CDMX (Mexico City) T +52 (55) 5456 7244 sales@nutec.com

T +27 (11) 452 5060 F +27 (11) 609 2405 info@combustion.co.za

GAS BURNERS _ Fives North American Combustion, Inc. Click the icon below to navigate through the Table of Contents or use the top right icon to search for specific documents.

Industry can do it

EcoFornax ™ LE _ Powerful NOx reduction through fuel staged lean premix technology

ECOFORNAX ™ LE

APPLICATIONS

— Boilers — Thermal fluid heaters — Process heaters — Incinerators

ULTRA LOW NOX NO FGR

The LE uses a lean premix primary flame and dilute secondary combustion to achieve less than 18 ppm (corrected to 3% O2) NOx without FGR in many applications. The LE's lean premix technology also provides low NOx with preheated air.

UNIQUE PATENED DESIGN

The LE provides the ultimate in emission reductions of NOx CO, and VOCs. The technology uses patented lean premix and dilute combustion technologies to safely combust heat releases up to 250 million Btu/h HHV. PATENT NUMBERS

Exceptional performance through cutting-edge technology

US 5,407,345 US 5,554,021 US 5,667,376 US 5,730,591 EP 0 804 647 B1 US 5,605,452 LICENSED PATENTS US 5,201,650

Manufacturing

LE FEATURES

— < 8 ppm, 0.01 lb NOx per MMBtu with FGR — < 20 ppm NOx without FGR — Low CO and VOC emissions — High intensity, compact flame — Sizes from 1.0 to 250 million Btu/h HHV — Turndown up to 20:1 — robust design, rugged and reliable with no moving parts LOW NOX WITH PREHEATED AIR GET EVEN LOWER NOX WITH FGR When FGR is utilized with the LE, the NOx emissions can be taken to even lower levels; below 8 ppm (corrected to 3% O2), 0.01 lb NOx per MMBtu.

SCAN BELOW TO SEARCH OUR DIGITAL CATALOG FOR MORE INFORMATION ON PRODUCTS USED IN THIS APPLICATION.

The use of a lean premix core, combined with adiabatic flame temperature control of the primary reacter zone, allow the LE to minimize NOx emissions even for preheated air systems.

CONTACT

Fives North American Combustion, Inc. 4455 East 71st Street Cleveland, OH 44105 - USA

T +1 800 626 3477 F +1 216 373 4237

Fives North American Combustion, Inc. contact: fna.sales@fivesgroup.com

Industry can do it

www.fivesgroup.com

Combustion

Industry can do it

Magna-Flame ® RM _ Low emissions dual-fuel burner

MAGNA-FLAME ® RM

APPLICATIONS

— Boilers — Process heaters — Air heaters — Dryers and Calciners — Incinerators — Soil Remediation

PROVEN PERFORMANCE

North American's Magna-Flame® RM has been serving the boiler and process heater industries for over 25 years, and with over 1,000 units in operation, this proven workhorse is now solving today's tough environmental problems .

UNIQUE DESIGN

The Magna-Flame® RM uses rapid mixing technology and internal chamber gas recirculation to reduce NOx and CO emissions. For stringent applications the RM accepts external flue gas recirculation (FGR) to further reduce NOx far below current regulatory requirements

Exceptional performance through cutting-edge technology

Manufacturing

RM FEATURES

RM Burner firing light oil

— High flame intensity — Sizes from 15 to 150 million Btu/h HHV — Turndown up to 10:1 (gas), 5:1 (oil) — Prepackaged & tested burner management systems available — Low emissions with FGR — Heavy duty construction — No moving parts — Gas and liquid fuel including heavy oils — Full line of pre-engineering & aftermarket services HOW IT WORKS The Magna-Flame® RM uses rapid mixing technology and self- induced chamber gas recirculation to minimize the production of NOx and CO. The illustration show the fuel gas and combustion air enter the burner, where they are rapidly mixed at the base of the swirl vanes. This rapid mixing technology eliminates the NOx- generating hot spots that are found in many conventional burner designs. The fast recirculating action in the burner throat induces oxygen- deficient gases from the combustion chamber to reduce NOx and CO emissions. FGR may be added to the combustion air stream to dilute the flame temperature and to further reduce emissions.

RM Burner firing natural gas

SCAN BELOW TO SEARCH OUR DIGITAL CATALOG FOR MORE INFORMATION ON PRODUCTS USED IN THIS APPLICATION.

Recirculation

Gas Connection

Main Air Inlet

 Internal recirculation zone induces combustion chamber gases

Gas De fl ector Disk



Air Spin Vanes

Recirculation

CONTACT

Fives North American Combustion, Inc. 4455 East 71st Street Cleveland, OH 44105 - USA

T +1 800 626 3477 F +1 216 373 4237

Fives North American Combustion, Inc. contact: fna.sales@fivesgroup.com

Industry can do it

www.fivesgroup.com

North American Magna-Flame ™ LNI ™ The Premier Low NOx Hot Air Burner

Breaking the low NOx barriers without the use of FGR.

