Gas kiln burners for tunnel kiln

Types of gas kiln burners for tunnel kiln

Gas kiln burners for tunnel kilns are designed to suit different types of tunnel kilns. The following are several gas burner types commonly used in tunnel kilns.

• Multi-channel gas burners

  Multi-channel gas burners are burners with several equidistant channels. Each of them is a passage of a specific diameter, which smoothly supplies gas to the kiln chamber. The channels are organized from the bottom up, horizontally parallel to each other, and perpendicular to the airflow. This design helps create an equal distribution of heat. The kiln can be heated uniformly thanks to the symmetrical allocation of flame and temperature. Therefore, the quality of the products is improved.

• Composite gas burners

  Composite gas burners are made up of various elements, including gas supply, air supply, flame stabilization, and atomization devices. The gas and air nozzles are also known as the mixing head, where thorough blending occurs before the mixture is ejected into the tunnel kiln by the flame stabilization device. The flame stabilization features a distinct design to hold the flame steady in the combustion chamber. It also ensures rapid combustion and prevents backfire. Atomization devices are in charge of liquid fuel atomization and injection.

• Cross-draught gas burners

  Cross-draught gas burners are whose primary air-gas flow direction differs from that of other channel burners. Tunnel gas cross-draught burners create a perpendicular flame to the kiln's charge. The design helps improve the mixing of fuel in the air and enhances thermal efficiency.

• Rotary gas burners

  Rotary gas burners utilize the rotary air compressor to mix gas and air. The gas is released as a jet through the compressed rotating air into a fine mist. The combustion takes place after the mixing of the two in the tunnel kiln.

• Double-regulator gas burners

  Double-regulator gas burners are used to control air and gas pressure by two distinct regulators. This enables precise control over the burner's capacity and the mixture ratio, thus providing fine adjustment.

Specifications and Maintenance

The performance of a kiln kneader machine is mainly determined by its specifications. Specifications Gas kiln burners for tunnel kilns may vary depending on various factors, including the material, age, and technology used to manufacture them. Nevertheless, the following specifications are common in most gas kiln burners.

• Gas flow rate: This is the amount of gas that the burner can transmit per unit of time, usually measured in cubic meters or feet per hour. Different kilns have different requirements, and if this is not followed closely, it can result in poor performance.
• Gas pressure: It should be noted that this is the pressure at which the gas is supplied to the burner. Various burners work well with different pressure levels, so if the pressure level is low or high, it can affect how well the kiln is used.
• Orifice size: The size of the orifice controls the flow of gas and air to be mixed and burnt. If the orifice is too big or small, the mix of air and gas will not be enough, and the burning will not work well for the kiln.
• Design type: The design of a gas burner affects how heat is put out and how the gas and air are put together and burnt. Some common designs are venturi, atmospheric, and pressure-regulated burners.
• Materials: Gas kiln burners are made from materials which are able to withstand high temperatures and resist corrosion. Common materials used include stainless steel, refractory ceramics, and high-temperature alloys.

Proper maintenance of gas burners in the kiln is crucial. It helps to ensure optimal performance, safety, and longevity. The following are gas kiln burner maintenance tips:

• Regular Inspection: Establish a regular inspection schedule for the burner components. Look for damages or signs of wear and tear.
• Cleaning: Burner parts are usually blocked by debris, soot, and impurities. Clean parts like orifices, air mix passages, and nozzles using brushes or compressed air to allow free gas flow and prevent clogging.
• Lubrication: Lubricate the moving parts of the gas burner with high-temperature grease, especially the slides and pivot points of the automatic control mechanisms.
• Adjustment: Make periodic adjustments to the gas pressure and airflow to optimize the combustion process for efficiency and minimize emissions. Monitor the flame characteristics closely and make adjustments promptly if any changes are detected.

