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Elster ECOMAX 0C, Technical Information

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ECOMAX · Edition 02.11

7

Application > Examples of application

1 .3 .2 ECOMAX

®

 in direct heating systems

Gas Cold air

Flue gas

ECOMAX

®

 self recuperative burner in a direct heating sys-

tem with an eductor for extracting the flue gases from the 

furnace. The eductor generates a vacuum with a centrally 

positioned nozzle and thus draws the flue gases out of the 

furnace chamber through the burner’s heat exchanger. The 

maximum achievable air preheat temperature amounts to 

approx. 700°C, depending on the application.

ECOMAX

®

 with eductor and burner control unit BCU

Summary of Contents for ECOMAX 0C

Page 1: ...due to its maintenance friendly modular design Uniform distribution of temperature by means of a high burner impulse Low polluting level thanks to staged combustion Direct ignition and monitoring 7 sizes for a broad output range from 15 500 kW Highly efficient with a ceramic burled tube recuperator a cast steel ribbed tube recuperator or a flat tube recuperator Self recuperative burner ECOMAX for ...

Page 2: ...Project planning information 22 6 1 Flame control 22 6 2 Purging air and cooling air 23 6 3 Recommended burner control units 24 6 4 Gas connection 25 6 4 1 Valves 25 6 4 2 Operation with LPG 26 6 4 3 Air gas ratio control 26 6 5 Air connection 27 6 5 1 Indirect heating 27 6 5 2 Direct heating 28 6 6 Flue gas guide tube FGT for direct heating 29 6 6 1 For ECOMAX C 29 6 6 2 For ECOMAX M 30 6 7 Radia...

Page 3: ...02 11 3 t To be continued 9 Accessories 49 9 1 Flue gas guide tube FGT kit 49 9 2 Flue gas eductor 49 9 3 Ceramic radiant tube SER C 50 9 4 SICAFLEX segmented flame tube 50 9 5 P2 P3 set Eco 51 Feedback 52 Contact 52 ...

Page 4: ... in conjunction with metallic or ceramic radiant tubes and the segmented ceramic flame tube SICAFLEX as indirect heating equipment whenever the combustion gases are to be separated from the product 1 2 Direct heating In conjunction with an eductor to extract the flue gases the burner is used to save energy in a direct heating system Ap plications include industrial furnaces and firing systems in t...

Page 5: ...ECOMAX Edition 02 11 5 Application Roller hearth furnace Bogie hearth furnace Batch furnace ...

Page 6: ...s are fed through the ceramic or metallic heat exchanger heating the additional supply of cold combustion air flowing in the opposite direction The maximum achievable air preheat temperature amounts to approx 700 C depend ing on the application Gas Cold air Metallic radiant tube Flue gas Sicaflex Ceramic radiant tube SER C Flame tube Gas Cold air Flue gas SICAFLEX segmented flame tubes must be fit...

Page 7: ...s tem with an eductor for extracting the flue gases from the furnace The eductor generates a vacuum with a centrally positioned nozzle and thus draws the flue gases out of the furnace chamber through the burner s heat exchanger The maximum achievable air preheat temperature amounts to approx 700 C depending on the application ECOMAX with eductor and burner control unit BCU ...

Page 8: ...ECOMAX Edition 02 11 8 2 Certification 2 1 Approval for Russia Certified by Gosstandart pursuant to GOST R Approved by Rostekhnadzor RTN ...

Page 9: ... also secures the burner insert It is made of cast aluminium which means it has a low weight The housing has a double wall design The combustion air is fed into the burner via the outer annular gap This cools the burner housing und reduces emissions 3 2 Recuperator All ceramic The surface of the all ceramic recuperator which is made of SiSiC for high thermal stress is burled in order to achieve hi...

Page 10: ... air guide tube made of heat resistant steel 3 4 Gas insert The gas insert consists of the gas connection flange the gas lance with mixer unit and the ignition electrode also serves as monitoring electrode For operation with LCV gas the gas insert is equipped with a special mixing system Gas insert with combustion chamber for Ecomax M and Ecomax FTR Gas insert without combustion chamber for Ecomax...

Page 11: ...integrated combustion chamber 4 5 With swirl plate and ceramic combustion chamber Ceramic ECOMAX M 1 3 With mixing fun nel and ceramic combustion chamber Metallic 4 6 With swirl plate and ceramic combustion chamber Metallic ECOMAX FTR 1 3 With mixing fun nel and ceramic combustion chamber Metallic 4 5 With swirl plate and ceramic combustion chamber Metallic ...