— Steel Reheat Furnaces — Aluminum Melters — Forge Furnaces — High Temp Furnaces

Operating Features —Combustion air temperatures up to 1200°F —Capacities ranging from less than 1 million Btu/hr to over 20 million Btu/hr —Excellent temperature distribution —Easy to retrofit on existing installations —Stable, clean combustion without excess air

LNI Benefits —Ultra low NOx with preheated combustion air —Designed for low excess air operation —Low CO and VOC emissions —No FGR required —Cost effective, compact design

Magna-Flame ™ LNI ™

HOW LNI WORKS All direct NOx reduction strategies revolve around three basic principles: control of peak flame temperature, reduced in-flame oxygen concentration, and reduced in-flame residence time. The LNI system takes advantage of all three techniques resulting in extremely low NOx emissions, even for high temperature, high air preheat applications. The Magna-Flame operates as a conventional nozzle mix burner when the furnace temperature is below 1400°F. Above that temperature, fuel is switched to strategically positioned nozzles adjacent to the burner tile port. The fuel and air jets entrain large volumes of products of combustion, greatly reducing the local oxygen concentration. In the flame envelope, these entrained gases limit the maximum combustion temperatures, leveling out temperature spikes that generate high NOx emissions. All

combustion takes place within the furnace volume, not the restricted tile port, providing short high temperature residence times further inhibiting the NOx production. After combustion, the gases lose their heat through radiation and convective heat transfer to the work. These cooled gases travel throughout the furnace and are again entrained by the burner air and fuel jets, sustaining the NOx inhibiting process . Low NOx Injection (LNI) of the fuel and air into the furnace chamber provides the highest potential efficiency. The LNI system takes advantage of the largest source of “free” FGR, the furnace itself, to produce uniquely low NOx emissions from high temperature systems.

Nozzle Mix

Magna-Flame LNI

POC

Gas

AIR AIR

Gas

NO EXTERNAL FGR OR EFFICIENCY LOSS In many high temperature combustion systems flue gas recirculation is used to reduce NOx emissions from burners. FGR systems require piping runs and a blower that supply the furnace exhaust gas to the combustion air. If FGR is added to combustion air after the recuperator, or if the system dœs not have a recuperator, the thermal efficiency can be reduced by as much as 15%. If FGR is added prior to the recuperator, system efficiency can be maintained, but a larger recuperator may be required to accept the additional volume. In either case, combustion air piping and burner size may increase due to oxidant volume. LNI is an “in-furnace” direct NOx control method that maintains the highest possible efficiency without requiring larger size

combustion equipment. While other combustion systems may use up to 50% FGR, LNI offers lower NOx emissions without any decrease in system efficiency or added equipment costs. NO COMPLEX REFRACTORY (as with staged combustion air) A very practical advantage of LNI low NOx technology is the simplicity of construction of the burner and tile. Burners that use air staging to reduce NOx emissions require complex refractory construction that can be prone to failure. The reduced port tile and in-furnace combustion of an LNI system further protect burner internals as radiation received by burner internals is reduced.

CONTACT fna.sales@fivesgroup.com T +1 800 626 3477 - F +1 216 373 4237

Fives North American Combustion, Inc. 4455 East 71st Street - Cleveland, OH 44105 - USA www.fivesgroup.com

North American HiRAM ® LNI ™ Ultra low NOx... air, oxygen, or both

— Steel Reheat Furnaces — Aluminum Melters — Forge Furnaces — High Temp Furnaces

Operating Features — Oxidant can be cold or preheated air, oxygen, or a combination

— Self-cooling design can eliminate cooling water — Capable of firing on-ratio or with high excess air — Accommodates high temperature load heating or dry out and cure cycles for any refractory — Low pressure combustion air means lower horsepower required

HiRAM ® LNI ™

HOW LNI WORKS

Low NOx Injection (LNI) of the fuel and air into the furnace chamber provides the highest potential efficiency and lowest NOx. The LNI system takes advantage of the largest source of “free” flue gas recirculation (FGR), the furnace itself, to produce uniquely low NOx emissions from high temperature systems. All NOx reduction strategies revolve around three basic principles: control of peak flame temperature, reduced in-flame oxygen concentration, and reduced in-flame residence time. The LNI system takes advantage of all three techniques resulting in extremely low NOx emissions, even for high temperature, high air preheat applications. The HiRAM LNI operates as a low NOx nozzle mix burner when the furnace temperature is below 1400°F. Above 1400°F, fuel is switched to strategically positioned nozzles adjacent to the burner tile port. The fuel and air jets entrain large volumes of products of combustion, greatly reducing the local oxygen concentration. In the flame envelope, these entrained gases limit maximum combustion temperatures to level out temperature spikes that generate high NOx emissions. All combustion takes place within the furnace, not inside the tile port, providing short high temperature residence times that inhibit NOx production. After combustion, the gases lose their heat through radiation and convective heat transfer to the work. These cooled gases travel throughout the furnace and are again entrained by the burner air and fuel jets, sustaining the NOx inhibiting process.

