As a key component in industrial furnaces, the failure of regenerative burner may affect combustion efficiency, energy consumption and equipment life. The following is a systematic analysis of common failures and corresponding solutions based on technical principles and practical experience:
I. Ignition Failure or Unstable Flame
Cause Analysis:
1.Abnormal gas pressure (excessive/insufficient) -Check the pressure regulating valve and pipelines for blockages or leaks, then adjust to the design pressure (e.g., natural gas typically requires 20-50kPa).
2. Air-fuel ratio imbalance-Calibrate the flow meter, verify the proportional valve or PLC control parameters, ensuring the air-fuel ratio matches the fuel type (e.g., higher air ratio required for LPG).
3. Ignition electrode contamination or improper spacing-Clean carbon deposits on electrode surfaces and adjust spacing to 3-5mm (refer to equipment manual).
Solutions: -Use a multimeter to check ignition transformer output voltage (normal ≥10kV), replace aged electrodes.
-Install flame detectors (e.g., UV probes) for real-time monitoring and trigger alarm systems.
II. Heat Storage Body Blockage or Efficiency
Reduction Typical Symptoms:
-Increased flue gas temperature with uneven furnace temperature distribution
Root Causes:
1. Accumulation of dust or slag (common in metallurgical furnaces)
-Regular back-blowing of heat storage bodies (ceramic honeycomb or spherical packing), frequency adjusted according to fuel cleanliness (e.g., daily cleaning required for heavy oil combustion).
2. Heat storage body fragmentation-Use materials with better thermal shock resistance (e.g., cordierite or silicon carbide), avoid abrupt cooling/heating operations.
Optimization Measures:
-Install differential pressure sensors to monitor heat storage body resistance, automatically trigger maintenance alerts when exceeding set values (e.g., 2kPa).
III. Burner Head Damage or Deformation
Causes:
1. Local Overheating-Inspect the burner's cooling system (water-cooled or air-cooled) to ensure flow rate ≥ rated value (e.g., water flow 2m³/h).
2. Fuel Injection Angle Deviation-Adjust the burner's swirl vanes or nozzles to create a diffused flame pattern, preventing direct contact with furnace walls.
Preventive Measures:
-Use high-temperature resistant alloys (e.g., 310S stainless steel) or ceramic coatings to extend service life.
Conduct regular infrared temperature monitoring of burner surface temperatures.
IV. Abnormal Combustion Caused by Directional Control Valve
Malfunction Common Issues:
-Delayed directional switching, gas leakage, or jamming.
Troubleshooting Steps:
1. Electromagnetic Valve Inspection-Test coil resistance (normal range 20-50Ω), clean carbon deposits from valve core.
2. Cylinder or Hydraulic Drive System Maintenance-Replace seals, lubricate guide rails, ensure switching cycle ≤1 second. Upgrade
Recommendations:
-Implement dual electromagnetic valve redundancy design to avoid single-point failure; Install 0.5-1 second gas shut-off protection during directional switching.
V. Control system faults
Comprehensive countermeasures:
1. Abnormal PLC/instrument signals
-Re-calibrate thermocouples and oxygen sensors, check the anti-interference capability of shielded cables.
2. Incorrect parameter setting
-Check the combustion curve (e.g., air-fuel ratio in heating section needs dynamic adjustment), save backup parameters.
6. Other Notes-Seasonal effects:
Anti-freezing is required in winter (such as heating belt for cooling water pipes), and attention should be paid to electrical insulation when humidity is high.
-Energy consumption anomaly investigation:
If gas consumption increases suddenly, comprehensive inspection of heat storage efficiency, valve sealing and insulation layer condition should be carried out.
The above is the common failure and solution of regenerative burner. If the problem still exists, it is recommended to contact professional technicians for inspection and maintenance.
