Gas burners – find manufacturers and suppliers

Gas burners generate heat for heating systems, industrial processes, thermal treatment operations and commercial applications through the controlled combustion of gaseous fuels.

Depending on the design, natural gas, liquefied petroleum gas, biogas, process gas or other suitable gaseous fuels can be used.
A gas burner combines fuel gas and combustion air in a defined ratio, ignites the mixture and produces a flame adapted to the respective application.
Gas burners are used, among other things, in boilers, furnaces, drying systems, melting plants, heat treatment equipment, commercial kitchens and workshop applications.
Depending on the application, they are available as atmospheric burners, forced-draught burners, premix burners, surface burners, industrial burners or compact hand-held and table burners.
The following provides an overview of typical designs, applications, advantages, limitations and important selection criteria for gas burners.

Types of gas burners

Atmospheric gas burners

Atmospheric gas burners use the pressure and flow of the escaping gas to draw in part of the required combustion air.
Additional air reaches the flame from the surrounding environment. A separate fan is not required for this type of burner.
Atmospheric burners are used, for example, in heating appliances, cooking equipment, laboratory devices and smaller commercial installations.
Combustion quality depends, among other factors, on gas pressure, air supply, burner geometry and ambient conditions.

Forced-draught gas burners

Forced-draught gas burners supply combustion air by means of a fan.
The gas and air volumes can therefore be matched precisely, allowing stable operation across different output ranges.
Forced-draught gas burners are commonly used on boilers, heat generators, drying systems and industrial combustion installations.
Depending on the design, they operate in single-stage, two-stage, progressive two-stage or modulating mode.

Premix burners

In premix burners, the gas and combustion air are largely mixed before leaving the burner.
The prepared mixture then burns on a burner surface or inside a burner head.
Uniform mixture formation can produce compact flames, even heat distribution and low emission values.
The design must reliably prevent the flame from flashing back into the mixing section.

Surface burners

Surface burners distribute the gas-air mixture across a larger burner surface.
Combustion takes place, for example, on metal fibres, ceramic surfaces, perforated plates or specially shaped burner elements.
Surface burners provide uniform heat output and can be used for direct heating, drying, coating or heat treatment.
The burner surface must be suitable for the required temperature, surface heat output and process atmosphere.

Infrared gas burners

Infrared gas burners heat a ceramic or metallic burner surface that emits a large proportion of the energy as thermal radiation.
The heat can therefore be transferred directly to workpieces, materials or product surfaces.
Typical applications include drying processes, paint and coating systems, food processing, shrinking operations and workplace heating.
Distance, alignment and shielding influence the heat distribution on the material being heated.

Industrial gas burners

Industrial gas burners are designed for defined thermal processes in furnaces, dryers, reactors and production systems.
They are available in different output ranges, flame shapes and installation positions.
Depending on the process, long or short flames, high flow velocities, intensive flue gas recirculation or particularly uniform temperature distribution may be required.
The design is often adapted to the specific installation, taking into account the combustion chamber, process medium, temperature and required controllability.

Single-stage and multi-stage gas burners

Single-stage gas burners essentially operate at a fixed burner output and are switched on or off according to heat demand.
Two-stage burners can change between a low and a high output stage.
Multi-stage designs allow better adaptation to changing load conditions and can reduce frequent switching cycles.
For processes with strongly fluctuating heat demand, continuously variable output control can be advantageous.

Modulating gas burners

Modulating gas burners continuously adapt their output within a defined control range to the current heat demand.
For this purpose, the gas and air volumes are adjusted together and monitored by a suitable burner control system.
Modulation can enable more uniform process temperatures, longer operating periods and more efficient plant operation.
The usable modulation range depends on burner design, combustion chamber, gas type and control system.

Single-flame and multi-flame gas burners

Single-flame gas burners produce one spatially concentrated flame.
They are used, for example, for localised heating, workshop operations, laboratory applications, cooking stations or smaller thermal processes.
Multi-flame burners distribute the heat across several burner openings and can heat larger or irregularly shaped areas.
Ring burners, line burners, oval burners and special designs are selected according to the required heat distribution.

