Saacke SKV Com M

SKV Burners

For economic and environment-conscious combustion of all liquid and gaseous fuels, i.e. even super-heavy oils.

Combustion and Energy Systems

The SAACKE Rotary Cup Ato Where the combustion of liquid and

quality throughout the entire wide control

gaseous fuels makes high demands on

range. The combustion process is optimally

economy, operational reliability, range of

controlled by the accurate distribution of the

control, environmental consciousness and

combustion air as primary, secondary and

quality, SAACKE burners are first choice

tertiary air.

products. The well-proved rotary atomizing principle is the best condition for a perfect

The essential part of the rotary cup atomizer

combustion.

is its rotating atomizing cup. The liquid fuel is supplied into this cup almost without any

The basis of the SAACKE rotary cup burner

pressure. The centrifugal forces produced by

technology is the multi-stage rotation- and

rotation draw a wafer-thin homogeneous

air atomization with thermal support. The

and closed film from the entering oil flow.

result of this technology is a very fine oil

This film is then uniformly distributed on the

atomization with a narrow homogeneous

inside of the cup.

droplet spectrum and a constantly high When the fuel film leaves the cup rim, the existing surface tension makes that it is widened up into an extremely fine film mist. The primary air emerging with a high kinetic energy concentrically around the cup rim now carries out the final and essential part of the atomization. The result: optimum combustion.

No other burner system is able to burn super-heavy oils so efficiently.

omizer The Sectional View shows the principle of the multi-stage rotation- and air atomization of the SAACKE rotary cup atomizer.

The SKV-Low NOx Technolog

With its modular design, the SKV burner which is composed of optimally matched components offers not only an operatorfriendly concept but also easy service and maintenance and represents the actual state-of-the-art in firing technology. - The product range includes SKV oil burners, SG gas burners and combined burners of type SKVG - Capacity range 0.5 - 45 MW - Universally applicable for flame/smoke tube boilers, water tube boilers, thermal oil boilers, combustors and process engineering plants - Well-proved in land- and marine installations - Reliable, long-life SAACKE quality made in Germany - The modular design allows quick retrofitting for any other liquid or gaseous fuel. SAACKE burners are, therefore, a future-oriented investment allowing the operator to feel free and independent from supply- and price fluctuations on the fuel market.

Windbox / Gas ring burner / Secondary air distributing and feeding system with directional vane ring / Internal flue gas recirculation / Tertiary air distributing and feeding system / Outer air annulus ring - The combustion air guiding system based on many years of experience and recent research results obtained in the SAACKE fluidics lab allow easy and individual adaptation to any required plant operating conditions. - The precise air guiding and distribution system provides for controlled combustion in staged air streams and guarantees low values of NOx and solids content. - The adjustable air register consists of heat resistant CrNi-steel. It can be swung open thus allowing the access to the boiler. - The gas ring burner technology realizes cross-flow mixing with fuel-rich and fuel-poor zones on a large outlet diameter (low energy density). The result: a low-noise combustion well adapted to the boiler with very low NOx emissions.

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Burner swing-out assembly / Rotary atomizing cup and primary air fan with the common drive / Gas-electric or light oil-electric ignition - Optimum combustion with low excess air and small emission of solids due to a particularly fine and homogeneous rotary- and air atomization with thermal support = saving fuel costs and reducing the needs of boiler cleaning. - Constant low excess air, even at boiler loads of less than 20 %, technically possible by using the primary air as component of the combustion air with high mixing energy = increase of the boiler efficiency especially in partial loads - The rotary cup burner’s ability to fire any fuel of variable quality, viscosity and contamination = increase of reliability in operation. - Low pressure fuel supply, the central fuel feed to several burner plants through only one pump and strainer unit, the insignificant wear as well as easy access to the most important burner components when swinging the rotary cup atomizer open = reduction of maintenance cost to a minimum. - By its separate and monitored flame, the ignition burner for gas or light oil ensures absolutely safe, pressure-shock free ignition of the main flame.

SAACKE Compound regulation system /Actuating of rotary oil valve, gas control damper, primary- and secondary air dampers - By means of precise mechanics, the SAACKE compound regulator guarantees the reproducible, safe and almost hysteresis-free metering of fuel and combustion air or other additional flows. - All fuel and air flows can be set independently and modulating over the entire control range. - Power transmission is made via solid linkages and high-quality hinged bearings. This assures longtime constancy of the settings and highest liability of operation. - The electric servomotor (maintenance-free synchronous motor) with robust gear can be equipped with max. 4 limit switches and 4 signaling potentiometers for external functions.

