A Hot Gas Generator (HGG) is a system designed to efficiently transfer the thermal energy produced by one or more burners to a process air or gas stream, which is subsequently used in industrial applications such as drying, heating, curing, dehydration, mineral processing, building materials manufacturing, food processing, and many other thermal processes.
Our hot gas generator has the full capability to offer complete control and instrumentation systems to suit each customer’s requirement – from simple to very advanced and sophisticated controls. Temperature control loops, fuel ratio control loops, instrumentation for over temperature by stand alone instruments or PLC based SCADA software control systems are offered.
Capacidades
From 0.5 MMBTU/h to 300 MMBTU/h
Temperature range
From 212°F to over 932°F
Types of combustion
Direct and indirect
Settings
Horizontal or vertical
Compatible fuels
Natural gas, LP gas, diesel, biogas, process gases, and alternative fuels
Industries
Food, chemicals, mining, cement and construction materials, paper, and general manufacturing
Control and automation
PLC, HMI, SCADA, remote monitoring, and process data logging
Hot gas generators can be designed in either vertical or horizontal configurations and can operate under different heating principles.
Direct-fired systems
Combustion products are mixed with the process air stream to maximize thermal efficiency.
Indirect-fired systems
Utilizing heat exchangers can be employed, keeping combustion gases completely separated from the process air.
The combustion system can be adapted to the specific needs of each application, incorporating nozzle-mix burners, premix burners, air-stream burners, or specialized combustion technologies focused on emissions control, energy efficiency, and temperature uniformity.
Our hot gas generators are custom-engineered for each application, optimizing critical variables such as operating temperature, airflow, temperature uniformity, combustion efficiency, available installation space, and ease of maintenance.
Hot Gas Generators (HGGs) stand out for their ability to adapt to a wide variety of industrial processes, providing a reliable, efficient, and controlled source of thermal energy.
Every process presents unique operating conditions. For this reason, hot gas generators can be configured in either horizontal or vertical arrangements, adapting to space constraints, maintenance requirements, and installation conditions at each facility.
Hot gas generators can be designed to handle anything from small airflow requirements to large-capacity systems for high-production industrial processes, while maintaining uniform temperature and airflow distribution.
One of the primary design objectives is to achieve homogeneous temperature distribution throughout the air stream. This improves final product quality, reduces process variability, and increases operational repeatability.
Through proper combustion system design, mixing chamber engineering, and optimized airflow distribution, available thermal energy can be utilized more effectively, reducing fuel consumption and operating costs.
Compared with other industrial heating technologies, hot gas generators offer a highly competitive solution due to their operational simplicity, low maintenance requirements, rapid thermal response, and high efficiency.
Equipment can be engineered to integrate directly with dryers, ovens, conveying systems, curing chambers, production lines, and other industrial processes, minimizing modifications to existing infrastructure.
Because available space is often a significant constraint in industrial facilities, modern hot gas generators are designed to maximize thermal capacity while minimizing footprint, making them ideal for retrofit projects and plant expansions.
These systems are built for demanding industrial environments using high-quality materials and robust structural designs that ensure reliability, safety, and long service life under severe operating conditions.
Systems incorporate industrial safety devices and control philosophies designed to protect both personnel and equipment, including: flame supervision systems, pressure monitoring and control, automatic startup and shutdown sequences, temperature monitoring and diagnostic and alarm systems
Systems can incorporate different levels of automation, ranging from basic temperature control to advanced platforms featuring:
Depending on the application, hot gas generators can be designed to operate with a variety of energy sources, including:
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In the food industry, hot gas generators are used for drying and dehydrating agricultural products, grains, seeds, spices, fruits, vegetables, and processed foods. They are also employed in ovens, roasters, and air-conditioning systems where temperature stability is critical to product quality.
The chemical industry utilizes hot gas generators for drying powders, resins, fertilizers, pigments, chemical compounds, and various intermediate products. These systems provide precise temperature control, preventing product degradation and ensuring uniform processing conditions.
Drying processes for mineral concentrates, industrial sands, clays, carbonates, gypsum, bentonite, and other raw materials require large volumes of heated air. Hot gas generators provide a reliable and efficient thermal energy source for rotary dryers, fluidized beds, and other mineral processing equipment.
In the cement and construction materials industry, hot gas generators are used to dry raw materials, alternative fuels, aggregates, pozzolans, slag, gypsum, and other materials involved in the production process. They are also widely applied in the manufacturing of gypsum board, bricks, ceramic products, and refractory materials.
Paper and cardboard production require substantial thermal energy to remove moisture and condition products throughout various stages of the manufacturing process. Hot gas generators can be integrated into drying and air-handling systems to improve thermal efficiency and reduce operating costs.
Beyond the industries mentioned above, this technology is commonly used in metallurgy, automotive manufacturing, glass production, textiles, recycling, waste treatment, pharmaceuticals, and general manufacturing, where controlled hot air streams are required for heating or drying processes.
Hot Gas Generators (HGGs) are widely used in industrial processes where thermal energy must be transferred efficiently to a process air or gas stream. Their operating range can vary from low-temperature applications near 100°C (212°F) to processes requiring temperatures above 500°C (932°F), depending on the material characteristics and process requirements.
Their primary application is in drying, curing, dehydration, heating, and thermal conditioning operations. Due to their versatility, these systems are used across a wide range of industries, helping improve productivity, product quality, and overall energy efficiency.
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It is a system that efficiently transfers the thermal energy produced by one or more burners to a stream of air or process gas, which is used for drying, heating, curing, dehydration, and other industrial thermal processes.
In direct combustion, the combustion gases mix with the process air stream to maximize thermal efficiency. In indirect combustion, a heat exchanger keeps the combustion gases completely separate from the process air, which is ideal for applications where air purity is critical.
NUTEC Bickley manufactures hot air generators with capacities ranging from 0.5 MMBTU/h to 300 MMBTU/h, suitable for processes of any scale.
They can be designed to operate on natural gas, LP gas, diesel, specialty liquid fuels, biogas, process gases, and alternative fuels, depending on the requirements of each application.
They are primarily used in the food, chemical, mining, cement and building materials, paper, metallurgical, automotive, glass, textile, recycling, waste treatment, and pharmaceutical industries, among others.
From basic temperature controls to advanced platforms with industrial PLCs, HMI screens, SCADA systems, remote monitoring, integration with industrial networks, and process data logging and analysis.
We serve multiple industries through the design, building and installation of combustion systems, thermal insulation and highly specialized industrial furnaces, kilns and ovens. We are focused on understanding our customers’ needs and supplying the best equipment at the most competitive price.
In a major, high-value project – the second at this particular plant in Mexico – NUTEC Bickley will supply a 125m-long tunnel kiln to one of the world’s leading advanced ceramics manufacturers.
Explore NUTEC Bickley's latest innovative project, a highly flexible, energy-efficient shuttle kiln for the European sanitaryware sector.
NUTEC Bickley is in the process of transporting all modules of a 50m-long electric tunnel kiln to the advanced manufacturing facility operated by one of North America’s leading producers of ultra-high-purity alumina and associated products.
We offer specialized technical support and advice to ensure that you choose the solution that best suits your needs. Fill out this form or contact us to talk to us now.
Custom Furnaces and Kilns Manufacturer for Complex Thermal Challenges in North America
