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www.kromschroeder.com

Heat treatmentprocesses in the

ceramics industryEdition 09.09 GB


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2 Heat treatment processes in the ceramics industry Edition 09.09

Catalogue DVD with

Product Selection and

Docuthek

Spare parts list DVD

Innovation which pays offSaety, lower energy consumption and ac-tive environmental protection are issues outmost importance or operators o indus-trial kilns.

SafetyElster Kromschrder gas control and saetysystems oten do more to make industrialplants sae and to provide operating person-nel with optimum protection than is requiredby the relevant standards and regulations.

SystemsHigh quality in combustion processes is

achieved with adapted systems manu-actured by Elster Kromschrder. Field buscomponents with communication capabilitycontrol these systems.

Existing installations can thus be easily mod-ernised and extended at low cost.

Modular designThe specially coordinated product range o-ers excellent modular design options. Foryears now, we have been very successullytaking these important steps into the uture othe modular system in kiln engineering.

Gas typesAll Elster Kromschrder systems are suit-able or town gas, natural gas and LPG. Inaddition, we can supply a large assortmento reliable gas controls and burners or sew-age gas, landfll gas, biologically producedmethane, generator gas and coal gas.

Straightforward start-up proceduresElster Kromschrder systems are a key cost-cutting actor because they are easy to as-semble and install. Start-up procedures areaccordingly short and straightorward. Wealso oer special training courses or various

customer and product groups, should youwant extra support. Our competent ServiceTeam is also there to help.

Optimum price/performance ratio

Elster Kromschrder oers technically opti-mised concepts or your process engineer-ing applications in the ceramics industry witha avourable price/perormance ratio.

High availability thanks to rst-class serviceThe design and rugged construction o theElster Kromschrder kiln systems add up toa long service lie. Preventive maintenanceis essential or trouble-ree operation, highavailability and economy. This is why ourService Team oers you tailor-made main-tenance contracts.

Extensive technical documentationMultilingual leaets and operating instruc-tions, planning olders and KromschderSystem Technology manuals available inprint or on DVD make it easy or you tooperate products rom our diversifed range rom manual valves, gas flters and gaspressure regulators, etc. to complete sys-tems. You can download up-to-date ElsterKromschrder inormation rom the Inter-net at any time.

www.kromschroeder.comwww.docuthek.com

Roller hearth kiln

(Ceric Wistra works photograph)

Roller hearth kiln

(Sacmi works photograph)

Tunnel kiln

(Riedhammer works photograph)

Title page:

Conveyor kiln

(Riedhammer works

photograph)


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Heat treatment processes in the ceramics industry Edition 09.09 3

Heat treatment processes inthe ceramics industryKiln atmosphere andtemperature distributionUsing Elster Kromschrder impulse burn-ers with air/gas ratio control, it is possible

to achieve an homogeneous temperaturedistribution throughout the kiln atmos-

phere. Based on an efcient cross-current principle, our burners ensureoptimum mixing o gas and air.

Reduction systems

Reduction systems using Elster Kromschrderproducts allow low-pollutant production withuniorm colour range without the additionaluse o coal and minerals. With our availableknow-how and an extensive range o prod-ucts, we are capable o elaborating individualsystems.

Hot air compensationFlue gas temperatures must be kept aslow as possible i a gas-fred installationis to work with a high level o efciency.To do so, the heat in the ue gas can bereturned to the process by directing it through

heat exchangers in order to raise the tem-perature o the combustion air.

Elster Kromschrder can supply the neces-sary control valves or gas and air.

Competence in gas technologyOwing to the use o ultra-modern technol-ogies, Elster Kromschrder is an innovativepartner in the fne ceramics and heavy clayindustry.

We develop individual solutions in close co-operation with our industrial kiln builders.

Increase in efciency thanks to self

recuperative burnerBurners with integrated recuperator allowan energy saving o up to 30% due to airpreheating up to 700C.

