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Duoblock (EN) 28-10-2013

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Duoblock burners for industrial and process-related installations Technical information EK-DUO 2-4 (600 kW – 16 000 kW) RPD 20-100 (500 kW – 45 000 kW) www.elco-burners.com

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Industrial burners as part of a comprehensive solution On track to success with ELCO Wherever large-scale power generation is needed, ELCO has a proven track record of being a partner you can depend on. Whether it involves the provision of a heating system for a major property development, thermal process engineering in industry, the production of process steam, or the use of special fuels, we will design, construct and install a tailor-made total solution in accordance with your specific requirements. Competent advice In the construction of large thermal installations: the road to success is mapped out from the very beginning. Competent advice is therefore of crucial importance. With over 80 years of experience as well as our own research and development, we have the know-how that you need to see your project come to fruition: from conceptual design, planning, project development and project management to commissioning and the provision of continuos service support for the installation throughout its entire life cycle. First-class products ELCO industry burners enjoy a first-class reputation. This is built on many years of experience from a wide variety of applications and methodical research and development. Whether the demands stems from extreme environmental conditions, such as those experienced on an oil rig in the Caspian Sea, to keeping pollutant emissions in a Swiss production facility to a minimum, renowned boiler and system manufacturers trust in our products and opt for the tailor-made engineering solutions of ELCO. Comprehensive system competency Our know-how spans the whole range of burner peripheral equipment. In addition to combustion engineering, wecover every aspect of measurement and control engineering for efficient, safe and permanently fault-free operation of your heating installation. Everything from one source and perfectly matched. Outstanding service As an ELCO customer, you can depend on your installation to perform reliably. Our guarantee is backed up by a service that sets standards in the industry. Contents Duoblock range: the basic concept EK-DUO range overview RPD range overview ELCO operations and Systems EK-DUO: technical data and overall dimensions RPD: technical data and overall dimensions 4 5 5 6 12 14

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Duoblock range The basic concept Benefits of a separately installed fan In contrast to monoblock burners, duoblock burners are made up of two units, or blocks, as the name implies: The burner head with the air inlet, and the separately-installed fan. The two units are connected via an air duct. The separate installation of the fan offers several benefits: • he fan can be installed in a separate room to the boiler, for instance in the cellar; this results in considerably t lower noise levels in the boiler room; • hen the fan is installed in the same room, a fan enclosure can be used to achieve optimum sound absorptiw on, without inhibiting access to the burner; • ess space required in front of the boiler/combustion chamber; l • ndividual fan layout with optimum adaptation of the fan characteristic curve to suit the pressure ratio of the i heat generator. This guarantees pulsation-free and stable burner behaviour, even on heat generators with high resistance on the exhaust side; • ombustion air can be preheated to increase installation efficiency; c • ower weight loading on the boiler front; l • ore direct access to the burner head. m Setting the flame configuration The air housings in the RPD duoblock burners are each fitted with adjustable air deflector plates, which can be used to swirl the combustion air flowing in from the sides. The flame configuration can hereby be directly influenced according to the geometry of the combustion chamber. Flame geometry Setting Flame formation formation Flame Angle of twist (°) Pressure loss (mbar) Air swirler Air swirler position position Position 1 (normal) POS 1 POS 0-201 Air swirler angle Air swirler 0 - 20° angle Pressure loss Pressure loss mbar 30 0 - 20° 30 mbar 30 l l d d Spindle-flame Spindle-flame Position 2 POS 2 POS 2 20-30 Air swirler angle Air swirler 20 - 40° angle Pressure loss Pressure loss mbar 38 20 - 40° 38 mbar 38 l l d dLong flame Long flame Position 3 POS 3 POS 3 Air swirler30-40 angle Air swirler 40 - 55° angle Pressure loss Pressure loss mbar 45 40 - 55° 45 mbar 45 l l d d Medium length flame Medium leng Position 4 POS 4 POS 4 Air swirler40-70 angle Air swirler 55 - 70° angle Pressure loss Pressure loss mbar 55 55 - 70° 55 mbar 55 l l d d Short flame Short flame