Page 12: ...towards the tip of the burner Some of this air is fed into the inside of the burner where it combusts in the first combustion stage The rest of the combustion air flows out through the gap between the combustion chamber and the recuperator head at high speed before combustion takes place in the second combustion stage here This process means that fewer pol lutant emissions are produced The hot flu...

Page 13: ...cast steel ribbed tube re cuperator Ecomax M or a metallic flat tube recuperator Ecomax FTR Selection is dependent on the type of heating and the furnace temperature Burner Furnace temperature C Heating direct indirect Ecomax C 1300 approx 1200 Ecomax M 1150 approx 1000 Ecomax FTR 950 approx 850 The max allowable temperature of the radiant tube must be observed ...

Page 14: ...iciency η Flue gas temperature on recuperator inlet C Cold air burner Burner Size Recuperator Output ceramic C metallic M metallic flat tube FTR kW Ecomax 0 25 Ecomax 1 36 Ecomax 2 60 Ecomax 3 100 Ecomax 4 180 Ecomax 5 250 Ecomax 6 500 available For operation with natural gas For operation with coke oven gas the output is approx 80 for operation with LCV gas approx 65 Precise dimensioning is avail...

Page 15: ... of the burners see page 14 Burner design refers to natural gas and LPG In the case of coke oven gas the output of the burners is reduced to about 80 higher outputs are only possible with higher supply pressure In the case of LCV gas the output of the burners is reduced to about 65 of the rated output 5 4 Burner length The burner length G should be selected so that the burner is flush with the ins...

Page 16: ...ng on the technical requirements for the process cool ing can be implemented in two stages Actuating the air valve for the burner terminal 22 initiates normal cooling actuating a second air valve for the additional cooling air connection initiates additional cooling The additional cooling air valve is actuated separately by the process control system For wiring on site we recommend using a BCU C w...

Page 17: ...666 ECOMAX 6 Differential air pressure measuring kit DA 1 on the ECOMAX burner 5 7 Differential air pressure measuring kit DA 2 with pressure switch The differential air pressure measuring kit DA 2 is used for the automatic monitoring of the air flow on the burner ECOMAX in conjunction with the burner control unit BCU 465 see page 24 Recommended burner control units The pressure switch monitors th...

Page 18: ...the factory Order No For burners 22800971 ECOMAX 1 2 22800972 ECOMAX 3 4 5 22800973 ECOMAX 6 5 8 Flue gas monitoring kit DW The flue gas monitoring kit DW with pressure switch is used in conjunction with the burner control unit BCU 465 see page 24 Recommended burner control units on ceramic radiant tubes for automatically checking for ruptures The pressure switch monitors the flow rate of air and ...

Page 19: ...ECOMAX Edition 02 11 19 When using the flue gas monitoring kit DW the fan pressure must be 10 mbar higher as the measuring orifice causes a pressure loss in the flue gas pipe Selection ...

Page 20: ... DA13 DA23 DW3 T3 S3 Z3 ECOMAX 0C ECOMAX 1C ECOMAX 2C ECOMAX 3C ECOMAX 4C ECOMAX 5C ECOMAX 1M ECOMAX 2M ECOMAX 3M ECOMAX 4M ECOMAX 5M ECOMAX 6M ECOMAX 1FTR ECOMAX 2FTR ECOMAX 3FTR ECOMAX 4FTR ECOMAX 5FTR 1 On request 2 Orifice size on request 3 If none this specification is omitted standard available Order example ECOMAX 3MB545 100P0DA1 t ...

Page 21: ...as LPG LCV gas 395 to 695 Burner length in mm 22 to 5002 Orifice for burner output in kW2 P03 Gas flange with purging air connection K3 Additional cooling air connection A3 Kanthal electrode DA13 DA23 Differential air pressure measuring kit Differential air pressure measuring kit with pres sure switch DW3 Flue gas monitoring kit with pressure switch T3 NPT connection S3 Spacer for SICAFLEX flame t...