Applications of gas burners

Heating and heat generation systems

In heating systems, gas burners generate heat for boilers, hot-air generators, thermal oil systems and other heat generators.
The burner output must match the output range of the heat generator and the resistance of the combustion chamber.
Coordinated control of the burner, boiler and heating system is essential for safe and economical operation.

Industrial furnaces and heat treatment systems

Gas burners heat industrial furnaces used for hardening, annealing, forging, sintering, firing and other heat treatment processes.
Depending on the process, high temperatures, defined heating rates or uniform temperature distribution may be required.
The flame must affect workpieces, furnace linings and the process atmosphere only in the intended manner.

Drying and coating systems

In drying systems, gas burners provide process heat for drying paints, coatings, building materials, paper, textiles, wood or agricultural products.
The heat can be transferred directly through hot gases or indirectly through a heat exchanger.
With direct heating, it must be determined whether combustion products are permitted to come into contact with the material being dried or with the process medium.

Metalworking

Gas burners are used for preheating, heating, flame straightening, soldering, melting and other operations involving metallic materials.
Flame output, flame shape and attainable temperature must suit the material and the processing method.
Uneven heating can cause distortion, internal stresses or changes in material properties.

Food processing and commercial kitchen equipment

In food processing and commercial kitchen equipment, gas burners are used for cooking, baking, roasting, grilling, flame treatment and heating.
Depending on the application, open flames, ring burners, line burners or indirectly heated systems are used.
Cleanability, material selection, ignition safety and uniform heat distribution are particularly important in these areas.

Construction sites and workshop applications

Mobile gas burners are used for roofing work, drying, shrinking, weed control, heating and other workshop operations.
Liquefied petroleum gas from cylinders or mobile supply systems is often used as the fuel.
Hoses, pressure regulators, connections and safety devices must be suitable for the gas type, operating pressure and conditions of use.

Laboratory and test applications

Small gas burners produce an adjustable flame in laboratories for heating, sterilising or processing samples and equipment.
Depending on the working environment, safety burners with flame monitoring and automatic gas shut-off may be required.
Use must be coordinated with ventilation, workplace design and the substances involved.

Advantages of gas burners

• Rapid provision of process and heating energy
• Direct or indirect heating possible
• Wide range of outputs and designs
• Good control of heat output
• Continuously modulating versions available
• Different flame shapes can be produced
• High process temperatures achievable
• Compact burner designs possible
• Operation with different gaseous fuels
• Integration into automated systems and control systems
• Uniform heat distribution with surface or multi-flame burners
• Mobile versions available for workshop and construction-site use

Limitations of gas burners

• Gas supply, gas pressure and burner must be precisely matched.
• Incomplete combustion can produce carbon monoxide, soot and other undesirable combustion products.
• An adequate supply of combustion air is required for operation.
• Flue gases must be safely discharged depending on the burner and application.
• Leaking gas lines or faulty fittings can create considerable safety risks.
• Ignition, flame monitoring and safety shut-off must operate reliably.
• Flames can locally overheat materials or products.
• Open burners are not readily suitable for explosive or highly flammable environments.
• Gas composition and calorific value can influence burner behaviour.
• Combustion noise and fan noise may require sound insulation measures.
• Contaminated burner openings or incorrectly adjusted air volumes reduce combustion quality.
• Maintenance and adjustment of many systems may only be carried out by qualified personnel.

Important selection criteria for gas burners

Gas type

The first step is to determine which gaseous fuel is to be used.
Natural gas, liquefied petroleum gas, biogas and process gases differ in calorific value, composition, density and required supply pressure.
The burner, gas valves, nozzles, seals and control components must be explicitly suitable for the intended gas type.

Burner output

The required burner output depends on the heat demand of the process or heat generator.
In addition to maximum output, the lowest continuously usable output must also be considered.
An oversized burner may cycle frequently or offer insufficient control. An undersized burner may fail to achieve the required temperature or heating time.

Turndown ratio

The turndown ratio describes the relationship between maximum and minimum burner output.
Where heat demand changes, a wide control range allows better adaptation to the process.
However, the minimum usable output may be limited by the combustion chamber, flue gas system and required flame stability.