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Duoblock burners EK-DUO The EK-DUO models are high-performance burners offering well-engineered duoblock technology at an affordable price. The separate fan installation of the burner allows to overcome high combustion chamber resistance. These burners are predominantly used to burn standard fuels, i.e. domestic light oil and natural gas, and used in shell boilers, water tube boilers and thermal oil boilers. They reach a high control range of up to 1:8 with gas, 1:3 with oil, 1:5 with pressure atomisation and up to 1:5 with steam atomisation. For Low NOx requirements, the tried-and-tested Diamond burner head for gas burners or the Free Flame burner head for oil or dual fuel burner can be used. The fuel-air mixture is adjusted solely using a modern electronic compound controller. 0 2000 4000 6000 8000 10000 12000 14000 16000 EK-DUO 2.550 EK-DUO 2.700 EK-DUO 3.850 EK-DUO 3.1000 EK-DUO 4.1300 EK-DUO 4.1600 Duoblock burners RPD RPD burners are suitable for almost any firing-related task. In addition to the torsion apparatus integrated in the air housing for the secondary air, they also have a separate adjustment option for the primary air, and therefore offer many adjustment possibilities for influencing flame geometry and atomisation. Thanks to its flexible, modular design and the fact that it is based on a wide range of solutions that have proved effective in practice, RPD burners are used anywhere where complex tasks and high technical requirements demand customised heating installation solutions. Typical areas of use include: • burners for multiple gases and/or multiple liquid fuels; • use of fuels with low calorific values; • thermal disposal of gas or liquid substances; • thermal neutralisation of exhaust air; • pilot or auxiliary burners in waste incineration plants. Burner control regulation may be designed in accordance with the task and is, where possible, implemented via digital combustion manager as well as an electronic compound for a precise fuel-air ratio. For simpler tasks, mechanical compound systems are also available. Pre-heated combustion air can also be used in order to achieve greater energy-saving potential. 0 5000 10000 15000 20000 25000 30000 35000 40000 45000 50000 RPD 20 RPD 30 RPD 40 RPD 50 RPD 60 RPD 70 RPD 80 RPD 90 RPD 100 Special fuels and designs on request.

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ELCO operations and Systems EDP and RGC Systems Burners for multiple gases and exhaust air: processes and applications Modern disposal solutions with ELCO burner technologies In different production processes, some of the exhaust air formed contains liquid or gas residues. Modern waste incineration processes make it possible to dispose of these pollutants in an environmentally-friendly and costeffective manner. With the duoblock series, ELCO is offering technical solutions for optimum implementation of these disposal concepts. Thermal disposal In the picture it is shown a burner that channels contaminated N2 gas via a double-jacketed head directly into the combustion process, disposing of it thermally. At the same time, the hydrogen gas that is formed during the production process is used to generate heat. Hydrogen, coal gas or heavy oil (HFO) is used as the primary fuel. Furthermore, a liquid residue (glycol/ water mixture) is also burnt. Individual installation concepts are planned and implemented to suit the requirements of our customers. Gas 1 Gas 2 Primary air Secondary air Liquid fuel 1 Liquid fuel 2 Steam/air Offgas Mixing zone 1 Mixing zone 2 Mixing zone 3 Ignition and auxiliary firing for large boilers and process installations: cold or hot-air applications, liquid and/or gas-forming fuels. Illustration: Pilot and auxiliary burners for a waste vessel, cold-air design, heating oil fuel, with compressedair atomisation and high-voltage igniters with pneumatic feed apparatus. Functions: • ontrolled boiler start-up of approximately 4 hours for the purpose of warming up the entire system to >850°C; c • gnition of the waste fire once the waste has been introdued via the waste hopper; the radiant heat of the ignii tion burners ignites the waste; the burner remains in operation until the waste fire is able to maintain the combustion process of its own accord; • auxiliary firing during the waste operation if the boiler room temperature falls below the permissible level. 6

