Combustion Catalog | Fives North American

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

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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Energy | Combustion Energy | Combustion

TABLE OF CONTENTS Product Literature

BUL L ET I NS , BROCHUR ES , SUP P L EMENTS , S P EC I F I CAT I ONS , CAPAC I T I ES

—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.

Energy | Combustion er y | sti

USA OFFICES

NEW YORK Buffalo 888 808 9167 OHIO Cleveland 216 271 6000

GEORGIA Atlanta 678 407 0775 GREAT LAKES Detroit 734 207 7008 INDIANA Crown Point 219 662 9600 MISSOURI St. Louis 573 564 3788

TENNESSEE Nashville 216 373 8613 TEXAS Houston 281 693 0074 WASHINGTON Seattle 425 530 0096

ALABAMA Birmingham 205 956 8191 CALIFORNIA Bakersfield 888 209 2751 CALIFORNIA Los Angeles 216 373 8474

PENNSYLVANIA Philadelphia 216 373 8325 PENNSYLVANIA Pittsburgh 216 373 8498

CONNECTICUT New England 216 373 8351

Energy | Combustion er y | o b stio er y | sti

INTERNATIONAL CONTACTS

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 UNITED KINGDOM Fives North American Combustion UK, Ltd. Heath Mill Road Wombourne Wolverhampton WV5 8BD ENGLAND T +44 (0) 1902 891 200 F +44 (0) 1902 895 552 fna.salesUK@fivesgroup.com

NETHERLANDS Fives North American Combustion Netherlands B.V. Parellaan 6, 2132 WS Hoofddorp NETHERLANDS T +31 (0) 297 380404 F +31 (0) 297 380438 fna.salesNL@fivesgroup.com SPAIN Fives North American Combustion Spain S.L. Plaza Sagrado-Corazon 4 Sub2, 48011 Bilbao SPAIN T +34 944 347 200 F +34 944 347 204 fna.salesSP@fivesgroup.com

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 11, Boulevard de Letz 13015 Marseilles FRANCE T +33 (4) 912 140 40 F +33 (4) 912 140 44 fna.salesFR@fivesgroup.com

DISTRIBUTORS (D)

PERU (D) Insercomgas SAC Santa Amelia 751 Lima 36 PERU

CANADA - West Alberta, British Columbia, Manitoba, Saskatchewan (D) Process Combustion Systems, Inc. #13-1515 Highfield Cres. S.E. Calgary, Alberta T2G 5M4 CANADA T +1 403 250 1075 F +1 403 250 1076 info@processcombustion.com CHINA (D) Shanghai EN-FA Combustion Equip. Co. Ltd. Room.1508 Building #8 No.950 Dailian Road Shanghai, P.R.C.

JAPAN (D) Shinko Shoji Company Ltd. 1-4-5 Toranomon Minatoku, Tokyo 105 JAPAN T +81 (03) 350 26251 F +81 (03) 350 36770 ssc-kawashima@msg.biglobe.ne.jp MEXICO (D) Nutec Bickley Carretera Saltillo-Monterrey KM 62.5 #100

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 +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

Santa Catarina, NL MEXICO CP 66359 T +52 (81) 8151 0800 F +52 (81) 8151 9599 sales@nutecbickley.com (D) Nutec Bickley CDMX (Mexico City) T +52 (55) 5456 7244 eduardoperez@nutec.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

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

T +86 21 6568 1261 F +86 21 6568 1603 jingtao.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

SOUTH KOREA (D) Kyung In Corp. #1-1508, ACE Hitech 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

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.

Combustion

Exceptional performance through cutting-edge technology Magna-Flame ™ LE

Meeting Tomorrow's Environmental Needs Today

Powerful NOx reduction through fuel staged, lean premix technology

Integrating the LE burner into a steam system will provide lower emissions, higher combustion efficiency, and better process control - all with proven reliability.

