Burner Types by Mechanical Structure
The physical construction of a burner dictates its installation footprint, maintenance ease, and capacity limit.
1. Integral / Monoblock Burners (Package Burners)
The most common design for small to medium commercial and industrial applications (up to ~20 MW).
Design
"All-in-one" unit. The combustion fan, motor, control panel, and valve train are often mounted directly on the burner housing.
Pros & Cons
- (+) Easy Installation: Bolt on, connect fuel and power, and run.
- (+) Compact: Small footprint.
- (-) Limitation: Fan size is limited by the weight the burner hinge/flange can support. Not suitable for very high capacities or high combustion air temperatures.
Typical Use
Packaged fire-tube boilers, small thermal oil heaters, bread ovens.
2. Split / Duoblock Burners
Standard for large industrial and utility scale applications (> 20 MW).
Design
The combustion fan is separate from the burner head. They are connected by a large air duct. The fan sits on the floor.
Pros & Cons
- (+) High Capacity: Fan can be as large as a room.
- (+) Preheated Air: Can handle hot combustion air (e.g., 200°C) from an air preheater, which would damage a monoblock's integrated motor/electronics.
- (+) Flexibility: Fan can be located in a sound-insulated room to reduce noise.
- (-) Cost: More expensive to install (requires ductwork, separate foundations).
Typical Use
Large water-tube boilers, power plants, district heating stations.
3. Modular / Line Burners
Used primarily for air heating applications.
Design
Constructed from modular sections (e.g., 1-foot straight sections, T-sections, crosses) that are bolted together to form a custom shape (like a grid) inside a duct.
Pros & Cons
- (+) Custom Geometry: Can be shaped to fit any duct size.
- (+) Uniformity: Distributes heat evenly across a large cross-section.
- (-) Application Specific: Only for low-pressure air heating, not for firing into a pressurized furnace.
Typical Use
Grain dryers, paint booth heaters, fresh air make-up units.