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ELCO operations and Systems GEM System Electronic burner control: high safety and low costs Digital combustion management, communication concept The use of digital technologies in burner control systems helps to reduce running costs, improve reliability of operation and lower pollutant emissions. The digital combustion managers used on ELCO burners are responsible not only for burner control (formerly the task of the traditional automatic combustion control unit) but also for fuel/ air regulation (formerly the task of the mechanical compound controller). Data stored electronically has replaced the mechanical characteristic curve and helps to achieve an unprecedented level of precision in air/fuel ratio regulation across the burner’s entire control range – a prerequisite for efficient as well as energy and cost-saving operation. Communication with central management systems is possible via the established bus protocol. Price advantage through integrated safety Safety chains, sensors and monitoring signals are arranged directly on the combustion manager, and servomotors, valves and frequency converters are controlled directly. This greatly reduces the costs associated with additional relays and wiring and keeps potential fault sources to a minimum. Integrated safety concepts, such as the automation of gas-valve leak monitoring, lower component costs and improve the operational reliability of the overall system. Other combustion-related functions that were previously fulfilled by separate devices may be integrated: • urner output regulator b • speed regulation of the combustion-air fan • operating hours counter • O2/CO regulation • start-up counter • interface with control technology • fault alert management Naturally, our combustion managers fulfil all relevant standards and regulations and are approved for intermittent and continuous operation. 20 16 1 2 18 10 3 11 12 19 7 6 5 15 14 4 13 9 17 8 20 1. SPS 2. Combustion manager 3. Display and operating unit 4. Laptop 5. Blast tube 6. Burner tube 7. Burner body 8. Secondary air connection 9. Servomotor 10. Extension equipment 11. Ignition burner 12. Nozzle rod assembly 13. Gas flap 14. Servomotor for gas flap 15. Oil regulation 16. Pump unit 17. Blower 18. O2/CO regulator module 19. Flame monitor 20. Gas regulation section 21. O2/CO probe 7

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ELCO operations and Systems GEM System Electronic burner control: high flexibility for precise and efficient processes Flexible operating modes with electronic compound For more complex tasks, digital firing managers offer various options. Depending on requirements, separate units are used here for digital burner control and electronic fuel-air regulation. Sliding fuel switchover If, for process-related reasons, the burner output may not be reduced during a fuel switch, the sliding fuel change can be used. During the switchover phase, the flow of the first fuel is reduced continuously and the second increased at the same rate until the change is complete. The sum of the two fuels during the switchover always amounts to the required burner output. Mixed firing If combustible residues and waste products are formed during production, it stands to reason that these should be disposed of in an environmentally-friendly, energy-saving and cost-effective manner in an existing heating installation. Usually, however, these waste fuels form in variable and insufficient quantities, so that it is only possible to use parallel multi fuel firing to form a main fuel. This kind of mix firing should be performed with an electronic compound controller, without laborious quantity measurements, in a fail-safe and tried-and-tested manner. User-friendly operation For burner commissioning and adjustments, the combustion manager is connected to a user-friendly or practiceoriented display and operating unit or to a PC. Menu-driven procedures guide the user safely and conveniently through the operating and commissioning process. Standby mode In the case of firing systems that frequently start and stop for process-related reasons, it may be logical not to shut down the burner completely, but to leave the ignition burner activated during breaks. This standby mode enables firing to start up immediately. Losses due to cooling are prevented. Freely-programmable burner controller In addition to the options described, ELCO also offers the burner control design as a freely-programmable system. The compound can be broken down electronically and the ratio controlled. Stud link position % 100 90 80 70 60 50 40 30 20 10 Air requirement Fuel 1 Fuel 2 Time t1: Δt2: t3: Δt4: t5: Δt6: t7: Process change of fuel signal reduction of gas output by the light oil basic load release of light oil valves sliding process for fuel flaps against one another in connection. Gas switches to the gas basic load, oil switches to the required output minus gas basic load gas valve shutdown oil simulates the missing output change completed t 0 10 t2 t1 t3 20 30 40 50 60 70 t4 t5 t7 80 90 100 110 120 t6 8