Water injection system for the reduction of solids - In order to achieve an even higher burn-out of the heating medium “heavy fuel oil” and a reduction of the content of solids in the flue gases, water is added to the oil via nozzles before the oil enters the rotary cup atomizer. - The water finely distributed in the oil evaporates in the hot combustion zone immediately downstream of the outlet of the rotary cup which acts as an emulsifier. - The expanding water vapor makes that the atomized oil droplets are dispersed even finer so that the fuel oil - due to the larger surface - is burnt optimally and the content of combustible solids in the flue gas is reduced to a minimum. - This effect is further optimized by a chemical reaction, the “water-gas-reaction” which supports the burn-out of otherwise hardly combustible fuel components. Gas ring burner - The gas ring burner technology realizes cross-flow mixing with fuel-rich and fuel-poor zones on a large outlet diameter (low energy density). The result: a low-noise combustion well adapted to the boiler with very low NOx emissions.

Advantages of the rotary atomizing technology Economic * The large range of control minimizes standstill losses and extends the service life of the boiler. * Finest homogeneous atomization results in optimum combustion and reduces boiler fouling. * The constant low excess air, even at boiler loads down to 20 %, increases the efficiency of the boiler. * The speed control system (option) reduces the electric service costs. * The O2 control system (option) optimizes the efficiency of combustion.

Reliable in operation * For safe “starts from cold”, it is only necessary to provide for electric current as auxiliary energy. * The burner’s ability to fire on any fuel of differing quality, grade, pressure, viscosity, temperature or degree of contamination assures continuous readiness for operation. * The absolutely safe and pressure-shock free ignition (at low burner load) is always ensured by a separate and monitored ignition flame.

Environmental conscious * Emission values which are even lower than those specified by the stringent German emission regulations make proof of highest combustion quality. Oil operation: Low NOx and low solids content as a result of multistage rotation- and air atomization with thermal support. Gas operation: Low NOx as a result of gas ring burner technology with fuel-rich and fuel-poor zones on a large outlet diameter. * Emission minimizing measures can be integrated without problems. * A water injection system reduces the content of solids in the flue gas further without the need of an additional emulsifier.

The Technical Performances The rotary cup atomizer The high-precision atomizer has been designed on the basis of our latest researches and is manufactured with the highest possible accuracy. Its most characteristic features are: Rotary atomizing cup • computer-calculated geometry • optimally shaped cup rim • integrated pre-distributor • finest hard-chrome plated surface • inner air guiding • vibration-free running due to alignment to VDI 2060 Q 2,5 • uniform film formation and finest atomization are even assured for a long operation time when firing contaminated oil

Primary air fan, shaft and drive • integrated high-performance fan • pressurized primary air, high pulse for optimum combustion • precision-type shaft with ball- and roller bearings • long time lubrication even in standard design, small maintenance needs • in case of re-lubrication: over-greasing impossible • high-tech Poly-V drive with high efficiency (low heating), slip-free and long service life • maintenance-free three-phase a.c. motor which can be sized for all voltages and frequencies • the high-pressurized primary air in connection with the characteristics of the rotary atomizing cup results in high combustion quality even when firing superheavy fuel oils otherwise never achieved

Oil guiding system, oil valves • heated up to the oil outlet thus assuring safe start from cold • oil circulation up to the compound regulator, even in case of burner standstill • low-pressure system, only low oil pressure and low pre-heating temperature required • no hoses, only solid pipings • burner can be swung in open position without disconnecting the oil system, clean handling • labyrinth packing ring avoids surplus flow of oil • only one oil meter (low-pressure) required in the supply piping • oil valves TÜV-approved in compliance with DIN-EN regulations • robust, compact design of SAACKE valves of type ESV (optional), directly actuated, axial sealing, without control drillings • high pull-up capacity, no holding capacity, safe even in case of voltage drop down to 85 % • can be heated electrically The SAACKE know-how systematically developed and collected during decades makes proof especially in certain details which are not considered in other burner makes. The consequent attention given to all relevant facts ensures that SKV plants are firing systems with highest possible availability and reliability.