They are used or direct heating or in con-junction with single-ended radiant tubes orindirect heating o kiln systems.

Lambda control and correctionElster Kromschrder demonstrates its valueas a competent partner in individual solu-tions be it or constant lambda correctionor as switchable oxidation/reduction cyclesin a burner control system.

Reduction system

High-velocity ceiling

burner

Overhead fring with

BIC burners

Controlled gas pres-

sure system

Roller hearth urnace

with sel recuperative

burners

Roller hearth kiln

(Inter Kilns Industry works photograph)

Roller hearth kiln

(Dum-Kilnogy S.A. works photograph)

Intermittent shuttle kiln

(Tagasago works photograph)


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Staged control(Impulse control)

The industrial kiln systems built or heavyclay production are mostly equipped withimpulse control.

With this type o control, the output impulserom the burner is strong enough to producea uniorm distribution o temperature in thekiln atmosphere and a good level o circu-lation.

A pneumatic air/gas ratio control system

oers maximum saety thanks to air defcien-cy cut-out. A constant lambda value is main-tained despite changing air pressures.

Staged control without a pneumatic ratio con-trol system oers the additional option ocentral lambda adjustment.

Roller hearth kiln

(Sacmi works photograph)

Tunnel kiln

(Instalat B.V. work photograph)

Intermittend shuttle kiln

(Riedhammer works photograph)


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Continuous controlIntermittent shuttle kilns and tunnel kilnsequipped with this control system are the low-cost solutions typically used in the productiono heavy clay and fne ceramics. Continouscontrol combined with hot air is used to reachvery high temperatures (e.g. engineeringceramics). Continuous control with a pneu-matic air/gas ratio control system oersthe advantage o a constant lambda valueover a broad control range with simultane-ous air defciency cut-out.

Continuous control o the gas ow rate at

constant air ow rate allows capacity ad-justment with virtually constant outlet velocityat the burner.

Continuous control with an electronic air/gas ratio control system allows optionaloperation with constant lambda value overa broad control range, capacity adjustmentwith virtually constant outlet velocity at theburner and individual control o required O2or CO atmospheres


(Keratek works photograph)

Roller hearth kiln

(Siti works photograph)


(Eisenmann works photograph)


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(Keramischer Oenbau works photograph)

Tunnel kiln

(Keller H,C,W works photograph)


(Riedhammer works photograph )

Important products for yourprocessPot burners BIC+SLGUsing Elster Kromschrder pot burnersprovides an homogeneous temperaturedistribution in reducing and oxidising kilnatmospheres.

Existing gas lances can be exchanged easilywithout additional installation eort. It is pos-sible to adapt the burners to any pot coveron the basis o the well-known Elster Krom-schrder high-velocity burners.

Annular excess air burners BIC+RSGRegardless o the control method be it im-pulse-controlled or modulating-controlled,the Elster Kromschrder annular excess airburner is designed or high-speed kilns withclosed combustion chambers.

The secondary air allows the ame tempera-ture to be matched to the kiln temperaturewith high burner impulse. The two-stagecombustion allows a broad control rangeboth in oxidising atmospheres and in reduc-

ing atmospheres. The secondary air injectionachieves short cooling times.

Excess air burner BIC..LThis burner can be ignited at all outputsettings over the entire control range. Theextremely high excess air reaching up toapprox. 1500% ensures a very high pulsemagnitude even at a low burner rating. TheBIC..L is thus ideal or applications requiringprecise temperature control and consistentproduct quality. The modular design meansthat it can be easily adapted to the kiln ge-ometry.

Self recuperative burner ECOMAX

Burners with integrated recuperatorECOMAX allow an energy saving o up to30% due to air preheating up to 700C. Theyare used or direct heating or in conjunctionwith single-ended radiant tubes or indirectheating o kiln systems.

Burner BIC with integratedreduction lanceThe time-tested Elster Kromschrder high-velocity burner can be ftted with an additionalgas lance and separate gas connection toorder. This lance allows it to be operated

with a very high excess gas or reductionprocesses.