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ELCO operations and Systems GEM System O2/CO regulation: forever optimum O2/CO regulation for optimum combustion The efficiency of a heating installation is, to a large degree, contingent on the burner working with the optimum fuel/air ratio (λ). If the burner is supplied with too little air (λ<1), the proportion of flue gas made up of unburnt fuel particles in the form of CO, CxHy and soot increases sharply. Not only are these unburnt fuel particles harmful to the environment, they also contain latent heat, which is carried away from the combustion process. If the burner is supplied with too much air (λ>1), the proportion of unburnt fuel particles similarly increases. More notably, however, the surplus air in the heating installation is heated and leaves the plant through the chimney at an elevated temperature, literally blowing away the operator’s valuable energy reserves. For this reason, the goal of any burner calibration should be to set the air-to-fuel ratio no higher than is necessary. Nevertheless, a margin of safety has to be maintained because a number of disturbance variables have a bearing on the fuel/air mixture control process. These include: Air: • temperature • pressure • humidity Fuel: • calorific value • viscosity • pressure Contamination: • burner • boiler Mechanics: • hysteresis of the actuators Variations in air density alone –caused by temporary or seasonal weather changes– can have an effect on the O2/CO value of more than 1%. Every service engineer will therefore adjust the O2/CO value to such a level that, even in the worst conditions, emissions of CO, CxHy and soot remain within acceptable limits. The solution is provided by an O2/CO regulator, which measures the air surplus continuously and corrects the ratio to the stored setpoint value for each operating point. How an O2/CO regulator pays for itself The period in which investment in an O2/CO regulator pays for itself fundamentally depends on a range of system-specific factors. However, based on theoretical calculations and on comparison measurements carried out on completed installations, a potential saving of 1,0% to 1,5% of annual fuel costs can be considered realistic. Relationship between pollutant emissions and the efficiency of a heating installation Formation of soot, CO, CH Soot limit O2 λ opt Heat lost in flue gas η CO CH CO η O2 CH λ<1 λ=1 λ>1 9

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ELCO operations and Systems Variatron Speed regulation: noise reduction and energy saving Conventionally, the air in modulating burners is regulated by an air flap. In the partial load range, a large amount of the air pressure generated by the ventilator goes to waste. With speed regulation, the speed of the combustion-air fan is varied continuously depending on the burner output required. Full speed is reached only at maximum burner output. In the predominant partial load range, the lower speed translates into significant reductions in power consumption and noise emissions. Savings on electrical energy 120 A speed regulator makes it possible to conserve valuable electrical energy. Air flap regulation 100 The diagram compares the power consumption of a burSpeed regulation ner ventilator with speed regulation with a burner venti80 lator with air-flap control. In the medium output range, a saving of around 70% is achieved, decreasing at full 60 and low load. Therefore, the total savings over an operating year depends fundamentally on the load of the hea40 ting installation. For installations that are predominantly operated close to nominal output –mainly in the process 20 engineering industry– the achievable saving is likely to be relatively small. The majority of plants, however, make 0 10 20 30 40 50 60 70 80 90 100 great demands on the modulation range. Often, maxiBurner output (%) mum burner output is demanded for only a few hours a year. For the most part, these are outnumbered by the hours of operation under reduced load in which power consumption is significantly reduced by speed regulation technology. Energy savings of 40% - 50% have been proven in a real-world environment in plants with a conventional heat-demand pattern. Pre purging inhabit mode If one combustion chamber contains multiple burners, you can choose whether the burner should be started with or without preliminary air, depending on whether or not a burner is already in operation. Reduced noise emissions Where airflow is regulated by an air flap, not only does the air pressure generated by the ventilator go to waste, but this process and the subsequent collapse of pressure are, more particularly, accompanied by a certain amount of noise. The graphic shows the sound level curve for a burner with speed regulation and for a burner without. This real example demonstrates that, at approximately 50% burner output, a sound level reduction of around 7 dB(A) is achieved. To put this into context, the human ear perceives a 10 dB(A) increase in the sound level as being twice as loud. Power consumption (%) 90 Sound pressure level [db(A)] 88 86 84 82 80 78 76 74 72 20 30 40 Air flap regulation Speed regulation 50 60 70 Burner output (%) 80 90 100 10