Page 22: ...rmore we recommend using bend resistant Kanthal electrodes for ignition standard with ECOMAX C in this case We recommend the UV sensor UVS 10D1 with integral purging air connection Order No 84315202 for burner length 545 For burner lengths greater than 545 mm and for burner size Ecomax 0 the UV sensor UVS 10L1 Order No 84315203 with lens is required For attaching the UVS 10 an adapter set Eco UVS ...

Page 23: ...nected to the purging air connection on the gas flange next to the electrode or in the case of UV control to the purging air connection of the UV sensor The purging air is tapped upstream of the air control valve so that the purging air continues to flow even if the burner is switched off In order to limit the volume of purging air special nozzles can be used which are adjusted to the required air...

Page 24: ...n burner control units BCU 460 L 8 and BCU 465 L 8 On request we can also provide parameter lists for the pro grammable air supply and air post ventilation on the BCU 465 Heating Recommended burner control unit BCU 460 L 8 BCU 465 L 8 SER C ceramic radi ant tube 1 2 5 Metallic radiant tube 1 5 Direct 4 3 5 1 Pre purge is required following a false start in order to avoid damage to the radiant tube...

Page 25: ...s should have the same nominal size Use bends with the largest possible radii The pressure loss of the integrated orifice is approximate ly 10 mbar 6 4 1 Valves A slow opening and quick closing gas valve is to be used as an automatic shut off valve A quick opening and quick clos ing gas valve is to be installed as a second automatic shut off valve unless the relevant application standard allows us...

Page 26: ...ff 6 4 3 Air gas ratio control In order to ensure the required air gas ratio when equipping the burners with only gas and air valves without a pneumatic ratio control system precise control of the gas and air pres sures as well as monitoring of these pressures is necessary in accordance with the relevant standards e g EN 746 2 For pneumatic air gas ratio control we recommend the vari able air gas ...

Page 27: ... to pipework and valves are to be taken into consideration A quick opening quick closing air valve or solenoid actuator should be used Burner Air valve Butterfly valve so lenoid actuator Ecomax 0 VR 20 N Ecomax 1 VR 25 N Ecomax 2 VR 40 N Ecomax 3 VR 50 N Ecomax 4 VR 65 N Ecomax 5 BVHM 65 MB 7 VR N ECOMAX 0 ECOMAX 4 MB 7 BVHM ECOMAX 5 Other types of control on request Project planning information ...

Page 28: ...3 to 5 times as long as the nominal diameter of the connection must be provided up stream of the differential air pressure measuring kit DA 1 All valves and fittings should have the same nominal size and nominal connection diameter Use bends with the largest possible radii The pressure loss of the measuring orifice is approx 6 mbar A quick opening quick closing air valve or solenoid actuator shoul...

Page 29: ...n the height of the furnace extension so that the front edge of the recuperator is flush with the inside edge of the furnace lining S1 0 20 mm The FGT is to be insulated with Cerablanket or similar mate rial so that no hot furnace atmosphere reaches the furnace extension 6 6 1 For ECOMAX C S1 A P1 Furnace extension Flue gas guide tube FGT Burner FGT external A in mm ECOMAX 0C 140 ECOMAX 1C 180 ECO...

Page 30: ...MAX M S1 A P1 Furnace extension Flue gas guide tube FGT Burner FGT external A in mm ECOMAX 1M 133 ECOMAX 2M 156 ECOMAX 3M 193 ECOMAX 4M 254 ECOMAX 5M 287 ECOMAX 6M 390 Project planning information Flue gas guide tube FGT for direct heating ...

Page 31: ... tube 6 7 1 Ceramic radiant tube SER C for indirect heating Install the radiant tube free of mechanical stress Ensure that there are threaded bolts on the furnace flange to attach the ceramic radiant tube to the furnace Ensure that there is an annular gap of 20 mm between the radiant tube and the furnace lining The flange thickness P1 of the radiant tube SER C is either 32 or 37 mm depending on th...

Page 32: ...ifugal casting or in welded form The ef ficiency of the burner Ecomax M is determined by the internal diameter di of the radiant tubes in the vicinity of the burner The following dimensions are recommended Burner Radiant tube internal diameter di mm recommended min ECOMAX 1M 128 127 ECOMAX 2M 148 147 ECOMAX 3M 187 184 ECOMAX 4M 250 246 ECOMAX 5M 280 280 6 7 3 Radiant tube distances For furnace tem...