Breakthrough technology for the ultimate in performance

APPLICATIONS

ULTRA LOW NOX WITHOUT FGR The Magna-Flame 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. LOW NOX WITH PREHEATED AIR GET EVEN LOWER NOX WITH FGR When FGR is utilized with the Magna-Flame LE, the NOx emissions can be taken to even lower levels; below 8 ppm (corrected to 3% O2), 0.01 lb NOx per MMBtu.

— Boilers — Thermal fluid heaters — Process heaters — Incinerators

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/hr — Turndown up to 20:1 — Robust design, rugged and reliable with no moving parts

UNIQUE PATENTED DESIGN

The Magna-Flame 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/hr.

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 LICENSED PATENTS US 5,201,650

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

CONTACT US: Fives North American Combustion, Inc. 4455 East 71st Street - Cleveland, OH 44105 - USA Tel: +1 800 626 3477 - Fax: +1 216 373 4237 Email: fna.sales@fivesgroup.com

www.fivesgroup.com

Combustion

Low emissions dual-fuel burner Magna-Flame RM ™

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. 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.

• Boilers • Process Heaters • Air Heaters • Dryers and Calciners • Incinerators • Soil Remediation

Typical RM Burner Emissions Natural Gas Typical R Burner Emissions

FEATURES • High flame intensity FEATURES:

100 90 80 70 60 50 40 30 20 10 0

• Sizes from 15 to 150 million Btu/hr • Turndown up to 10:1 (gas), 5:1 (oil) • Prepackaged and tested burner management systems available • Low emissions with FGR • Heavy duty construction • No moving parts • Gas and liquid fuels including heavy oils • Full line of pre-engineering and aftermarket services available

No FGR

20% FGR

0 10 20 30 40 50 60 70 80 90 100

Excess Air % Excess Air %

Magna-Flame RM ™

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. Fig. 1 illustrates how 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.

Fig. 1 - Magna-Flame RM (gas fired version)

Recirculation

Main Air Inlet

Gas Connection

Gas Deflector Disk

Air Spin Vanes

Recirculation

 Internal recirculation zone induces combustion chamber gases

OIL FIRING Because of the Magna-Flame RM’s rapid mixing and internally recirculated flame, it is also an excellent oil burner. With an efficient tip emulsion atomizer, the RM is capable of firing a wide range of liquid fuels including #2 and #6 distillate fuel oils. The internally recirculated flame makes the RM effective at minimizing thermal NOx. And combined with FGR, the burner has demonstrated reduced NOx emissions with certain oils comparable to those attained with gas flames.

RM Burner firing light oil

RM Burner firing natural gas

CONTACT US: Fives North American Combustion, Inc. 4455 East 71st Street - Cleveland, OH 44105 - USA Tel: +1 800 626 3477 - Fax: +1 216 373 4237 Email: fna.sales@fivesgroup.com

www.fivesgroup.com

Combustion

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 1200F —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 . 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

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

POC

POC

POC

Gas

AIR

AIR

AIR

AIR

Gas

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 US: Fives North American Combustion, Inc. 4455 East 71st Street - Cleveland, OH 44105 - USA Tel: +1 800 626 3477 - Fax: +1 216 373 4237 Email: fna.sales@fivesgroup.com

www.fivesgroup.com

Combustion

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

LNI mix to 1400 F

LNI above 1400 F

POC

POC

POC

Air

Air

Air Air

Gas

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 US: Fives North American Combustion, Inc. 4455 East 71st Street - Cleveland, OH 44105 - USA Tel: +1 800 626 3477 - Fax: +1 216 373 4237 Email: fna.sales@fivesgroup.com

www.fivesgroup.com

Combustion

North American HIRAM ®

High Velocity, RAMEffect, LowNOx Burners

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 HIRAMWORKS 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/hr 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. 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.

Scale in feet

0 1

2

3

4

5

6 7

8

9 10

Scale in feet

0 1

2

3

4

5

6 7

8

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.