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ELCO operations and Systems Diamond Head Diamond Head technology: low emissions and reliable operation Today, across almost the whole of Europe, national legislation places restrictions on the emission of environmental pollutants. Under particular scrutiny are nitric oxides, which are held to be the cause of acid rain and are subject to very strict limits. Nitric oxides form at high combustion temperatures. Thus, a cooling of the flame temperature through recirculation of already cooled flue gases has proven to be an especially effective measure for reducing emissions. The Diamond burner head has been specially designed with this principle in mind. At the chevron openings, flue gases are drawn out of the combustion chamber and into the mixing zone of the burner head where they are mixed homogeneously with the fuel and combustion air. The result is a uniform flame pattern with no temperature peaks and the lowest of nitric oxide emission values, compliant with limits anywhere in Europe. Free Flame Free Flame technology: the pinnacle of low-polluting burner engineering The greatest challenge in the development of a low-polluting burner is how to achieve compliance with emission limits during light oil operation. This is because the light oil has to be mixed homogeneously with the combustion air and the recirculated flue gas – and, for this to be possible, it must have evaporated as completely as possible before it has even been delivered to the flame. The Free Flame burner head provides an excellent solution to this problem. Atomised light oil is sprayed from the nozzle, evaporated in the evaporation and premixing zone and intensively mixed with the air and flue gas. Only then it is ignited. As a result, the flame burns homogeneously and without the temperature peaks that are conducive to the formation of nitric oxide. It does so forward of the burner head and not, unlike conventional burners, directly at the burner outlet. The flame is stabilised across the entire output range by a precisely defined swirl flow and, if necessary, by a pilot burner. 11

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EK-DUO Technical data Combustion type - = Standard U = Low NOx gas - Diamond Head U2 = Low NOx gas - Diamond Head UF = Low NOx light oil - Free Flame Range and type EK-DUO 2, 3, 4 Size Max power (kW) Fuel G = Natural gas GL = ual fuel (gas/light oil) D L = Light oil EK-DUO 3.1000 G - EU2 KN Operation R = 2 stage progressive mechanical E = 2 stage progressive electronic Combustion head KN = short KM = medium KL = long 0 2000 4000 6000 8000 10000 12000 14000 16000 18000 20000 kW EK-DUO 2.550 EK-DUO 2.700 EK-DUO 3.850 EK-DUO 3.1000 EK-DUO 4.1300 EK-DUO 4.1600 600 ... 6200 650 ... 7800 900 ... 9500 1000 ... 12000 1750 ... 13000 2000 ... 16000 Value dependent on design variant Model EK-DUO 2.550 EK-DUO 2.700 EK-DUO 3.850 EK-DUO 3.1000 EK-DUO 4.1300 EK-DUO 4.1600 Fuel Gas • • • • • • Gas/ Light Oil • • • • • • Light Oil • • • • • • Heavy Oil Gas/ Heavy Oil Operation Mechanical Electronic • • • • • • Gas • • • • • • Low NOx Light Oil • • • • • • Gas/ Light Oil • • • • • • 12

