Properly designed and installed burner tiles contribute to: 

  • Accurate metering of combustion air
  • Effective fuel-air mixing
  • Flame stability under various operating conditions
  • Flame shaping for optimal heat transfer
  • Emissions reduction, particularly for NOx and CO

Understanding the role of burner tile is essential for maintaining stable, efficient, and clean combustion. 

How Burner Tile Affects Burner Performance 

Metering the Combustion Air 

  • The throat of the burner tile is designed to allow a precise amount of air into the combustion reaction at a given pressure drop.
  • If the throat is too small, airflow is restricted, leading to incomplete combustion and higher CO emissions.
  • If the throat is too large, excess air enters the burner, reducing efficiency and increasing NOx formation.

Mixing the Air and Fuel 

  • Many burner tiles feature channels or zones that promote proper fuel-air mixing.
  • Good mixing is essential for complete combustion, preventing unburned fuel from exiting the burner and reducing emissions.
  • Poor mixing can lead to flame instability, increased CO emissions, and uneven heat distribution.

Maintaining Flame Stability

  • Once combustion is initiated, stability becomes a priority.
  • Burner tiles are designed with ledges and shoulders that create low-pressure areas to help anchor the flame.
  • The hot chamber effect created by the tile helps sustain combustion and prevents flame blowout.

Molding the Flame 

  • The burner tile helps shape the flame to ensure proper heat distribution inside the heater.
  • Burners can be designed with either flat flame or round flame patterns, depending on the heater configuration.
  • Proper flame shaping prevents flame impingement on tubes, which can lead to excessive tube metal temperatures and premature failure.

Minimizing Emissions

  • Burner tile design plays a major role in controlling NOx and CO emissions.
  • The tile’s contours and flow paths allow controlled fuel and flue gas interactions that reduce NOx formation.
  • Strategic placement of ledges and low-pressure zones helps to stabilize the flame and lower CO emissions.
  • Advanced burner tile designs, such as those found in low-NOx burner technology, optimize these features to meet stringent emissions regulations.

Effect on Operations 

Burner tiles that are incorrectly designed, installed, or maintained can cause: 

  • Flame instability, leading to poor heat distribution and operational inefficiencies.
  • Flame impingement on process tubes, increasing the risk of overheating and tube failure.
  • High emissions, resulting in regulatory compliance issues.
  • Poor air control, affecting burner efficiency and fuel consumption.

Proper burner tile installation and maintenance are key to avoiding these issues and ensuring long-term burner reliability. 

Corrective and Preventive Actions 

  • Always follow the burner manufacturer’s specifications for burner tile installation.
  • Refer to the burner drawing and installation manual to ensure correct dimensions and placement.
  • Verify tile position and throat size before turning the heater over to operations for start-up.
  • Regularly inspect burner tiles for cracks, erosion, or improper fit that may impact performance.

For expert guidance on burner tile installation and performance optimization, contact our experts.