Burner Nozzle and Tip Set

Function

Atomisation quality directly controls combustion completeness. A well-functioning nozzle set produces droplets in the 50–100 micron range, yielding clean combustion with minimal carbon monoxide, soot and excess air. As nozzle orifices enlarge through erosion or partially block through carbon fouling, flame shape degrades — producing an elongated or irregular flame that impinges on drum internals, raises stack emissions, increases fuel consumption and imbalances the heat profile across the aggregate curtain. Timely nozzle replacement maintains design heat output, keeps stack emissions within permitted limits and prevents costly refractory burn-through at the drum entry zone.

Construction & quality

Nozzle bodies are machined from 316 stainless steel for corrosion resistance against fuel impurities and high-temperature oxidation at the burner throat. Swirl tip inserts are produced from tungsten-carbide alloy or hardened tool steel (60–64 HRC) to resist erosion from fuel-borne particulate. Orifice geometry is EDM-machined to ±0.02 mm bore diameter tolerance. All swirl chambers are ultrasonically cleaned and flow-bench tested against an individual flow-rate certificate before packing. Each kit includes high-temperature Viton O-rings and anti-seize compound for tip installation.

When to replace

• Visible carbon build-up on the tip orifice or within the nozzle swirl chamber.
• Irregular or pulsating flame observed through the burner sight glass at normal fuel pressure.
• Rising stack smoke opacity or CO alarm activation at the standard fuel-to-air ratio.
• Fuel consumption increasing without a corresponding rise in plant output tonnes per hour.
• Tip orifice measurably enlarged beyond ±0.10 mm of nominal bore when checked with a go/no-go gauge.