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EK-DUO B B1 Overall dimensions T3 (pilot burner extension lenght) B2 FL T1 T2 H H1 Ignition gas connection G1/2" Air connection flange FD Flange DIN 2633 Gas connection with 90° pitch, rotating Air connection with 45° pitch, rotating L2 L1 Details of boiler front plate 22,5° ° 45 M Model EK-DUO 2.550 EK-DUO 2.700 EK-DUO 3.850 EK-DUO 3.1000 EK-DUO 4.1300 EK-DUO 4.1600 Space requirements and dimensions L1 670 827 840 L2 340 386 440 K1 400 480 525 K2 600 690 725 M M12 M12 M20 K1 K2 Model EK-DUO 2.550 EK-DUO 2.700 EK-DUO 3.850 EK-DUO 3.1000 EK-DUO 4.1300 EK-DUO 4.1600 Weight* (kg) 320 ... 400 320 ... 400 400 ... 470 400 ... 470 400 ... 420 400 ... 420 Gas connection DN80 DN80 DN100 Space requirements and dimensions H 1241 1481 1491 H1 804 944 929 B 750 950 1000 B1 125 120 122 B2* 40 40 40 T1 255 290 420 T2 537 622 802 T3* FL* FD* 378 2005 ... 2150 320 ... 570 1810 ... 2390 350 ... 590 441 ... 456 2600 ... 2770 350 ... 620 506 *: value dependent on design variant 13

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RPD Technical data Fuel G = Natural gas F = Liquid gas GL = ual fuel (gas/light oil) D L = Light oil S = Heavy oil GS = ual fuel (gas/heavy oil) D Range and type RPD 20 ... 100 RPD 60 G - E KN Operation R = 2 stage progressive mechanical E = 2 stage progressive electronic Combustion head KN = short KM = medium KL = long 0 5000 10000 15000 20000 25000 30000 35000 40000 45000 50000 kW RPD 20 RPD 30 RPD 40 RPD 50 RPD 60 RPD 70 RPD 80 RPD 90 RPD 100 500 ... 3 300 669 ... 6 215 901 ... 8 230 1 400 ... 11 160 2 232 ... 15 418 3 000 ... 20 636 5 500 ... 34 500 7 000 ... 42 000 7 000 ... 45 000 Value dependent on design variant Model RPD 20 RPD 30 RPD 40 RPD 50 RPD 60 RPD 70 RPD 80 RPD 90 RPD 100 Fuel Gas • • • • • • • • • Gas/ Light Oil • • • • • • • • • Light Oil • • • • • • • • • Heavy Oil • • • • • • • • • Gas/ Heavy Oil • • • • • • • • • Operation Mechanical • • • • • • • • • Electronic • • • • • • • • • Gas Low NOx Light Oil Gas/ Light Oil 14

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RPD Overall dimensions B FL T R H2 H4 Air connection flange L1 Details of boiler front plate RPD 20 - 60 22,5° 22,5° 15° L2 H1 H3 FD RPD 70 - 100 15° Model RPD 20 RPD 30 RPD 40 RPD 50 Space requirements and dimensions L1 510 670 670 830 840 1026 1192 1390 1390 L2 316 410 410 506 560 690 790 832 832 K1 270 385 423 470 520 640 740 883 935 K2 500 790 790 990 1040 1200 1400 1750 1750 M M10 M12 M12 M12 M12 M12 M12 M12 M12 K2 K1 K2 K1 RPD 60 RPD 70 RPD 80 RPD 90 RPD 100 set screw M Model RPD 20 RPD 30 RPD 40 RPD 50 RPD 60 RPD 70 RPD 80 RPD 90 RPD 100 Weight* (kg) 300 ... 430 300 ... 430 350 ... 450 450 ... 600 500 ... 640 700 ... 900 900 ... 1200 1100 ... 1400 1150 ... 1450 Gas connection R2” R3” R3” R5” R5” R5” R8” R8” R8” Space requirements and dimensions H1 385 620 620 675 700 780 820 905 905 H2 265 373 373 475 497 580 675 850 850 H3 650 993 993 1150 1197 1360 1495 1755 1755 H4 425 650 650 740 825 900 1000 1100 1100 B 530 830 830 1030 1080 1240 1450 1800 1800 T 325 416 416 535 622 731 860 890 890 R 1265 1265 1743 1760 2010 2320 2720 2720 FL 250 317 442 370 312 469 600 810 810 FD 260 371 409 456 506 626 710 870 920 *: value dependent on design variant 15

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