HIRAM LNI BENEFITS —Ultra-low NOx, even with 100% oxygen —Major fuel savings potential —Evenly dispersed hot gas radiation improves heating —High-velocity discharge for enhanced convection heating —Low emission are enhanced by proprietary control systems

Nozzle mix to 1400 °F

LNI above 1400 °F

POC

Air

Air Air

Gas

LNI uses low NOx technology patented by Tokyo Gas Co. Ltd. of Japan and further developed by Fives North American Combustion, Inc., the exclusive world-wide licensee for use of this technology. U.S. Patent No. 4,945,841.

Gas

Optional Oxygen

CONTACT fna.sales@fivesgroup.com T +1 800 626 3477 - F +1 216 373 4237

Fives North American Combustion, Inc. 4455 East 71st Street - Cleveland, OH 44105 - USA www.fivesgroup.com

High Velocity, RAM Effect, Low NOx Burners North American HIRAM ®

Exceptional performance for aluminum melting, heat treat furnaces, drying, air heating, forging, incineration, ladle and tundish heating, rotary dryers, calciners, roasters.

North American HiRam Heating Benefits: — Reduced fuel consumption — Shortened cycle times — Uniform heating from churning furnace atmosphere — High turndown — Reduced tile discharge opening protects internals from furnace radiant heat and splash in melting furnaces

North Amercian HiRAM ®

HOW NORTH AMERICAN HIRAM WORKS

North American HiRAM improves heat transfer by reaching parts of the load that radiation cannot "see" and standard low velocity burners do not penetrate. True high velocity results from HiRAM’s exceptionally high Btu/h HHV input rates relative to its reduced tile discharge area. North American HiRAM burners combine large capacity with high velocity. Flames shown are natural gas (top right) and #2 fuel oil (bottom right) firing with 10% excess air at a rate of 15 million Btu/hr.

Scale in feet

0 1

6 7

9 10

Scale in feet

0 1

6 7

9 10

NOx can change with furnace temperature, fuel type, combustion air temperature, burner firing rate, and other factors. Contact your North American field engineer for an examination of your process for North American HiRAM heating.

LOW NOX

High velocity burners were developed by North American in the early 1960's and dramatically improved many industrial heating processes. High discharge velocity circulates furnace gases creating uniform furnace temperatures and reducing pollutants known as NOx. North American HiRAM reduces NOx by drawing furnace gases into the flame, which has much the same effect as vitiated combustion air. For such a large burner, North American HiRAM produces surprisingly low NOx numbers without the complexities of FGR (furnace gas recirculation) or staged air combustion. However FGR can be used on the North American HiRAM to reduce NOx levels even further. In applications requiring ultra low NOx emissions, the North American HiRAM LNI SYSTEM should be considered. The low NOx injection (LNI) of the fuel and air into the furnace chamber provides high efficiency and ultra low NOx. The LNI system takes advantage of the largest source of "free" FGR available — the furnace itself. The graph at the right shows comparative emissions.

Thermal NOx Emissions Typical Burner Capacities — 4 to 25 million Btu/hr Typical Furnace Temperature — 1800°F

LNI uses low NOx technology patented by Tokyo Gas Co. Ltd. of Japan, and further developed by Fives North American Combustion, Inc., the exclusive worldwide licensee for use of this technology. U.S. Patent No. 4,945,841

CONTACT fna.sales@fivesgroup.com T +1 800 626 3477 - F +1 216 373 4237

Fives North American Combustion, Inc. 4455 East 71st Street - Cleveland, OH 44105 - USA www.fivesgroup.com

North American FlatFlame ™ Burners

‘A’ ultra low NOx

Features — Creates large radiant heat source on furnace wall or roof

— Capacities from 0.2 to 10.0 mm Btu/h HHV — Combustion Air Temperatures to 1200 o F — Tiles available for 9” or 13” walls or roofs

Applications — Reheat furnaces — Cover annealers — Galvanizing tanks — Forge furnaces

Benef its — Ultra low NOx — Simple retrofit to existing burners — Uniform heating

‘A’ ultra low NOx , FlatFlame ™ Burners

NOx Emissions with 850°F Combustion Air

NOx Emissions with 70°F Combustion Air 200

200 180 160 140 120 100

180 160 140 120 100

Standard Flat Flame Burner

80 60 40 20 0

Series "A" Low NOx

1600

1800

2000

2200

2400

1600

1800

2000

2200

2400

Furnace temperature F

Ultra Low NOx Series “A” Injection Flat Flame Burner Models

Series Number

Firing

Capacities mm Btu/hr

Mountings

Max Combustion Air Preheat

Characteristics

at 16 osi*

for

wall & roof wall & roof wall & roof roof only roof only

4828A 4832A 4833A 4836A 4837A

Hot Air, On Ratio

0.3 to 5.0* w/1000°F air

1200°F 750°F 750°F 750°F 750°F

XS Air

0.2 to 2.6 0.2 to 2.6 0.2 to 6.6 0.2 to 10.0*

On Ratio

XS Air

On Ratio

*capacities for the 4828A-10 and 4837A-10 at 12 osi

The Series "A" injector assembly can be retrofitted to the equivalent standard Flat Flame burners. See Bulletin 4828A-4837A and Sheet 4833-4 for details.

