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Metal Melting Furnace Controllers by Stiefel - Accurate Control of Temperature for Melting Operations

Stiefel’s metal melting furnace controllers incorporate advanced PID algorithm with other features such as multi-zone control guaranteeing +/− 2 degrees rapid response for furnaces reaching 1600 degrees. Allow integration with IoT for monitoring melt quality in real time.
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Benefits of Stiefeld’s Solutions for Furnaces Used for Melting Metals

Absolute Control and High-Temperature Precision

Stiefel prioritizes performance with his combustion systems for furnaces used for melting metals. They provide an adequate heat supply at 1,600°C and beyond. Inconel nozzle water-cooled industrial burners and combustion chamber ceramics face extreme furnace conditions in steel, aluminum, and copper melting units. For instance, a Chinese steel mill benefited from uniform heating at 1,500 degrees Celsius in their arc furnace with our 15MW oil burners. Their melt times improved by 18 percent while keeping a consistent temperature at ±5°C. The advanced PLC controllers can real time change air fuel ratios which shift the optimal combustion parameters for various types of metal and scrap.

Environmental Compliance Through Low Emission Combustion

We focus on sustainability concerning low emissions NOx burners for metal processing. Our staged combustion and FGR systems stick to strict requirements and lower NOX emissions to ≤50 mg/Nm³. For instance, a German aluminum smelter utilizing our gas burners was able to considerably reduce NOx emissions from 120 mg/Nm³ to 45 mg/Nm³. In heavy industry, the ability to use biofuels or hydrogen blends (up to 20%) helps meet decarbonization target plans.

Reliable Components For Heavy-Duty Applications

The Stiefel burners possess rugged components that have a long lifespan and work even during harsh conditions. sip cap two nozzles sharply resistant to wear. Their seal of Tungsten carbide also endure 3x better than general grade stainless steel nozzles in the furnaces of US copper refineries due to their sediment shredding metal vapors and slag. The ignition systems also reduce overheating glitches/outages by cam 40% due to their dependability under rife particles under a\high course pressure dust setting, heats to ATEX certification explosions proof ignition. During furnaces, blast meltz units are outfitted with coverards streams that endure ports corrosive and out perform, also losing the flue gas acids waste reaching uptore over 80% along the process, finishing with an overall system efficiency of 92% Custom customizable furnace, modules With Tailored Solutions Multi Classification. For hybrid burners revive directly fuel relying on auxiliary systems witd. stand 500kW-20MW Poweres

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Stiefel’s controllers improve the efficiency of metal melting by burner output control that is fuel temperature and metal load dependent. The multi-zone feature permits independent control of charge, melt, and superheat phases, achieving an 18% reduction in energy waste. In our implementation with an aluminum recycling plant, our controller improved metal melting rates by 20% with no change in how temperature was controlled, allowing for better metal purity and less dross. The HMI touchscreen displays real-time values of melt rate, fuel and emissions which is critical for lean manufacturing.

Frequently Asked Questions

Do Stiefel’s burners have the capability to withstand the high thermal loads during steel melting?

Yes, our burners can handle extreme temperatures since they are equipped with water cooled jackets and refractory linings that hold structural integrity at 1,600°C. A Japanese steel plant’s electric arc furnace uses our oil burners. To accomplish rapid melting of scrap steel, our 20MW oil burners are used with the electric arc furnace. Heats output stability also maintains consistent quality of the metal. Atomization of the fuel oil for heavy oils is done at high pressure (200 bar) through nozzles ensuring fine misting which enhances the fuel-to-slag ratio by 60%. Unburned carbon in slag is reduced by 60%.
Fuel consumption is reduced by 20-25%. In the case of a Turkish aluminum plant, $120,000 was saved annually on natural gas due to using our heat recovery system in their reverberatory furnace. Kas Technology’s heat recovery system also contributed significantly to the gas per year. This along with the VSDs for blowers reinforces their energy use during the low-load phases like furnace tapping and ladle heating.
Yes, our burner systems can be adjusted for oxygen enrichment to a maximum of 30% O2. This increases the melting rate and reduces energy consumption in high-purity metal production. A Swiss precision casting facility uses Stiefel’s oxygen-fuel burners to melt titanium alloys and achieves faster melting with minimal oxidation, yielding 8% better result while maintaining low NOx emissions.
We provide OEM-grade spares such as ignition electrodes and solenoid valves and these parts have 98% commonality with other major burner brands. Our global service team gives 24x7 remote diagnostics through IoT sensors that provide real-time data regarding problem detection like nozzle wear or coil overheating. A UK foundry reduced unplanned downtime by 65% with our Comprehensive predictive maintenance program.

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customer evaluation

Zhang Wei
High-Temperature Reliability for Our Steel Mill

Stiefel’s 15MW oil burners have been critical to meeting demands in our steel melting operations. The water-cooled nozzles and Inconel combustion chambers can endure daily 1,500°C heat and the exact temperature control contributed to 15% reduction in steel rework. The structure is low-NOx which enables us to comply with China’s environmental regulations.

Hans M.
Energy-Efficient Solution for Our Aluminum Smelter

Changing to Stiefel’s gas burners with heat recovery systems led to a 22% reduction in energy costs in our aluminum furnaces. The quick disconnect nozzles allows us to switch between scrap and primary aluminum melts and saves us countless hours of downtime. They are dependable and effective- metal processing will not be the same without these burners.

Maria G.
Durable Burners for Our Copper Refinery

Stiefel’s tungsten carbide nozzles have outlasted replacement for over two years in our copper refinery. This is in stark contrast to the standard nozzles with a six month lifespan. I have never been more comfortable because of the explosion proof ignition systems Stiefel offers in my high risk environment and the parts supply is unrivaled.

Akiko S.
Custom Oxygen-Fuel Solution for Specialty Metals

We co-developed an custom oxygen-fuel burner for our nickel based superalloy melting furnace with Stiefel. The castings made experienced a remarkable improvement due to their precise temperature control and ability to handle high oxygen concentrations. Their experts in material science and emissions control made all the difference.

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Advanced Heat Recovery Technology

Advanced Heat Recovery Technology

Stiefel regenerative systems capture waste heat for preheating air and water as well trimming energy costs for other processes, Strieveel’s solutions are proven to reduce expenditure. A Dutch steel foundry reported a stunning 12 month ROI on their heat exchanger investment.
IoT-Enhanced Efficiency Improvements

IoT-Enhanced Efficiency Improvements

Our burners are equipped with IoT capabilities to allow real-time monitoring of furnace functions, providing valuable insights. An Italian aluminum plant leveraged the data analyzing combustion efficiency to boost productivity without affecting the quality of the metal by reducing melt times by 12%.
Sustainability and Global Approvals

Sustainability and Global Approvals

Globally, our solutions are trusted with certifications such as CE, UL, ATEX, and CSA. Stiefel is a preferred partner for metal manufacturers in the EU Green Deal and US net-zero initiatives as our low-emission renewable fuel Capability fuels enables sustained emissions reduction supporting passer’s sustainability goals.