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 Combust ion, Inc. , the exclus ive worldwide l icensee for use of thi s technology. U.S. Patent No. 4,945,84 1

CONTACT US: Fives North American Combustion, Inc. 4455 East 71st Street - Cleveland, OH 44105 - USA Tel: +1 800 626 3477 - Fax: +1 216 373 4237 Email: fna.sales@fivesgroup.com

www.fivesgroup.com

Combustion

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/hr — 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

Benefits — 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

Standard Flat Flame Burner

80 60 40 20 0

80 60 40 20 0

Series "A" Low NOx

Series "A" Low NOx

1600

1800

2000

2200

2400

1600

1800

2000

2200

2400

Furnace temperature F

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

4828A 4832A 4833A 4836A 4837A

Hot Air, On Ratio

0.3 to 5.0* w/1000F 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

roof only roof only

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 US: Fives North American Combustion, Inc. 4455 East 71st Street - Cleveland, OH 44105 - USA Tel: +1 800 626 3477 - Fax: +1 216 373 4237 Email: fna.sales@fivesgroup.com

www.fivesgroup.com

Combustion

North American Magna-Flame ™ LEx

Cutting emissions through cutting-edge technology

IImplementing the LEx burner into your thermal process will provide you with lower emissions, higher combustion efficiency, and better process control — all with proven reliability.

Breakthrough technology for the ultimate in performance

UNIQUE PATENTED DESIGN The Magna-Flame 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. LOW NOX AND CO WITHOUT FGR The Magna-Flame 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 .

Fig. 1

MULTI-FUEL CAPABILITY The LEx is capable of firing a wide range of gaseous fuels cleanly; from low Btu waste streams to conventional purchased gases to refinery gases. Additionally, the LEx is capable of firing No. 2 oil providing back-up fuel options.

COMPACT FLAME GEOMETRY, HIGH HEAT RELEASE

The LEx system generates compact, high

intensity flames, reducing process influence on the combustion system performance.

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

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

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.

Magna-Flame ™ LEx

REDUCED CHAMBER LENGTH

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.

Unlike conventional burners, the LEx flame exits the reaction chamber fully combusted and ready to heat the process. In most applications, the combustion chamber size may be reduced to take advantage of LEx high combustion intensity.

Compliance test data of natural gas, NOx, and CO emissions

APPLICATION

NOx

CO

Yankee hood

8.2

50.3

Air heater / spray dryer

8.7

2.1

Gypsum board dryer 69.7 Emissions in ppmv corrected to 3% O 2 8.7

LEx Features

LEx - CROSS SECTION

Main Combustion Air Inlet

— Ultra low NOx and CO without flue gas recirculation — High heat release — Sizes up to 400 million Btu/hr

Radial Air Inlet

— Turndown up to 20:1 — Multi-fuel capability — Patented technology — Robust design — Rugged and reliable — No moving parts

Radial Gas Inlet

Primary Gas Inlet

Integrated Mixing Elements

Primary Reaction

The North American Commitment We continuously provide our customers with innovative solutions for all their combustion needs. Our creative energy and engineering expertise come together to provide the latest in combustion technology – supplying breakthrough new products and solutions that improve your facility's performance – and your bottom line. We provide our customers with full-service support. End-to-end, we ensure every customer is completely satisfied. From initial consultations through field installation and service, North American provides complete customer support throughout the entire process.

CONTACT US: Fives North American Combustion, Inc. 4455 East 71st Street - Cleveland, OH 44105 - USA Tel: +1 800 626 3477 - Fax: +1 216 373 4237 Email: fna.sales@fivesgroup.com

www.fivesgroup.com

Combustion

Magna-Flame ™ GLE

Meeting Tomorrow's Environmental Needs Today

Sub-5 ppm NOx for the oil field industry

Lowest NOx Combined with Highest Thermal Efficiency Introduced for steam generator applications in 1994, with 400 separate applications of GLE burners now operating worldwide. —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 —Repeatable performance using proprietary CMS algorithms