WARNING: Situations dangerous to personnel and property may exist with the operation and maintenance of any combustion equipment. The presence of fuels, oxidants, hot and cold combustion products, hot surfaces, electrical power in control and ignition circuits, etc., are inherent with any combustion application. Components in combustion systems may exceed 160°F (71°C) surface temperatures and present hot surface contact hazard. Fives North American Combustion, Inc. suggests the use of combustion systems that are in compliance with all Safety Codes, Standards, Regulations and Directives; and care in operation.

CONTACT fna.sales@fivesgroup.com T +1 800 626 3477 - F +1 216 373 4237

Fives North American Combustion, Inc. 4455 East 71st Street - Cleveland, OH 44105 - USA www.fivesgroup.com

Industry can do it

EcoFornax ™ LEx _ The LEx burner provides lower emissions, higher combustion effeciency

ECOFORNAX ™ LEX

APPLICATIONS

— Air heating — Process drying — Incineration — MACT pharmaceutical — Soil remediation — Calcining

LOW NOX & CO NO FGR

The LEx emissions of NOx are less than 10 ppm for most air heating and drying applications. Additionally, CO emissions are under 50 ppm even when process temperatures are low.

UNIQUE PATENED DESIGN

The LEx provides unparalleled reductions in burner NOx and CO emissions through patented premix technology. With hundreds of LEx installations worldwide, North American is the leader in delivering ultra low emissions combustion solutions for air heating, mineral processing, drying, incineration, and soil remediation applications.

PATENT NUMBERS US 5,407,345 US 5,554,021 US 5,667,376 US 5,730,591 EP 0 804 647 B1 US 5,605,452

Cutting emissions through cutting-edge technology

Manufacturing

LEX FEATURES

— Ultra low NOx and CO without flue FGR recirculation — High heat release — Sizes up to 400 million Btu/h HHV

— Turndown up to 20:1 — Multi-fuel capacity — Robust design — Rugged and reliable with no moving parts

LOWER TOTAL INSTALLED COST With the high capacities (up to 400 million Btu/hour) available in the LEx, a single burner is able to meet large input needs instead of manifolding several line burners. The result is a simplified system design. The LEx has no moving parts or complicated staging devices normally found in competing low emission burners .

SCAN BELOW TO SEARCH OUR DIGITAL CATALOG FOR MORE INFORMATION ON PRODUCTS USED IN THIS APPLICATION.

LEx - CROSS SECTION

Main Combustion Air Inlet

Radial Air Inlet

Radial Gas Inlet

Primary Gas Inlet

Integrated Mixing Elements

Primary Reaction

ULTIMATE PERFORMANCE

COMPACT FLAME HIGH HEAT RELEASE

The LEx system generates compact, high intensity flames, reducing process influence on the combustion system performance.

HOW IT WORKS

The LEx uses a method of lean premix combustion and a controlled reaction zone to achieve ultra low NOx and CO operation. NOx emissions from premix combustion decrease rapidly as the amount of excess air is increased. LEx burners use this method to provide ultra low NOx emissions. See Fig. 1 The LEx burner establishes a lean premix and then combusts the mixture in a controlled reaction zone. The fuel and air are introduced separately into the burner where they are intimately mixed within the integrated mixers. This mixture is then directed into the reaction zone where the lean combustion takes place.

Fig. 1

Committed to customer satisfaction

CONTACT

Fives North American Combustion, Inc. 4455 East 71st Street Cleveland, OH 44105 - USA

T +1 800 626 3477 F +1 216 373 4237

Fives North American Combustion, Inc. contact: fna.sales@fivesgroup.com

Industry can do it

www.fivesgroup.com

Industry can do it

EcoFornax ™ GLE _ Sub-5 ppm NOx for the oil field industry

ECOFORNAX ™ GLE

PERFORMANCE

Lowest NOX combined with highest thermal efficiency. Introduced for steam generator appllications in 1994, with 400 separate applications of GLE burners now operating worldwide.

ADVANTAGES

— Sub-5 ppm NOx with 25% FGR and 15% excess combustion air — Sub-15 ppm without FGR — CO emission levels generally undetectable — Utilizes advanced lean burn partial premix combustion technology — Repeatble performance using proprietary CMS algorithms

DESIGN

The GLE accommodates a wide range of fuel gases and heating values. It procduces the desired flame envelope to maximize radiant heat transfer.

Meeting tomorrow's environmental needs today

Manufacturing

GLE FEATURES

— Inline fan discharge centerline for minimal footprint and ease of installation — Compatible with damper of VFD air flow control — Nozzle mix pilot conveniently utilizes combustion air directly from the fan discharge — Widely deployed, proven performance, and reliability

EcoFornax™ GLE Burner Emissions Performance - Kern County Steam Generators

15 14 13 12 11 10

9 8 7 6 5 4 3 2 1 0

SCAN BELOW TO SEARCH OUR DIGITAL CATALOG FOR MORE INFORMATION ON PRODUCTS USED IN THIS APPLICATION.