Compound regulator

Fan, windbox

The compound regulator is a SAACKE invention that is well-known since decades and is continuously optimized: • made of fluid- and wear-resistant special cast • oil flows for full load and small load can be set independently from each other • the oil flow for full load can be set individually by axial setting of the rotary valve when making full use of the setting angle thus making the compound regulator a valve with variable nominal bore ! • multilayer cam strips made of CrV-spring steel, cam blocks made of precision-fine cast • cam followers with needle bearings, clearance- and maintenance-free • radial adjustment of the cam followers to the cam strip by rotary seat, no mechanical overload • can be disconnected from the servomotor for commissioning purposes, with locking device • equipment with up to 3 cams of same design, e.g. for 2 air dampers and 1 gas damper

Fan • precise energy-saving design of volume and pressure in relation to the individual capacity requirements of the plant • efficiency of even more than 80 % • optimized course of characteristic curves adapted for large control ranges • stable, low-vibration design • reduction of vibrations by burner mounting on vibration dampers and vibration decoupling by means of separately delivered elastic connections to the windbox • selected special fan impellers and casings with well adapted design allow direct fitting to various windbox types • variable constructive types make it possible to assure the most favorable location in the plant, e.g. on the boiler, underfloor, separate installation place or room • compact, price-efficient design with disk-type sound absorber • corresponding to the most stringent noise reduction regulations • available with sound cabins or suction- or discharge-side sound absorbers (optional) • adaptation to all control-engineering variations such as swirl controller or speed control (optional) • for light oil/gas burners with flue gas recirculation for NOx reduction • flue gas recirculation fans in space-saving design with heat- and sound insulation • recirculation fans designed for highest thermal loads

Gas burner • possibility to burn gas of almost all grades, such as natural gas, propane or butane gas and even process gases and waste gases, etc. • combustion of gases having a very low heat value, furthermore co-combustion of waste gases is possible when main firing is assured with liquid fuel • simultaneous combustion of 2 gases • designed for large control range • absolutely flashback-proof thanks to the special design of the gas nozzles • requires only low gas pressure; operation, however, also possible with high gas pressure • design and equipment to German regulations DIN and DVGW • suitable for normal boiler brickwork, small mounting depth • gas ring made of steel of special resistance, cooled by the combustion air • front part lined with refractory material, Al2O3- content > 70 %, thus protected against flame radiation

Gas train • variably adapted compact gas trains, mounted ready for operation • in compliance with German Standards DIN and DVGW • assuring high safety: 2 safety shut-off valves • installation of the gas train adaptable to the local space conditions at and near the boiler • quality-assured, approved components • leak test system in connection with the SAACKE automatic sequence control system • design also possible for compatibility with automatic control systems of other manufacturers

Windbox • windbox for most favorable air directing with flow optimization • configurable for all plant specific requirements • durable surface protection by powder coating with well-defined coat thickness • integrated air dampers, both-side precisely supported without clearance, with optimum characteristic curve

Automatic sequence control system, control cabinet • oil-, gas- or combined oil/gas operation • approval to DIN EN 230 and DIN EN 298, CE approval no. to “Gas Appliances Guideline” • 72-hour operation without attendance according to TRD 604, Sheets 1 and 2, Section 5.4 • ignition by means of an ignition burner or direct ignition with ignition spark monitoring possible with suitable burner design • separately integrated safety circuits with connection terminals for safety elements “General”, “Oil” and “Gas” • integrated testing of the combustion air pressure monitor • integrated program- and start-up time monitoring • adjustable purge time • fully automatic control of the servodrive during the purge period • selectable running time of the servodrive • memory of collective trouble • integrated automatic leak testing system for the gas valves • interlock by external fault signal possible

• self-monitoring • thanks to the constructive design of the control system and various setting possibilities, the automatic sequence control system is suitable for almost all applications • plug-connections

Flame detection • type-certified flame detector, self-monitoring • high safety and long service life • 100 % inspected, especially for SAACKE • option: intensity indicator

Ancillary products, options Oil supply equipment Pumps and strainer group • low-pressure design, low noise, economic due to small current consumption and long service life • screw-type pump with integrated safety valve • compact unit with strainer or change-over strainer and valves and fittings • maintenance-free three-phase a.c. motor Preheater • efficient heat transmission to the counterflow principle • electric heating element (option) provides for a safe start of the burner plant if no steam or hot water are available as heating medium • TÜV-certified quality for highest operational reliability and service life • completely equipped with valves and fittings and control devices • extremely low power consumption thanks to the SAACKE rotary atomizing principle Pressure controller • available as inlet pressure controller (spill flow controller) or outlet pressure controller (pressure reducer), i.e. optimum design for the individual plant conditions • good control accuracy, low hysteresis • oil-hydraulically calculated special shaping of the control valves for large control ranges

