Energy-Efficient Regenerative Combustion System

Application Scope

The regenerative combustion system works with non-ferrous melting, holding and heating furnaces. Its regenerators recover exhaust heat to preheat combustion air for melting and holding processes used in aluminum and zinc ingot, billet, sheet, wheel and die-casting production.

Overseas Project Support

For export projects, Lanyu can configure the regenerative combustion system around local fuel or power conditions, plant layout, automation level, operator workflow and environmental requirements. The system can be proposed for new furnaces or retrofit projects after checking furnace size, fuel conditions and existing burner arrangement.

For a faster technical proposal and quotation, please share:

• Furnace type, chamber size, operating temperature and target production rate
• Current fuel type, gas pressure and burner quantity
• Expected fuel-saving target or exhaust temperature target
• Existing control system, fan arrangement and available installation space
• Destination country and any local emission or safety requirements

Working Principle

The Energy-Efficient Regenerative Combustion System mainly consists of two burners (or 3, 4, 5, etc., multiple burners). Below is a detailed explanation of its working principle:

Workflow

1. Air Heating Phase

   • Ambient temperature air from the auxiliary fan is switched into Regenerative Chamber A via a diverter valve.
   • The air is rapidly heated by alumina balls in Regenerative Chamber A, reaching 800–900°C.

2. High-Temperature Air Injection

   • The heated high-temperature air is then injected at high speed into the furnace through the burner, creating strong flames.
   • High-temperature air mixes thoroughly with fuel, ensuring efficient combustion and intensity.

3. Exhaust Gas Handling Phase

   • Hot exhaust gases from the furnace exit through Regenerative Chamber B.
   • The high-temperature exhaust gases release heat in Regenerative Chamber B, heating the alumina balls to approximately 1000°C.

4. Low-Temperature Exhaust Emission

   • After heat exchange, the exhaust gases are typically reduced to 100–180°C before discharge through the diverter valve.

5. Heat Switching and Alternating Operation

   • When the regenerative media in one chamber reach their heat storage capacity, the diverter valve switches.
   • The two regenerative combustion chambers alternate between heat absorption and release, maintaining a continuous cycle for energy efficiency and reduced consumption.

Key Components

• Burner: Responsible for injecting high-temperature air-fuel mixtures to generate strong flames.
• Diverter Valve: Controls the direction of airflow and exhaust gas flow, ensuring effective heat recovery and utilization.
• Regenerative Chamber A: Used for storing and releasing heat to warm incoming ambient air.
• Regenerative Chamber B: Handles high-temperature exhaust gases from the furnace while releasing stored heat to maintain system temperature.
• Alumina Balls: Thermal-storage medium selected for furnace temperature and repeated heat cycling.

Energy-Saving Benefits

• Significantly improves combustion efficiency through effective heat recovery.
• Reduces fuel consumption and lowers operational costs.
• Exhaust gas temperatures are typically controlled at 100–180°C to reduce discharge heat loss.

The reversing regenerative sequence recovers heat from high-temperature exhaust and preheats combustion air to reduce fuel use and exhaust temperature.

Technical Features

• Switching Cycle: 30-120 seconds
  The system ensures efficient operation and heat recovery with its rapid switching capability.

• Exhaust Gas Temperature at Discharge: Typically 100–180°C, with a maximum of 200°C Low exhaust gas temperature complies with environmental regulations and reduces thermal energy waste.

• Energy Consumption per Ton of Aluminum Products: Up to 50 m³ per tonne, with energy savings above 50% compared with traditional combustion methods Significant reduction in energy consumption enables efficient and economical production.

• Flame Characteristics: Strong flames and stable combustion between intense and stable Combines high combustion intensity with stable operation for optimal performance.

Main Specifications

100MK, 200MK, 300MK, 400MK, 500MK, 600MK