0.0 0.5 1.0

1.5

2.0 2.5

3.0 3.5 4.0 4.5

5.0

Stack O 2 (% - wet)

GLE system without FGR GLE system with FGR GLE-5 system with FGR

CONTACT

Fives North American Combustion, Inc. 4455 East 71st Street Cleveland, OH 44105 - USA

T +1 800 626 3477 F +1 216 373 4237

Fives North American Combustion, Inc. contact: fna.sales@fivesgroup.com

Industry can do it

www.fivesgroup.com

Diffuse Mode Combustion

Fives Combustion – Superior Performance by Design

Combustion technology for the 21 st century – best in class temperature uniformity in an ultra-low NOx design.

• Forge furnaces • Tunnel furnaces • Heat treat furnaces • Roller hearth furnaces • Continuous strip furnaces • High temperature furnaces

DMC DMC System Components

The DMC System is built on two key components: The Tempest ® DMC Burner and DMC Controller. TEMPEST ® DMC BURNER

DIFFUSE MODE COMBUSTION Diffuse Mode Combustion (DMC) is a flameless technology that can achieve ultra-low NOx emissions while improving temperature uniformity in a wide range of high temperature applications. The flameless technology allows fuel to combust in the furnace instead of within the burner tile. The result is a lower maximum flame temperature (ultra-low NOx) and elimination of point sources of radiant energy (+/-10° F temperature uniformity capable).

DMC CONTROLLER The DMC Controller is a Safety PLC based Burner Management System (BMS) that provides control of burner safety functions for furnaces incorporating Diffuse Mode Combustion. It provides control of all combustion safety logic including all required interlocks, flame supervision and transitioning between the standard and DMC modes of operation. The DMC Controller is designed to interface with the furnace process controls including automatically transitioning in a controlled manner to and from DMC mode as the furnace conditions dictate. The diagnostic and communication capabilities of the DMC Controller is greatly enhanced over conventional relay based systems. The integrated system reduces the complexity and quantity of hard wired circuits and related components, thereby significantly reducing the number of points of failure.

The Tempest® DMC Burner retains all of the best features of the Tempest burner series including high velocity combustion, low NOx emissions, wide operating range, reliable ignition, built-in air and gas metering orifices, flame rod flame supervision and proven rugged construction for long life. The simple design of the self-supporting alumina mullite tile, without any complex air and gas staging pathways, eases installation into any refractory wall and lowers the life cycle maintenance costs. The slotted tile’s restricted opening promotes furnace gas recirculation assisting in achieving the most stringent of temperature uniformity surveys. The Tempest DMC Burner is ideal for use with StepFire™, pulse firing or modulating control systems and can be used with cross connected ratio regulator, metered flow or thermal turndown system designs.

COMMON APPLICATIONS • Forge furnaces • Heat treat furnaces • Roller hearth furnaces • Continuous strip lines • Indirect fired rotary kilns

• Most continuous or batch furnaces in a NOx-sensitive location that operate part or all of the time at a temperature above the fuel's auto-ignition point.

CONTACT fna.sales@fivesgroup.com T +1 800 626 3477 - F +1 216 373 4237

Fives North American Combustion, Inc. 4455 East 71st Street - Cleveland, OH 44105 - USA www.fivesgroup.com

Instructions for Nozzle-Mix Gas Burners

Supplement GB-M1

SUGGESTED PIPING

Zone A (1 Burner)

Zone B (2 Burners)

Impulse tap should enter air line parallel to valve shaft to minimize turbulence effects .

Air

Motor Operated Valve

5 pipe dia.

3 pipe dia. min.

Nozzle-Mix Burners

Manual Air Valve

5pipe dia. min .

3 pipe dia. min.

Manual Air Valve

Flexible Nipples

Impulse Line 3⁄8 " OD minimum

Metering Orifice Limiting Orifice Gas Valve

10D min.

4D min.

Shutoff Valve

4D min.

10D min.

10D min. Shutoff Valve

4D min.

Gas

Air/Gas Ratio Regulator

2 psi max.

Tee for checking impulse pressure

* Limiting orifice gas valves must be mounted as close to the burner as possible.

INSTALLATION To minimize leaks around tile and to prevent cracking of tile by thermal expansion in the wall, see Supplements DF-M1 (for hard refractory lined furnaces) and DF-M2 (for fiber lined furnaces) for installation recommendations.

LIGHTING AND ADJUSTMENT Warning: Startup and adjustment of combustion equipment should only be done by trained personnel familiar with combustion technology, combustion equipment, and with the particular burner system, equipment, and controls.

