Combustion is an exothermic chemical reaction, which means that the process generates energy in the form of heat.
In industrial applications, this fuel is typically natural gas, which is primarily composed of methane (CH₄). When methane reacts with oxygen (air) and sufficient ignition energy is provided, it produces carbon dioxide (CO₂) and water (H₂O). However, what is truly valuable for industrial processes is the heat generated in the form of radiation and the hot gases produced by combustion.
Optimizing the combustion process means supplying the exact and correct amount of air and natural gas (or any other fuel). The importance of this lies in the fact that having an excess of either component leads to inefficiencies, which ultimately increase operational costs and negatively impact the process.
Calibrating a burner means adjusting the necessary elements within the combustion system to ensure that the air-to-fuel ratio remains as close as possible to the correct proportion.
Proper calibration of industrial burners directly impacts several areas of the process.
Correct calibration ensures optimal combustion, allowing the process to obtain the greatest possible amount of energy from the fuel.
Poor calibration can generate carbon monoxide (CO), a hazardous gas that can:
Unstable or excessively long flames can cause:
Generating more heat with the same amount of fuel helps reduce energy consumption and operating costs.
Excess air or fuel can affect product quality. For example, high oxygen levels at elevated furnace temperatures may cause premature oxidation in steel components.
Poor combustion performance directly affects process efficiency, causing energy losses, reduced thermal performance, and higher long-term operating costs.
It is essential to ensure that all physical components required for proper calibration are in place, as well as to verify the condition of the instruments and the reliability of the measurements being used.
Tip: Pressure gauges are critical, and it is very common for their importance to be underestimated in industrial plants.
It is important to confirm with the manufacturer the minimum pressure and flow requirements allowed for the burner.
Once these values are known, the air should first be adjusted to the minimum required level. Then, the fuel control element should be adjusted proportionally to supply the correct minimum amount of fuel relative to the air.
The maximum allowable air flow for the burner (as defined by the manufacturer) should be determined.
The air control element is then adjusted to achieve this flow, and subsequently, the fuel control element is adjusted to ensure the correct fuel-to-air ratio.
Must be ensured, and the flame should be visually verified to be stable.
In general, calibration of industrial burners is required across virtually all applications.
Processes such as drying, roasting, and dehydration:
Both OEMs and their supply chains
Processes such as melting, refining, and heat treatment:
Low-, medium-, and high-temperature processes across a wide range of industries and applications greatly
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.
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