Burner BICAThis BIC burner version with reduced weightis an ideal complement in the capacity rangeo tunnel and roller hearth kiln systems.

Ceramic tube sets TSCThe TSC ceramic tube set range covers allconceivable conditions o use. There aredierent versions or various ame shapes,capacities, ue-gas outlet velocities or ap-plication temperatures. Ceramic tubes haveproved their worth in the ceramics industrythroughout the world.

Insulation packageLong-lie burner insulation system to protectburners against aggressive kiln atmospheresand thermal load. This sturdy, patented sys-tem is directly mounted on new burners or

can be retroftted to existing installations. Suit-able or ceiling and side-wall mounting.


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(Eisenmann works photograph )


(Bricesco works photograph)

Tunnel kiln

(Lingl works photograph)

Valve series valVario

The new valve series valVario can be used orsaety, control and regulation purposes in airand gas supply systems to gas appliances.It can also be used or main gas control andsaety systems.

valVario is designed or a maximum inletpressure o 500 mbar and allows higher owrates with the same nominal size. The space-saving, compact design means that it is easyto install. On the standard version, the owadjustment can be checked using an indi-cator, whilst a blue LED is used to check theoverall unction. The device can also be ftted

with a position indicator or proo o closureswitch with integral visual indicator.

Actuators IC 20, IC 40Elster Kromschrder also makes a signifcantcontribution to the production o high-qualityproducts in the fne ceramics and heavy clayindustries by using high-quality kiln systems.This also includes actuators o the IC 20 andIC 40 series or direct mounting on butteryvalves BVG, BVA and BVH or gas, cold airand hot air up to 450C.

The basic unit, actuator IC 20, is controlledby a three-point step signal.

Due to its outstanding exibility, the IC 40 issuitable or various control types rangingrom continuous control to staged control.It can be parameterised using a PC with awide range o data being stored in a historystorage.

Lambda controls with linear ow control LFCThe ever more stringent requirements ap-plicable to the control quality o kiln at-mospheres necessitate high-quality butnevertheless low-cost regulating units. ElsterKromschrder linear ow controls o the newgeneration meet these requirements. Theycan be used optimally or wide lambda andcapacity ranges with continuous control oruninterrupted duty.

Automatic burner control units IFD 200

and IFD 400The IFD series are designed or directly ignitedburners in intermittent and continuous opera-tion. Flame control with ionisation signal orUV sensor. The burner status and the levelo the ame signal can be read directly romthe unit.

IFD 200 with one gas valve output; restartcan be activated on IFD 258. IFD 200-I withintegral, electronic ignition.

IFD 400 has 2 valve outputs and is suitableor multi-ame control. Restart available asan option.

Burner control unit BCU

The BCU series replaces the local controlcabinet. It unites the unctionally interrelatedcomponents o automatic burner controlunit, ignition transormer, operation-controlmodule or Manual/Automatic mode andoperating and ault diagnostic system in acompact housing. It is suitable or intermittentand continuous operation. Parameterisa-tion and extended diagnostics using the PCsotware BCSot.

BCU 370 or modulating-controlled orceddraught burners with activation signals orthe an and control valve and also with atightness control and Profbus-DP as op-tions.

BCU 440 or ionisation-controlled, single-stage burners with optimised connectionequipment or zonal wiring.

BCU 460, BCU 465 and BCU 480 or ionisa-tion- or UV-controlled burners with optionalProfbus-DP bus system.


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Elster Kromschrder GmbH

Postfach 2809 49018 Osnabrck

Strotheweg 1 49504 Lotte (Bren)

Germany

T +49 541 1214-0

F +49 541 1214-370

[email protected]

www.kromschroeder.com

www.elster.com

Kromschrder, a product

brand o the Elster Group

Copyright 2007 Elster Group

All rights reserved. 03250173

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