1. BASIC a) All manual and automatic fuel valves (gas and oil) must be closed. b) Open all furnace doors and flue dampers. Lock all burner air valves in full open position. c) Start combustion air blower and check rotation. d) Adjust control motor/air valve linkage(s) for low and high fi re. e) Set control motor(s) at high fire allowing furnace to purge for several minutes prior to lighting. Check motor amps with all burners at high fire. If in overload, adjust linkage to reduce the high fire air flow. f) Return the control motor to low fire. Linkage must not bind. 2. PILOTS a) Light the pilots in accordance with the pilot instruction sheet. 3. MAIN BURNER a) Open limiting orifice valve five turns (CCW) from full closed position. b) Open gas shutoff valve(s). If burner dœs not light within a few seconds, close gas shutoff valve and open limiting orifice valve one more turn; then open gas shutoff valve. Repeat purge/ignition attempts as necessary until burner lights.

c) Slowly open main air valve to high fire position, adjusting limiting orifice valve as necessary. d) Return control valve to low fire position. Adjust air/gas ratio regulator for desired flame. e) Repeat Steps (c) and (d) if necessary. Replace cover on limiting orifice valve. f) For multiple burner zones, approximate limiting orifice valve settings can be made by counting the number of turns open on the first valve. 4. TROUBLE-SHOOTING a) Gas supply pressure too high or too low (see appropriate regulator literature.) b) Impulse pressure too low to ratio regulator--check for dirt in line or connections; check method of connecting impulse line to air pipe (see regulator literature). c) Regulator not controlling--check method of connecting impulse line to air pipe; check regulator diaphragms (see regulator literature); if bleeder is used, check orifices for dirt.

Note: Prior to the first, and each subsequent lighting attempt, the main air valve must be fully opened for a period of time sufficient to provide for a minimum of (4) changes of atmosphere in the combustion chamber and flue. Failure to do so can result in the ignition of residual gas from previous lighting attempts, resulting in an uncontrolled fire or explosion and causing property damage and/or personal injury.

CONTACT fna.sales@fivesgroup.com T +1 800 626 3477 - F +1 216 373 4237

Fives North American Combustion, Inc. 4455 East 71st Street - Cleveland, OH 44105 - USA www.fivesgroup.com

3065 North American Aspirators and Gas Mixers

Dependable and uniform air/fuel mixtures

• Large range of available sizes for various applications

• Compact design allows for simple installation

• Rugged design for long life

• See Sheet 3065-M for sizing tables and dimensions in SI units

Design features and benefits of 3065 North American aspirators and gas mixers

3065 ASPIRATOR AIR/GAS MIXER FEATURES

3065 Aspirator Mixers are used to create a uniform air / fuel mixture to feed premix burner nozzles. Energy from blower air passing through the 3065 venturi creates suction, which entrains a proportional flow of gas at atmospheric (zero gauge) pressure. Multiple premix burner nozzles fed by a 3065 can be controlled by a single manual or motorized air valve. Proper air/fuel ratio is initially set by adjusting the integral V-port* valve built into the mixer. The ratio is maintained from high fire to low by an “atmospheric regulator” (zero governor) or by cross connecting the regulator (e.g., North American’s 7218).

— Mixes air with any fuel gas from 500 to 3,200 Btu/ft3 HHV — Over 200 size combinations to fit most applications

— 3/4" to 8" air inlet & premix outlet — Efficient design with low pressure loss

— Suitable for single or multiple premix nozzles — Rugged cast iron construction* for long life — Compact construction for easy installation — Mount in any position — Interchangeable displacement rods for optimum mixture pressure and suction ratio. — Rods can be changed without breaking air or gas piping — Built in gas adjustment valve cartridge* — Gas adjustment cartridge & gas inlet are interchangeable*

For coke oven, manufactured, and other gases corrosive to brass, specify 3065- -K Mixer with iron/steel parts in place of brass.

For an observation port in place of a -0 plug (no rod) specify 3065- -0-OBS (3065-1 to -8 sizes).

Rated Air Flow of each 3065 without rod (scfh)

Air P. (osi) "w.c. (4) 6.9

(8) 13.8 (12) 20.8

(16) 27.7

AIR INLET

Mixer  .P. "w.c. Mixture P. "w.c.

4.92

9.84

14.76

19.7

3065-0-0 3065-1-0 3065-2-0 3065-3-0 3065-3-S0 3065-4-0 3065-4-S0 3065-5-0 3065-5-S0 3065-6-0 3065-6-S0 3065-7-0 3065-7-S0 3065-8-0 3065-8-S0 3065-9-0

480 650 1220 1850 2740 3200 3960 4440 6420 6640

680 930

830 1130 2120 3210 4750 5550 6860 7700 11 110 11 510

960 1310

BURNER AIR VALVE

1730 2620 3870 4530 5600 6280 9070 9400

2450 3710 5480 6410 7930 8890

DISPLACEMENT ROD

BURNER

GAS INLET

12 800 13 300 21 900 26 400 45 400 68 300 103 500 138 000

V-PORT VALVE

10 950 13 200 22 700 34 100 51 700 68 800

15 500 18 700 32 100 48 200 73 200 97 300

19 000 22 900 39 300 59 100 89 600 119 000

ASPIRATOR MIXER

ATMOSPHERIC REGULATOR

Figure 1. Typical arrangement of 3065 Aspirator Mixer with burner, atmospheric regulator, and air valve.

*3065-9 Mixers have fabricated steel construction and a separate 1127-7-F limiting orifice butterfly valve in the gas line upstream of the mixer.