Fuel

Capacity range (MW) Burner size Burner type

Heavy oil

SKV

Light oil

SKV

Gas

SG

Heavy oil/gas

SKVG

Light oil/gas

SKVG

2 gases

SGD

Heavy oil/2 gases

SKVGD

Light oil/2 gases

SKVGD

Integrated Management System IMS (Initial value signalling system for burner control systems) • freely configurable inputs 230 V a.c. for initial value-, fault- and operational messages as well as operating mode presettings • relay outputs for control-, pushbutton- and special functions (e.g. collective fault output) • all message texts are freely configurable • instructive texts (What to do ?) and measuring point designations (KKS standard or similar) can be allocated to the text of each message • freely configurable time display for every message (actual time, instant, timer function, without time) • the messages can also be issued, in parallel with the clear text display, to a PC, printer or via modem • the last 250 messages are stored • freely user-configurable LEDs as “flashing”, “continuous light” or “off” • control and diagnostic functions can be selected via convenient software menus • the inputs can be projected in operating current or closed-circuit current mode • initial value messages are acknowledged via the control keyboard or optionally via inputs also automatically • remote data transmission of the messages via modem is possible

Water - fuel mixing system for solids-poor combustion MEF When firing “heavy” fuel oil, the injection of a maximum of 10 % water upstream of the burner inlet provides for a higher burn-out. At the same time, the content of solids in the flue gases is considerably reduced. The water finely distributed in the oil evaporates in the hot combustion zone immediately behind the outlet of the rotary cup. By the expansion of the water vapor, the oil droplets are decomposed even finer. The heavy fuel oil burns optimally due to the developed larger surface so that the content of combustible solids in the flue gases is reduced to a minimum. In most cases, MEF replaces cost-extensive filtering equipment thus representing the more cost-effective and maintenance-friendly solution. Further advantages are: • unrestricted use of heavy fuel oils • injection of the water immediately upstream of the burner, controlled via 4 magnetic valves in dependence of the load demand • simple and reliable mode of operation • easy retro-fitting in existing plants possible • no costly emulsifiers required • simple commissioning, maintenance-friendly Separate water feed unit with pressure vessel and water centrifugal pump, completely piped on a base plate together with all necessary valves and fittings, with double protection against a possible return of fuel oil into the water supply system.

Burner control with a fail-safe Programmable Logic Control (PLC) Type HIMA / Siemens • oil-, gas- or combined oil/gas operation • operation of up to 4 burners • one- or two-burner parallel operation • hardware inspected by TÜV (Class 1-6 to DIN V 19250) • software in compliance with the binding regulations to DIN, TRD and VDE • integrated evaluation of initial value fault messages • initial values monitored on IMS display

Electric control plants • land installations • marine installations • SAACKE-own manufacture of electric control plants • own final inspection facilities • development and realization of user-defined solutions in electric and control engineering Options • Wiring of the burners on a common terminal box with high-temperature resistant cable

0.455 왔 1.7

0.57 왔 2.26

0.57 왔 3.39

0.68 왔 4.53

0.74 왔 5.66

1.13 왔 6.79

1.13 왔 9.055

1.36 왔 11.32

1.81 왔 16.98

2.26 왔 20.4

2.60 왔 22.6

2.83 왔 28.3

3.62 왔 33.9

3.96 왔 39.6

4.53 왔 45.3

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The SKV is able to burn any liquid or gaseous fuel

Oil burner SKV

Safe investments by modular design

The SAACKE SKV burner represents a future-oriented investment because even the standard burner can be applied universally and adapted to various individual operating conditions. Its modular design further allows quick conversion to any other liquid or gaseous fuel: even liquid or gaseous waste fuels or other problematic fuels can be burnt. The burner’s ability to fire on any fuel of differing quality, viscosity or contamination assures operational reliability at any time. In addition, SAACKE rotary cup burners give you the possibility to burn different liquid and gaseous fuels simultaneously. It is also possible to provide for operation with preheated combustion air thus reducing service costs considerably.

Gas burner SG

The SAACKE SKV makes you independent from fuel supply problems or abrupt changes of the energy markets.

Count on this Service SAACKE production sites and service stations in 22 countries worldwide, additional 70 international SAACKE contact offices, supply of spare parts in 24-hour service, repair and replacement around the clock... We help competently and immediately – wherever you need us. Diagnostics via thight-knit, worldwide Tele Support & Service and extensive capacities in maintenance, repair and spare parts logistics enable us to ensure your burners‘ trouble-free operations long after assembly and commissioning at site. Tele Support & Service

SAACKE‘s customers worldwide can rely on fast availability regarding repair and replacement of all SAACKE burners. SAACKE‘s service partnership includes at the same time – depending on the individual agreement – maintenance and operational optimisation of your burners, training of boiler room personnel, safety inspections according to TRD or complete boiler room management by our specialists. In line with our burner systems, we offer a wide choice of services to choose from at any time, according to your special requirements. Our service is geared to on aim: to secure the functioning of your burners for many years – economic, eco-friendly, reliable!

replaces external servicing in many cases.