Page 33: ...metallic single ended radiant tubes The eductor ensures negative pressure in the radiant tube This prevents the inert gas atmosphere in the furnace being contaminated by flue gases from the burner in the event of leakage from the single ended radiant tube Gas Cold air Metallic radiant tube Flue gas ...

Page 34: ... system on the furnace should stop 10 mm away from the flue gas connector or be fitted flush with the eductor For indirect heating with flue gas monitoring kit DW and BCU 465 excessive negative pressure in the flue gas system or an excessively narrow flue gas pipe diameter on the fur nace can cause problems with setting the switching point of the pressure switch M Q 1 5Q 10 mm 5 1 5Q 2Q M 2Q Q 10 ...

Page 35: ...burner is adjusted based upon the negative pressure measured on the eductor If the furnace temperature is too high damage can occur to burners which are switched off due to the flow of hot flue gases over them For furnace temperatures 1000 C it is recommended that eductors with a mechanical flue gas valve AGK are used to avoid these excessive temperatures The flue gas system on the furnace should ...

Page 36: ... docu mentation to enable adjustment of the air and gas volumes thus changing the burner output accordingly 6 9 1 Differential air pressure measuring kit DA 2 with pressure switch The pressure switch should be set to approx 80 of the pres sure differential in normal operation Project planning information ...

Page 37: ...re 1150 C ECOMAX FTR metallic max application temperature 950 C Burner Output kW Flame length mm ECOMAX 0 25 250 ECOMAX 1 36 350 ECOMAX 2 60 450 ECOMAX 3 100 600 ECOMAX 4 180 800 ECOMAX 5 250 800 ECOMAX 6 500 800 Visible range for natural gas operation in the open air max connection rating and air index 1 15 7 1 Efficiency Heating direct Flue gas extraction 100 Lambda 1 1 Duty cycle 80 Diagrams fo...

Page 38: ... 100 200 300 400 500 600 700 800 900 400 500 600 700 800 900 1000 1100 0 100 200 300 400 500 600 700 800 900 1200 1300 1400 0 10 20 30 40 50 60 70 80 90 100 Efficiency Flue gas temperature C Air preheating C Cold air burner ECOMAX C Temperature on recuperator inlet C ...

Page 39: ... 100 200 300 400 500 600 700 800 900 400 500 600 700 800 900 1000 1100 0 100 200 300 400 500 600 700 800 900 1200 1300 1400 0 10 20 30 40 50 60 70 80 90 100 Efficiency Temperature on recuperator inlet C Flue gas temperature C Air preheating C Cold air burner ECOMAX M ...

Page 40: ...AX FTR 0 100 200 300 400 500 600 700 800 900 0 100 200 300 400 500 600 700 800 900 0 10 20 30 40 50 60 70 80 90 400 500 600 700 800 900 1000 1100 Efficiency Temperature upstream of recuperator C Flue gas temperature C Air preheating C Cold air burner ECOMAX FTR ...

Page 41: ... Edition 02 11 41 A1 F1 I 1 18 mm ECOMAX 0 14 mm M16 ECOMAX 0 M12 Q H1 T U J P K M A S1 C D G G1 J1 E B Technical data 7 2 Dimensions 7 2 1 ECOMAX C 8 mm X Y W 0 7 1 5 X B1 P1 W1 G C1 S1 D1 ECOMAX 0 3 30 mm t ...

Page 42: ...X 5C 336 273 95 298 95 695 R 1 345 920 98 DN 100 399 Type mm Weight4 U W3 X Y A1 B1 C1 D1 F1 G1 H1 I1 S1 kg ECOMAX 0C R 1000 2600 100 140 160 C1 n 250 50 30 90 182 210 S1 0 max 20 12 ECOMAX 1C R 1 142 182 280 200 30 330 90 236 290 20 ECOMAX 2C R 1 162 202 280 220 30 330 90 236 290 25 ECOMAX 3C R 2 202 242 325 260 30 385 90 280 330 33 ECOMAX 4C R 2 420 480 110 372 445 48 ECOMAX 5C R 2 420 480 110 3...

Page 43: ...tion 02 11 43 X Y W D1 0 5 1 5 X P1 G C1 S1 A1 F1 I 1 ECOMAX 0 14 mm ECOMAX 1 5 18 mm ECOMAX 6 23 mm M16 ECOMAX 0 M12 ECOMAX 6 M20 Q H1 T U J P K M A S1 C D G G1 J1 E B Technical data Dimensions 7 2 2 ECOMAX M t ...