See Sheet 3065-M for tables in SI units

Bulletin 3065 page 2

3065 Aspirator Mixer Operating Principles

PICKING THE AIR PRESSURE/MIXTURE PRESSURE MULTIPLIER

Aspirator mixers are used to create a uniform air/fuel mixture for burners that require premix. They normally operate with low pressure air (below 35"w.c.) and use the venturi effect to pull fuel into an air stream. This creates shear between the fuel and air flows that efficiently mixes them to make a high-quality premix. To ensure that the proper amount of fuel is mixed with the air, a ratio regulator is installed upstream of the mixer’s gas inlet. Normally the regulator is cross connected to the air or mixture pressure. If only very low-pressure gas is available, a zero governor (atmospheric regulator) must be used. A very wide range of 3065 mixer sizes with interchangeable displacement rods is available. Changing the rod size changes the mixer air orifice area and is easy to do without breaking piping. Built-in pressure taps are included at the inlet and outlet of every 3065. They can also be used as points to connect an impulse line for a cross connected ratio regulator. Knowing the pressures needed at these tap locations is important in the process of picking mixer sizes. — The pressure at the outlet of the mixer is the “Mixture Pressure” (mp). This is the pressure (plus any piping pressure losses) of the premix as it enters the burner. This pressure is based on the burner requirement.

North American 3065 mixers and many premix burners were designed in a time when many customers only had access to low pressure Natural gas, so zero-governor atmospheric regulators were the best option to control the air/fuel ratio. To ensure enough suction to pull the gas into the mixer the air pressure had to be approximately 3.5X the mixture pressure. The classic “rule of thumb” was the air pressure in osi should be twice the numerical value of the mixer pressure in inches water column. For example, if the desired mixture pressure at the burner nozzle was 4"w.c., the air pressure (ap) should be 8 osi (13.8” w.c.). Once sufficient gas pressure became widely available, most premix ratio regulators were cross connected. This eliminates the need for as much suction from the mixer, so a lower air pressure to mixture pressure multiplier can be used which allows for lower system air pressures. Using a low air pressure to mixture pressure multiplier like 2X allows for a lower system air pressure, but the result can be lower quality premix where the air and gas dœs not fully mix as quickly. adding extra distance between the mixer and the burner gives the air and gas more time to mix better. A high air pressure to mixture pressure multiplier, like the “classic” 3.5X produces a very uniform premix which allows the burner to be mounted closer to the mixer. See the Mixer Installation section in this bulletin for the minimum recommended straight pipe runs between the mixer and burner. Air pressure to mixture pressure multipliers below 3.5X can be used when application experience shows acceptable performance. Fortunately, it’s easy to change the characteristics of an installed 3065 mixer by replacing the displacement rod. Increasing the rod diameter will lower the capacity if the air pressure is maintained or increase the air pressure to mixture pressure multiplier if the air pressure is increased to match the old capacity. Using a smaller rod diameter dœs the opposite.

Air Pressure Tap (ap)

Mixture Pressure Tap (mp)

Gas Inlet

Interchangeable Displacement Rod

Body Throat

Burner Exit Port

Air Inlet

Figure 2. Typical 3065 Mixer & Premix Burner

— The pressure at the inlet of the mixer is the “Air Pressure” (ap). To get uniform air/gas mixing it’s important for the air pressure entering the mixer to be 2X to 4X that of the mixture pressure. Generally, the higher the “multiplier” the faster the air and gas mix together. — The “mixer differential pressure” (  p) is the pressure difference between the air pressure and the mixture pressure,  p = ap – mp. Mixer differential pressure is used to estimate the air flow through the mixer. Mixers should be sized so that the mixer differential pressure (  p) is at least 1⁄3 the air supply pressure (ap). Most North American premix burners have a minimum mixture pressure limit of .25"w.c., but depending on the piping configura- tion, often must be set higher to prevent flashback. This means the low fire air pressure setting at the mixer inlet is usually above 1"w.c. Follow the North American piping guidelines to reduce the risk of flashback at low fire and flame lift-off at high fire.

Bulletin 3065 page 3

Fuel/Air Ratio Control

Using a zero governor (atmospheric regulator)

Zero governors work by maintaining atmospheric pressure at their outlet by modulating gas in proportion to the amount of suction generated by air flowing through an aspirator mixer. To develop enough suction the air pressure must be 3.5 to 4X of the mixture pressure. Because it only requires suction from the mixer to pull the fuel into it, this control method is ideal when only low pressure gas is available. Since most locations have sufficient gas pressure, cross connecting the regulator has become more popular.

Zero Governor (Ratio Regulator)

3065 Mixer

Burner

Vent Connection

Air Valve

Figure 3. Typical ratio control system with zero governor ratio regulator

Using a cross-connected ratio regulator

There are a number of reasons to cross-connect the ratio regulator feeding a 3065:

Gas Line

— It maintains better ratio control if the combustion chamber pressure varies or is different than the room pressure. For example, premix burners used as pilot tips work better when cross connected. — By cross connecting the regulator it is not necessary to maintain a 3X to 4X air pressure to mixture pressure multiplier. Besides potentially reducing the air pressure requirement, this reduces the need for precise burner mixer sizing. The impulse line can be connected to the air or mixture pressure taps. The gas pressure at the ratio regulator inlet should be set to the impulse line pressure plus the pressure drop across the regulator. If the gas pressure is set higher than necessary, the air/fuel ratio adjustment will lose resolution and get touchy. Cross connecting to the mixture pressure provides slightly better ratio control resolution than using the air pressure tap, but there are advantages to using the air pressure tap for the impulse.