Usage scenarios of gas kiln burners for tunnel kiln

The primary purpose of gas burners for tunnel kilns is to fire the products placed in the tunnel kiln. However, they do offer some other potential applications in various industries, which are as follows:

• Firing ceramics and refractory materials: The main purpose of gas tunnel kiln burners is to fire ceramics. This includes pottery, sanitary ware, tableware, porcelain, bricks, tiles, and other refractory materials. The quality of the final products is largely affected by the uniformity of temperature in the kiln. Gas burners help achieve that.
• Firing porcelain like china: This is quite similar to the above. However, only high-quality, extremely durable, and heat-resistant materials need to be used. Also, the temperature in the gas tunnel kiln should be exceedingly high. The uniformity provided by gas burners for the tunnel kiln is necessary to ensure that all porcelain products are of superior quality.
• Glass production: Glass ceramics produced in the gas tunnel kiln have high-temperature resistance, good mechanical properties, and stability. Such that they can even be used in a high-temperature environment for a long time. The architecture requires materials with such properties. Gas kiln burners for tunnel kilns ensure that the glass-ceramics attain these properties by ensuring uniform heating. They also help the material reach the required temperature.
• Metal oxidization: Metal oxidization entails creating oxide layers on the surface of metals. The oxide layer can improve corrosion resistance, increase adhesion, and enhance aesthetic qualities. The application of gas burners is ideal for this. The process needs a high and precisely controlled temperature. Moreover, it is also necessary to create oxidation in the metal. Motors and reducers are also commonly used in this process. So, buying in bulk is ideal.
• Producing high-quality refractory products: High-quality refractory products are used to withstand extreme temperatures and support heavy loads. Therefore, they are commonly used in steel, cement, glass, and aluminum smelting industries. Refractory products become high-quality only when they are evenly heated to the same high temperature. Gas kiln burners for tunnel kilns make high even heating possible. So, they help produce high-quality refractory products.

How to choose gas kiln burners for tunnel kiln

When selecting the gas burner for tunnel kilns, some factors must be considered to ensure they meet the specific requirements of the industry. The following are some of the factors to consider when choosing gas kiln burners for tunnel kilns:

• Flame control and profiles: Buyers should look for burners with precise control options and various flame shapes to achieve the desired results. Investigate if the burner's control system allows fine-tuning of flame size, intensity, and temperature distribution. Additionally, consider burners that offer adjustable flame profiles, such as spreader, fouling-resistant, V-shaped, or W-shaped flames, to ensure they meet specific processing needs.
• Combustion efficiency: Select tunnel kiln burners with features that minimize fuel expenses and environmental impact. Look for burners equipped with advanced air-fuel mixing systems that optimize the combustion process. Check if the burner design reduces excess air requirements and enhances fuel utilization, thereby improving overall combustion efficiency.
• Emission performance: Consider the environmental impact of the gas burners and select those with low-emission attributes. Choose burners designed to minimize particulate matter, nitrogen oxides (NOx), sulfur oxides (SOx), and other relevant pollutants. Evaluate the burner's emission performance to ensure compliance with stringent environmental regulations and contribute to sustainable manufacturing practices.
• Durability and reliability: Select gas burners that are reliable and durable to reduce maintenance costs and downtime. Consider the materials used in the burner's construction and their resistance to thermal and corrosive degradation. Additionally, opt for burners that undergo rigorous testing to ensure their dependability in demanding tunnel kiln environments.

Gas kiln burners for tunnel kiln Q & A

Q: What is the difference between a burner and a gas kiln burner?

A: The burner is the component used to introduce and ignite fuel in the combustion chamber. However, a gas kiln burner refers to a specific type of burner designed for gas fuel usage in kilns. These burners are engineered to meet the unique requirements of kiln firing processes, ensuring controlled and efficient combustion for proper ceramic body firing.

Q: How many types of burners are there in a tunnel kiln?

A: There are mainly two types of burners used in a tunnel kiln technique, such as the disc type and the mixed type.

Q: What are the functions of kiln burners?

A: The primary function of kiln burners is to provide heat production in the form of high-temperature flames or hot gases for material drying or firing. Burners also control the temperature and pressure in the kiln by adjusting the gas flow and air volume.

Q: What are the advantages of using gas burners in kilns?

A: Gas kiln burners are automatic, offer precise and simple control, and emit less smoke, carbon dioxide, and sulfur dioxide compared to other fuels. Their operation is cleaner, resulting in higher-quality products with fewer defects.