Magna-Flame ™ GLE

GLE FEATURES —Accommodates a wide range of fuel gases and heating values —Produces desired flame envelope to maximize radiant heat transfer —Inline fan discharge and burner centerline for minimal footprint and ease of installation —Compatible with damper or VFD air flow control. —Nozzle mix pilot conveniently utilizes combustion air directly from the fan discharge —Widely deployed, proven performance, and reliability

Magna-Flame GLE Burner Emissions Performance - Kern County Steam Generators

15 14 13 12 11 10

9 8 7 6 5 4 3 2 1 0

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

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)

CONTACT US: Fives North American Combustion, Inc. 4455 East 71st Street - Cleveland, OH 44105 - USA Tel: +1 800 626 3477 - Fax: +1 216 373 4237 Email: fna.sales@fivesgroup.com

www.fivesgroup.com

Combustion

Fives Combustion – Superior Performance by Design Diffuse Mode Combustion

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

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).

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

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 diagnost ic and communicat ion 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 US: Fives North American Combustion, Inc. 4455 East 71st Street - Cleveland, OH 44105 - USA Tel: +1 800 626 3477 - Fax: +1 216 373 4237 Email: fna.sales@fivesgroup.com

www.fivesgroup.com

Combustion

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 fire. 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.

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 US: Fives North American Combustion, Inc. 4455 East 71st Street - Cleveland, OH 44105 - USA Tel: +1 216 271 6000 - Fax: +1 216 373 4237 Email: fna.sales@fivesgroup.com

www.fivesgroup.com

3065 North American Aspirators and Gas Mixers

Dependable and uniform air/fuel mixtures

• Large range of available sizes for various applications

• Rugged design for long life

• Compact design allows for simple installation

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 INLET

Air P. (osi)

4

8

12

16

Mixer D.P. ("wc) Mixer P. ("wc)

4.9

9.8

14.8

19.7

2

4

6

8

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 3065-8-0 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 11110 11510

960 1310

BURNER AIR VALVE

1730 2620 3870 4530 5600 6280 9070 9400

2450 3710 5480 6410 7930 8890 12800 13300

BURNER

DISPLACEMENT ROD

GAS INLET

V-PORT VALVE

ASPIRATOR MIXER

10950 15500

19000 22900 59100 89600

21900 26400 68300 103500

13200

18700

ATMOSPHERIC REGULATOR

34100 48200 51700 73200 65800 97300

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

1119000 138000

*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.

Bulletin 3065 page 2

3065 Aspirator Mixer Operating Principles

Aspirator (air-jet) mixers generally operate with low pressure air in the 3 to 20 osi (5 to 35"w.c.) range 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 uniform (high quality) premix. They are often used with a zero governor (atmospheric regulator) which controls fuel/air ratio when the air flow through the mixer is adjusted. To conform to field conditions or to get lower or higher mixture pressures (with more or less suction, respectively), 3065 mixers have interchangeable displacement rods that permit changing the mixer air orifice size. Rods can be changed without "break- ing" the piping. The rod diameter in 32 nds of an inch is stamped on the rod nut. 3065 mixers have a built in pressure tap to measure the air pressure as it enters the mixer and a tap to measure the mix- ture pressure as it exits the mixer. These taps can also be used as points to connect an impulse line for a cross connected ratio regulator control. 3065 mixers are suitable for operation over the entire range of conventional premix burners. Most North American premix burners have a minimum mixture pressure limit of .25"w.c., but depending on piping configuration, 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.

4. The “Air pressure/mixer differential pressure” ratio is important to know (along with fuel type) when picking a mixer size, especially when using a zero governor (atmospheric regulator) for fuel/air ratio control. — For air/natural gas or propane systems (800 Btu/ft3 or more), “the air pressure in osi should be 2X the numerical value of the mixer pressure in inches water column” or a 3.5 to 1 air pressure/ mixture pressure ratio. For example, if the desired mixture pres- sure at a burner nozzle is 4"w.c., then pick a mixer that requires 8 osi (14"w.c.) air pressure at the inlet to the mixer at the desired air flow rate (Note: 1 osi = 1.73"w.c.) — For coke oven gas and manufactured gas “the air pressure/ mixture pressure ratio is 4 to 1". So if the desired mixture pres- sure for a burner nozzle is 4”w.c. the air pressure at the inlet to the mixer at the desired air flow rate should be 16"w.c. (9.3 osi) If the ratio regulator is cross-connected to the mixer with an impulse line, the air pressure/mixture pressure ratio becomes less critical for ratio control. This gives the system designer an option to reduce the system air pressure requirement by choosing a mixer with less pressure drop.

