Thermal storage burner in the long-term high temperature use process, may produce the following effects and countermeasures, which need to be comprehensively analyzed from the aspects of material properties, thermal efficiency, operation stability, etc.:

1.Material Performance Degradation

 1. Refractory Material Degradation

-Thermal Fatigue Cracks: Frequent thermal cycling (e.g., above 1200℃) causes uneven expansion and contraction of refractory linings, leading to cracking or spalling.

-Chemical Erosion: High-temperature furnace gases containing CO and H₂O may react with refractory materials (e.g., high-alumina bricks), reducing structural strength.

 -Solutions: Select materials with enhanced thermal shock resistance (e.g., silicon carbide composite refractories), and perform regular inspections and replacements.

2.High temperature creep of metal parts

-Burner shell or connectors (such as heat-resistant steel) may undergo plastic deformation under long-term high temperature, resulting in sealing failure or structural deformation.

-Countermeasures: Use nickel-based alloy or add cooling design (such as water-cooled sleeve).

II. Heat Efficiency Reduction

1. Heat Storage Blockage and Sintering

-Ceramic heat storage materials (e.g., honeycomb structures) may experience reduced specific surface area due to prolonged ash accumulation or high-temperature sintering (>1300℃), which can decrease heat exchange efficiency by 20%-30%.

 -Maintenance Recommendations: Perform regular reverse-blow cleaning to control flue gas dust content; select sinter-resistant materials (e.g., cordierite).

2. Gas Leakage

-Aging of high-temperature sealing materials may lead to air/gas leaks, reducing combustion efficiency and increasing energy consumption.

-Improvement Directions: Implement flexible sealing structures or dynamic compensation designs.

III. Operational Stability Issues

 1. Burner Coking and Carbon Build-up

-When fuel is incompletely combusted, high-temperature carbon particles tend to deposit in the nozzle, affecting flame morphology (e.g., uneven burning).

-Preventive Measures: Optimize air-fuel ratio (recommended 1.1-1.2) and perform regular ablation cleaning.

3. Control System Failure Risk

-High-temperature environments may damage sensors (e.g., thermocouples) or solenoid valves, causing abnormal switching cycles.

-Solutions: Use high-temperature resistant shielded cables and shorten maintenance intervals for critical components (e.g., every 3 months inspection).

IV. Escalating Safety Risks

1. Flameback or Detonation

-Prolonged high-temperature conditions may alter gas flow velocity and mixing characteristics, increasing flameback risks (particularly during low-load operations).

-Design Optimization: Install flame detectors and implement multi-stage safety interlocks.

2. Increased NOx Emissions

-Continuous high-temperature combustion (>1400℃) significantly boosts thermal NOx formation, requiring control through staged combustion or flue gas recirculation (FGR) systems.

V. Economic impact

-Increased maintenance cost: Frequent replacement of heat storage body or refractory materials may increase the annual maintenance cost by 15%~25%.

-Decline in energy saving benefit: If the thermal efficiency drops from 85% to 70%, fuel consumption will increase significantly.

Recommended maintenance strategies:

1. Regular inspection: Check the surface temperature distribution of burners by infrared thermal imaging every month.

2. Parameter monitoring: Record the changes of exhaust temperature and pressure difference in real time to warn the risk of blockage.

3. Life prediction: Establish the remaining life model of key components (such as heat storage body) and replace them in a planned way.

By material upgrade, intelligent control and preventive maintenance, the service life of burner can be effectively extended (usually designed life 5-8 years, optimized can reach more than 10 years).