Burner design

Atmospheric burners, forced-draught burners, premix burners and surface burners differ considerably in air supply, flame formation and possible applications.
The suitable design depends on output, combustion chamber, process, control requirements and available plant equipment.
For replacement purchases, installation dimensions, burner tube, flange and connection positions must also be considered.

Flame shape

The flame shape influences heat transfer and temperature distribution inside the combustion chamber.
Depending on the application, short, long, wide, rotating or highly directed flames may be required.
The flame must not strike furnace walls, heat exchanger surfaces, workpieces or sensitive plant components in an uncontrolled manner.

Combustion air supply

Sufficient combustion air must be available for complete combustion.
For atmospheric burners, the room air supply and installation conditions must be taken into account. Forced-draught burners require a suitable fan and defined air passages.
Changes in air pressure, contaminated air filters or blocked air inlets can affect combustion performance.

Gas pressure and gas train

The gas pressure available at the installation site must be within the permissible operating range of the burner.
The gas train may include filters, pressure regulators, valves, pressure switches, valve proving systems and other safety devices.
All components must be designed for the gas type, flow rate, pressure rating and required safety concept.

Ignition and flame monitoring

Gas burners require a reliable ignition system and suitable flame monitoring.
Ignition can be electric or provided by a monitored pilot burner, for example.
If no stable flame is detected within the specified safety time, the gas supply must be shut off safely.

Control system and interfaces

The burner control system coordinates pre-purging, ignition, gas release, output control and safety shut-off.
Analogue, digital or bus-capable interfaces may be required for integration into automated systems.
During selection, it should be determined which signals, operating states, fault messages and measured values must be transmitted to the higher-level control system.

Emissions

Depending on gas type, burner design and adjustment, combustion produces different emission levels.
Nitrogen oxides, carbon monoxide and unburned components in particular may be relevant to plant design and approval.
Required emission limits should be defined during procurement and verified under realistic operating conditions.

Process temperature and heat transfer

The required process temperature alone is not sufficient for selecting a burner.
Heating time, heat distribution, flow conditions, product distance and the type of heat transfer must also be considered.
For sensitive products, indirect heating or a larger burner surface may be preferable to a concentrated flame.

Combustion chamber and back pressure

The dimensions and flow resistance of the combustion chamber influence the selection of a forced-draught gas burner.
The fan must provide the required air volume even against the existing furnace pressure.
Manufacturer performance curves and information from the plant engineer should therefore be evaluated together.

Materials and ambient conditions

The burner head, burner tube, housing and seals must withstand the temperatures and ambient conditions encountered.
Moisture, dust, corrosive atmospheres, vibrations and strong temperature fluctuations may require special materials or protection ratings.
Additional requirements for cleanability and corrosion resistance often apply in food, chemical and outdoor applications.

Standards and conformity

Different legal requirements, technical rules and standards apply depending on the burner design and application.
For forced-draught gas burners, the requirements of EN 676 may be relevant. For gas appliances within the applicable scope, the provisions of the European Gas Appliances Regulation must also be considered.
Industrial process systems may be subject to additional plant, occupational safety and emission-related requirements. The required documentation should therefore be checked for the specific application.

Maintenance and spare parts availability

Gas burners must be inspected, cleaned and, where necessary, readjusted at regular intervals.
Easily accessible ignition electrodes, flame sensors, nozzles, filters and wearing parts simplify maintenance.
For continuously operated systems, spare parts availability, technical documentation and accessible customer service are important procurement criteria.

Summary

Gas burners burn natural gas, liquefied petroleum gas, biogas, process gas or other suitable gaseous fuels and convert them into usable heat.
Depending on the application, atmospheric burners, forced-draught burners, premix burners, surface burners, infrared burners or application-specific industrial burners are used.
Typical applications include heating systems, industrial furnaces, drying systems, metalworking, food processing, construction sites and laboratory workplaces.
The main selection criteria include gas type, burner output, turndown ratio, flame shape, gas pressure, combustion air supply, combustion chamber, ignition, flame monitoring, emissions and interfaces.
As gas burners are safety-relevant components, the burner, gas train, control system and plant must be coordinated and operated in accordance with the applicable requirements.

Gas burners are available from various manufacturers and suppliers. Comprehensive information about manufacturers and suppliers of gas burners from around the world can be found on Exportpages.