5. The quality (uniformity) of the air/fuel mixture is a function of the percentage of air pressure used for mixing.

The minimum recommended air pressure drop for a cross con- nected system is 33% of the supply pressure. Using less pressure drop across the mixer will result in low quality air/fuel mixing. A minimum air pressure drop of 66% of the air pressure is required to use a zero governor with natural gas. If the ratio regulator is cross connected, it is acceptable to size the mixer so that the air pressure is 2X the mixture pressure. In this case the mixer pressure drop will be 50% of the supply pressure.

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 easiest way to pick the correct mixer for an application is to use the sizing tables in this bulletin. In cases where that is not appropriate, there are a number of factors to keep in mind. 1. “Mixture pressure”: this is the pressure of the premix as it leaves the mixer which is the same as the pressure the burn- er requires upstream of the nozzle, plus piping pressure losses between the mixer and the burner (if any).

ASPIRATOR MIXERS for 3/4" PREMIX PILOT TIPS

3065 mixers are suitable for supplying premix to single or multiple 3/4" pilot tips. The capacity of North American 4021 and 4027 pilot tips is similar to the capacity of a 4651-01-A size pre- mix burner, so use the -01-A data in the sizing tables when sizing for 3/4" premix pilot tips. Consult the pilot bulletin for actual pilot capacities and pressure requirements. The 4031 pilot mixer comes in one size, is simpler than the 3065 and is often preferred for use with a single 3/4" pilot tip. Old pilot systems that use the now obsolete 4035-01 and 4035-02 mixers can be replaced with the 4031 mixer. For better pilot tip reliability, pilot ratio regulators should be cross-connected downstream of the pilot air control valve to a pilot mixture or air pressure tap.

2. “Air pressure”: this is the pressure required to supply air into the mixer.

3. “Mixer differential pressure”: this is the difference between air pressure and the mixture pressure (dp = ap - mp). Besides helping to size the mixer, knowing the mixer differential pressure at the required flow rate, helps in estimating the air flow through the mixer during operation.

Bulletin 3065 page 3

Fuel/Air Ratio Control

Using a zero governor (atmospheric regulator)

A zero governor (atmospheric regulator) is a ratio regulator that relies on suction from an aspirator mixer to control air/fuel ratio. It is the classic way of controlling fuel air ratio in premix combus- tion system as it does not require high gas pressure supply. This is very important when gas delivery systems have limited supply pressures. Zero governors work by maintaining atmospheric pressure (zero pressure) at the regulator outlet. Increasing air flow through a mixers' venturi increases suction on gas line. To maintain its "zero" outlet pressure, the regulator opens its' gas valve to increase the amount of gas flowing to the mixer. When the air flow is reduced, the suction is decreased and the regulator valve closes to maintain the zero outlet pressure.

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

Gas Line

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

Zero Governor (Ratio Regulator)

3065 Mixer

Burner

— The combustion chamber pressure varies or is different than the room pressure. For example premix burner used as pilot tips are almost always cross connected. — The air pressure drop across the mixer is less than 66% of the air supply pressure, there may not be enough suction generated by the mixer to use a true zero governor. The regulator can be cross-connected to the mixture pressure tap or air pressure tap with an impulse line (ideally 3/8" copper or SST tubing). When a zero governor is cross-connected, the gas pressure at the zero governor (regulator) inlet must be at least equal to the impulse line pressure plus pressure drop across the governor. Do not set the gas pressure upstream of the ratio regulator higher than necessary. When the gas pressure is increased above optimum the air/fuel ratio adjustment will lose resolution and get touchy. Cross-connecting to the mixture pressure generally provides better ratio control resolution than using the air pressure tap. Use the air pressure tap to impulse line and regulator case is objectionable. For example when the fuel contains corrosive components.