Zero Governor (Ratio Regulator)

3065 Mixer

Burner

Air Valve

Impulse Line on Mixture Pres. Tap

Figure 3b. Typical ratio control system with zero governor ratio regulator cross-connected to the mixture pressure.

Gas Line

Zero Governor (Ratio Regulator)

3065 Mixer

Burner

Impulse Line on Air Pres. Tap

Air Valve

— Applications where having an air/fuel premix in the impulse line and regulator case is objectionable.

Figure 3c. Typical ratio control system with zero governor ratio regulator cross-connected to the air pressure.

— It leaves the mixture tap free to be used for a premix test tip for tuning the ratio setting.

— The air pressure tap is always in the same relative position. Because of the way the smaller 3065’s are made the rotation position of the mixer tap can vary. Consult Bulletin 7218/7219A, Instructions 7218-2, and the Practical Pointers book for additional information and set-up instructions for ratio regulators.

Bulletin 3065 page 4

Sizing 3065 Mixers Instructions

• For Standard North American premix burners:

Example C: to size a mixer for a burner running Natural Gas, that requires 6" wc @ 6,000 cfh air and using the classic air pressure to mixture pressure multiplier of 3.5X

North American 4651, 4659, and 4682 premix burners share the same capacity rating system but consult the individual burner bulletin and sheets for details and operating stability range. Not every size premix burner capacity is available for every burner nozzle type, or suitable to operate at every pressure on the sizing tables. — Table 1 shows mixer sizing recommendations for a single North American premix burner and Table 2 is for sizing multiple North American premix burners. As shown in the Table 1 header, the mixer inlet air pressure is assumed to be about 3.5X the mixture pressure. (for natural gas) Example A: Select a mixer for a single 4651-2-D burner with 16 osi (27.7"w.c.) air and 8"wc mixture pressure, with zero governor ratio control for natural gas. — Since this is a standard burner nozzle size with zero gover- nor ratio control, use Table 1. Find the -2-D burner and pick a 3065-2-0 mixer from the list to the left . Per Table 3A, the 3065-3-13 has the same mixer throat area, and offers more sizing options if field conditions require a new displacement rod choice.

ap = 6"w.c. X 3.5 = 21"w.c. air pressure  p =21" wc - 6"w.c. = 15"w.c.  p

— Use Chart 1 or Table 3 with the desired air flow and mixer  p to identify the correct 3065 mixer to match other premix burners for use with zero governor ratio control. Note that Chart 1 does not list every size mixer available. — Table 3 shows the mixer air capacity @ 1” w.c.  p, to find the right match, the air flow @ 15” w.c.  p must be converted using the square root law to show the equivalent flow at 1" w.c.  p.



 p = 15"w.c. @ 6,000 cfh air

  P 2  P 1

Solution: Q 2 = Q 1 x

  1

Q 2 = 6,000 x

 15

Example B: Select a mixer for feeding six (6) 4651-2-A burners, with zero governor ratio control for natural gas.

Q 2 = 1549 cfh air @ 1"

Using Table 3 : choose a 3065-5-16 mixer (with 2 ½ " connections), if 2" air piping is preferred then a 3065-4-S12 (with 2" connections) instead. Example D: An existing system has 20 small premix burners with a capacity of 500 cfh air each. The air pressure (ap) into the old mixer is 22"w.c. and the mixture (mp) is 7"w.c., pick a new compatible 3065 mixer to replace the old mixer.

— Since these are standard size burner nozzles with zero governor ratio control, use Table 2. Find the -2-A burner row move right and find the 6 burner column. Pick the 3065-6-20 Mixer from the list.

• For other premix burners if the required burner capacity, air pressure (ap) and mixture pressure (mp) is known:

— If the desired air pressure (ap) upstream of the mixer is not known, it can be estimated using the guidelines below.

- Total capacity = 20 x 500 cfh = 10,000 cfh air flow.

- Mixer  p available = 22"w.c. - 7 w.c. = 15"w.c.  p

• For Natural Gas, multiply the mixture pressure (mp) by 3.5

- Find mixer flow at 1.0“w.c.  p to use Table 3

• For Manufactured or Coke Oven Gas, mixer air pressure (ap) = mixture pressure (mp) X 4.0

Note: the mixer air pressure is 3.1X the mixture pressure, so cross connect the ratio regulator. (22/7=3.1)

• If the available system air pressure is limited, a lower air pressure to mixture pressure multiplier (2.5X for example) can be used if the ratio regulator is cross connected and proper distance between the mixer and the burner is maintained.

  1

Q 2 = 10,000 x

= 2582 cfh @ 1"w.c.

 15

— From table 3A pick one of these mixers: 3065-5-S13 with 2 ½ " connections or 3065-6-16 with 3" connections. Pick depending on preferred pipe size.

— To find mixer  p (differential pressure drop across mixer), subtract mixture pressure from air pressure (  p = ap - mp)

Bulletin 3065 page 5

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