Selection of the proper burner tile design and material requires knowing the operating temperature profile and thermal boundary conditions to ensure optimum performance.
A refractory burner tile is an essential component of a burner in a thermal processing system. Equipment downtime due to faulty operation of the burner tile can result in lost production with associated costs, which can far exceed the price of the burner equipment. Burner design has changed over the past 20 years due to increasingly stringent environmental regulations, leading to a compromise between efficient mixing of fuel and oxidizer and the need to reduce total fuel consumption and pollutant emissions, which requires moderately low flame temperatures to reduce NOx. Design strategies have led to the development of custom solutions for specific applications, including sophisticated burner designs using complex shaped tiles. For example, Fig. 1 shows a low-emission flat-flame burner consisting of a complex tile shape with sharp edges, nonuniform wall thicknesses and additional fuel jets to reduce NOx. The design is used to control a precise fuel oxidation process . Burner-tile refractory material requirements and evaluation methods, as well as effects of different refractory binder systems are discussed in this article.