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

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

Bulletin 3065 page 4

Mixer Installation - 8666 TESTIPS

3065 Mixers can be mounted in any position convenient to the application piping. The gas adjustment cartridge assembly can be mounted in either side of the mixer. Gas inlet is perpendic- ular to air line. Mixers are shipped with the valve closed and with right-hand assembly as shown. Plugged pipe taps (1/8") are provided for pressure readings. When mounting the 3065 mixer, leave clearance for removing the cap and Allen wrench adjustment of the gas valve. The cap conceals the gas adjustment, discourages tampering with the setting, and reduces the chance of gas leaks. The gas adjustment valve is not designed for tight shut off, use a suitable shut off valve upstream of the 3065 gas inlet.

When using a cross-connected regulator an impulse line can be taken off the tap provided on the 3065 mixer or use a tap location in a straight section of air piping. Taps in piping should come off from the side or top of a pipe to prevent condensate or dirt from entering it. Small impulse lines are easily plugged by dirt. Avoid sharp edges and abrupt changes of flow direction. Any burrs or nipples projecting into the pipe cause the air in the pipe will increase velocity. Any change in velocity gives a false pressure reading. Avoid dips in the impulse lines where condensed water could collect. If possible pitch impulse lines so water will run back to the air line and not to the regulator, where it could collect on the diaphragm and "fool" the regulator. Leave the connection at the regulator end of an impulse line till last; and blow out the impulse line from the regulator end until you can feel air coming through the tapped pipe. 8666 TESTIPS Flames often are not easily visible when sealed-in nozzles are used. An 8666 Testip facilitates setting desired air/fuel mixture. The Testip is installed in mixture line per diagram below; it is lit with a manual torch after main flame has been lit. Air/gas ratio is adjusted in the mixer until Testip flame seems appropriate: — A purple tinge indicates lean ratio. — A greenish-blue inner cone denotes a rich flame. — Compare testip flame with correct burner ratio setting. Testips are turned off after ratio setting has been set. They should be removed (and the hole plugged) when not in use. Do not use an 8666 Testip for final settings with mixers smaller than 1 ½ ", its capacity would represent too high a percentage of total capacity to allow accurate main flame settings. Use extra caution with 8666 Testips outdoors, the flame can be difficult to see in direct sunlight.

L.H.

R.H.

L.H.

R.H.

Gas Cartridge Assembly (self-contained) Turn gas adjustment plug clockwise to decrease gas

Right-hand assembly of cartridge furnished unless otherwise specified

Remove packing cap to make gas adjustment

Figure 4. Gas Cartridge detail of 3065 Aspirator Mixer

Installing elbows directly at the outlet of a 3065 mixer or using a short nipple between the 3065 mixer and burner can cause combustion instability, or require narrowly held air/fuel ratio settings. It can require the mixture pressure to be held lower than desired to avoid flame lift-off, and nuisance outages of flame supervisory devices. To help avoid these problems install straight unobstructed pipe with a minimum length of 5 L/D between the mixer and pre-mix burner nozzle. If space is limited, then mixer can be connected to the burner with two long nipples and an elbow (see sketch). Allow at least 4 pipe diameters on each side of the elbow. For additional information see: Handbook Supplement 14 "Straight Pipe Run Requirements".

Allow 6" minimum flame clearance

1⁄8 NPT

5 L/D (Min)

Burner

Mixer

5⁄8

4 11⁄16 "

Burner

5 L/D (Min)

Burner

Mixer

Burner

4 L/D (Min)

5 pipe dia.

5 pipe dia.

Figure 5. Minimum recommended straight pipe runs

Bulletin 3065 page 5

Figure 6. 8666 Testip

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