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The tunnel kiln burner is an indispensable component of the tunnel kiln that ensures the stability of supplying heat and raw materials. Several types of tunnel kiln burners exist. The selection typically hinges on the requirements of the products to be roasted, fuel availability, and technical conditions.
Oil Sand Tunnel Kiln Burner
The oil sand tunnel kiln burner is mainly composed of an oil gun, sand gun, mixing chamber, and wind box. Oil gun atomizes and sprinkles the oil, while the sand gun sprays the sand. In the mixing chamber, the oil and sand are mixed up and then blow out by the wind pressure from the wind box.
It is widely used in industries like cement, iron and steel, and ceramics.
Heavy Oil Tunnel Kiln Burner
Designed specifically for the burning of heavy oil, this kind of tunnel kiln oil burner adopts advanced atomization technology to atomize fuel oil. It looks like a metal gun barrel, equipped with an oil nozzle. When it works, pressurized oil flows through the nozzle, forming a fine mist that is mixed with the required amount of air for combustion.
It is primarily used in the metallurgy and ceramics industries.
Natural Gas Tunnel Kiln Burner
Natural gas tunnel kiln burners usually use high-volumes and high-pressure natural gas. They are fully automatic with a stable ignition system in the face of the most different weather conditions. A feature of these burners is that they can be adjusted precisely to the required production temperatures but also to economical gas consumption.
It is an ideal choice for the glass, ceramic, and construction materials industries.
Dual Fuel Tunnel Kiln Burner
As the name suggests, dual fuel tunnel kiln burners can use two fuels: oil and natural gas. They function by changing the combustion system so as to achieve a stable and efficient combustion of fuel. Because they have the flexibility to use different fuels, dual fuel tunnel kiln burners can be adapted to different environmental and industrial requirements.
It is extensively applicable in metallurgy, building materials, chemical industry, etc.
Tunnel kiln burners are critical components of tunnel kilns that are widely used in the machinery industry.
Ceramics and pottery manufacturing
Tunnel kiln burners are primarily used in the production of ceramics and pottery. These products include stoneware, porcelain, bricks, sanitary ware, and other ceramic products. The combustion system of the tunnel kiln is designed to meet the specific requirements of various ceramic products. For example, for ceramics with high firing temperature requirements, a high-temperature tunnel kiln burner must be used. Additionally, efficiency is also critical in pottery manufacturing. Therefore, tunnel kiln burners with quick-starting and stability are often chosen so that the kiln can respond quickly according to production needs.
Brick and tile production
In the brick and tile production industry, tunnel kiln burners are widely used in the production of fired bricks and ceramic tiles. This is because the combustion technology of tunnel kilns helps to achieve uniform firing, high-strength yields, and, at the same time, meet the quality requirements of the products.
In addition, in some large-scale brick and tile manufacturing plants, combined with tunnel kiln burners and other combustion systems, such as waste heat utilization systems, helps improve resource utilization efficiency.
Glass melting
Tunnel kiln burners can be used to melt glass in the glass production industry. For example, in container glass, flat glass, and special glass production, the glass raw materials need to be melted and shaped through high temperatures. Also, the precision and stability of the firing temperature are vital for the quality control of the glass. The melting and shaping process must ensure that there are no bubbles and other defects. Therefore, tunnel kiln burners with precise control of firing temperature are usually chosen to ensure that the raw materials are fully melted and the quality of the product is excellent.
Refractory material production
In the production of refractory materials, tunnel kiln burners are used to fire and shape products such as high-temperature ceramics, refractory bricks, and insulating ceramics. The high-temperature resistance of refractory materials is essential in many high-temperature industrial processes and applications, such as steelmaking, metal smelting, cement manufacturing, and petrochemical refining.
Metallurgical industry
The metallurgical industry also uses tunnel kiln burners in the following ways:
In the steel production industry, for example, in the production of fired bricks and other metallurgical refractory materials, high-temperature tunnel kiln burners are often used. Their job is to shape the product and ensure good stability and chemical resistance. The fired bricks and other refractory materials can meet the high-temperature requirement and provide a necessary lining and insulation for the steel production equipment.
In addition, metallurgical industries often need to deal with large production volumes and high combustion efficiencies. Therefore, combined combustion systems such as tunnel kiln burners and fluidized bed furnaces are used to improve the utilization of resources.
When choosing a tunnel kiln burner, several factors need to be considered to ensure the most suitable option for the specific application:
Fuel compatibility
Selecting a tunnel kiln burner that is compatible with the fuel type used is essential. Different fuels may have unique requirements regarding quality, viscosity, and atomization.
Process requirements
Each industry has distinct process requirements that the burner must meet. Consider factors such as the temperature range needed, heating rates, and the ability to maintain consistent and controlled combustion. Choose a burner designed to optimize the specific industrial process's efficiency and combustion characteristics.
Burner design and features
Consider the specific design and features of the kiln burner. Different burners may have additional capabilities, such as multiple fuel options, quick-change assemblies, digital servo control, low emissions, and lead-free permanent molds. Evaluate these features based on the industry's demands and prioritize the ones that enhance operational efficiency and environmental sustainability.
Emissions regulations and environmental sustainability
Complying with emissions regulations is critical to avoid legal issues and promote environmental sustainability. Choose a kiln burner that meets the required emissions standards, as determined by the relevant regulatory bodies in a particular region or country.
Efficiency and performance
Consider the efficiency and performance of the burner. Look for high thermal efficiency to minimize energy consumption and operational costs. Evaluate combustion performance, including stability, response time, and the ability to handle varying fuel qualities and flame characteristics.
Maintenance and support
When selecting a tunnel kiln burner, consider the maintenance and support requirements. Assess the maintenance needs, including the frequency and complexity of tasks, to ensure they align with available resources. Evaluate the support network provided by the manufacturer, including technical assistance, spare parts availability, and service centers.
Application-specific considerations
Other application-specific considerations may depend on the industry and specific processes. This can include factors such as the size and capacity of the kiln, the geometry of the combustion chamber, and any unique requirements related to the materials being processed.
Q1. What is the difference between a tunnel kiln burner and tunnel kiln electric rods?
A1. Tunnel kiln burners are used to supply heat to the kiln for firing products, while electric rods are used to provide heat. Generally, burners are used in settings where fuel (gas, oil, or coal) is burned to produce heat, and electric rods are utilized in locations where electricity is converted into heat.
Q2. Are tunnel kiln burners required for all types of kilns?
A2. No, the kiln may not need a tunnel kiln burner depending on the heat source and design. Some may utilize burners or other forms of combustion to generate heat. Electric tunnels are also alternatives.
Q3. How much heat does a tunnel kiln burner produce?
A3. The amount of heat produced will vary depending on the size of the tunnel kiln burner, the fuel being used, and how long it is allowed to burn. Generally, the heat is measured in kilowatts.
Q4. What are the safety considerations when using tunnel kiln burners?
A4. Several safety precautions should be followed, such as ensuring adequate ventilation to prevent the buildup of harmful gases, making sure the burner is properly maintained and inspected regularly, and following the manufacturer's instructions and guidelines.
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