Page 44: ...COMAX 6M 390 370 150 400 150 695 R 1 530 1177 137 DN 150 Type mm Weight T U A1 C1 D1 F1 G1 H1 I1 S1 kg3 ECOMAX 1M 331 R 1 280 C1 n 250 50 30 330 90 236 290 S1 0 max 20 35 ECOMAX 2M 331 R 1 280 30 330 90 236 290 48 ECOMAX 3M 353 R 2 325 30 385 90 280 330 58 ECOMAX 4M 399 R 2 420 50 480 110 372 445 93 ECOMAX 5M 399 R 2 420 50 480 110 372 445 105 ECOMAX 6M 598 R 3 690 50 740 150 550 650 228 1 Lengths...

Page 45: ...ECOMAX Edition 02 11 45 A1 F1 I 1 18 mm ECOMAX 0 14 mm M16 ECOMAX 0 M12 Q H1 T U J P K M S1 C D G G1 J1 E B A Technical data Dimensions 7 2 3 ECOMAX FTR X Y W D1 0 5 1 5 X P1 W1 G C1 S1 t ...

Page 46: ...45 70 ECOMAX 5FTR 399 R 2 420 50 480 110 372 445 74 1 Lengths 695 mm in 100 mm increments 795 895 995 mm etc additional lengths on request 2 545 595 645 or 695 mm 3 For length G 545 mm Type mm A B D E G1 J K M P Q ECOMAX 1FTR 133 109 212 60 545 6952 R 1 2 269 625 43 DN 50 ECOMAX 2FTR 156 128 212 60 545 6952 R 1 2 283 625 73 DN 50 ECOMAX 3FTR 193 164 262 83 545 6952 R 1 2 292 820 79 DN 65 ECOMAX 4F...

Page 47: ... 230 DN 32 269 6402 R 1 625 4152 43 ECOMAX 1 6201 R 1 2 5911 R 1 331 DN 50 269 6902 R 2 625 4302 43 ECOMAX 2 6201 R 1 2 7301 R 1 331 DN 50 283 7652 R 2 625 4662 73 ECOMAX 3 8201 R 1 2 7751 R 2 353 DN 65 292 7002 R 2 820 4952 79 ECOMAX 4 6601 R 3 4 8801 R 2 399 DN 100 353 8202 R 3 820 5452 98 ECOMAX 5 7001 R 1 7651 R 2 399 DN 100 345 8202 R 3 920 5452 98 ECOMAX 6 9901 R 1 598 DN 150 530 13752 R 4 1...

Page 48: ...ECOMAX Edition 02 11 48 8 Maintenance Twice per year but if the media are highly contaminated this interval should be reduced ...

Page 49: ... gasket as well as 4 threaded bolts washers and nuts for attaching it to the burner Order No on request 9 2 Flue gas eductor For direct heating The eductor generates a vacuum with a centrally positioned nozzle and thus draws the flue gases out of the furnace chamber through the burner s heat exchanger On burners with metallic single ended radiant tubes The eductor ensures negative pressure in the ...

Page 50: ...SER C 100 088 100 160 140 1000 2600 SER C 142 128 142 200 182 1500 2600 SER C 162 148 162 220 202 1500 2600 SER C 202 188 202 260 242 1500 2600 In 100 mm increments Other lengths on request Further information can be found in the Technical Information bulletin Ceramic radiant tube SER C Order No on request 9 4 SICAFLEX segmented flame tube For guiding hot flue gases in single ended radiant tubes F...

Page 51: ... achieve safe ignition and monitoring of the ECOMAX burner and to avoid condensation and overheating Nozzle Order number P2 set Eco 2 5 E 22801111 P2 set Eco 4 0 E 22801108 P3 set Eco 2 5 B 22801107 P3 set Eco 4 0 B 22801106 Suitable for burners see page 23 Purging air and cooling air Accessories ...

Page 52: ...hoose a product Planning To look for information My scope of functions Technical department Sales No answer Remarks Adobe Reader 7 or higher required www adobe com Contact Elster GmbH Geschäftssegment LBE Postfach 220327 42373 Wuppertal In der Fleute 153 42389 Wuppertal Germany T 49 202 60908 0 F 49 202 60908 20 info lbe online de www lbe online de www kromschroeder com The current addresses of ou...

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