around 46 MJ/kg

The specific calorific value of LPG is around 46 MJ/kg or 12.78 kWh/kg depending on the
composition of LPG
Calculate the energy required to heat up 50 kg of aluminium from 200C to
3000C. The specific heat capacity is 913 J/kg K.

q=mcΔT
where:
•q is the heat energy supplied in joules
•m is the mass of the object in kilograms
•c is the specific heat capacity of the object, here it's in joules per

kilogram kelvin
•ΔT is the change in temperature

Here, ΔT=3000∘C−200∘C=2800∘C=3073.15 K.
So, we get:
q=50kg⋅913 JkgK⋅3073.15K
=140289298 J
≈140.29 MJ
Now that's a lot of heat energy!
Hydrogen (H2) 120-142 MJ/kg
Methane (CH4) 50-55 MJ/kg
Methanol (CH3OH) 22.7 MJ/kg
Dimethyl ether - DME (CH3OCH3) 29 MJ/kg
Petrol/gasoline 44-46 MJ/kg
Diesel fuel 42-46 MJ/kg
Crude oil 42-47 MJ/kg
Liquefied petroleum gas (LPG) 46-51 MJ/kg
Natural gas 42-55 MJ/kg

One megajoule (MJ) is equal to 0.2777777777777778 kilowatt-hours (kWh). To convert

megajoules to kilowatt-hours, multiply the number of megajoules by 0.277777778. For
example, 10 megajoules is equal to 2.7778 kilowatt-hours.
Here, ΔT=200∘C−30∘C=2800∘C=170 K.
So, we get:
q=8000kg⋅913 JkgK⋅170K
=800 X 913 = 7304000 X 170 = 1241680000 J

≈1241680000/1000000 = 1241.68 MJ

So 1 LPG Gas Cylinder wait is 14 Kg

1 Kg – 46 MJ

So 1 Cylinder capacity will be = 644 MJ

=1241.68 / 644 = 1.92807 Gas Cylinder

For 5 Hours = 9.64037 Cylinder

So we Required 135 Kg For 5 Hours

Per Kg Rate is 65 Rs so for 8000 Kg for 5 Hours We

Required = 8773 Rs
One megajoule (MJ) is equal to 0.2777777777777778 kilowatt-hours (kWh). To convert
megajoules to kilowatt-hours, multiply the number of megajoules by 0.277777778. For
example, 10 megajoules is equal to 2.7778 kilowatt-hours.
So we required 344 Kw Burner mean 400 Kw Burner For Aging Furnce
Which Capacity is 8 Ton
Bloom Combustion (India) Private Limited
Block J-344, Near Quality Circle,
MIDC - Bhosari, Pune,
Maharashtra, India, PIN 411 026
T| +91-020-27130344
info.bloomindia@bloomeng.com
Recuperative versus regenerative burners
In order to boost efficiency, many industrial processes use heat recovery systems that will strip heat
out of the waste gases and deliver it back to the process. Cochran explains that recuperative
systems affect this heating by using an external (usually metallic) heat exchanger where the waste
gases flow through the hot side (thus cooling off) and the combustion air flows through the cold side
(thus accepting heat to return to the process). So, recuperative burners recover heat from the tube
exhaust and use it to preheat fuel gases. “For a regenerator, the waste gas and air alternately flow
through a common case of heat storing (often ceramic) material. As the waste gas passes through,
it gives up heat to the media, and when the air passes through later, it retrieves the heat and
brings it back into the process,” Cochran said.
Regenerative burners are alternately fired in opposite directions and discharge exhaust through a
refractory bed or case, which captures a large portion of the heat. When the refractory is heated,
the flow is reversed and the opposite end of the tube collects exhaust heat. The goal of both
regenerative and recuperative designs is to capture heat energy that would otherwise be wasted.
Last says that regeneration is extremely efficient and will cut most fuel bills in half. “Regeneration
is relatively costly, difficult to incorporate in a retrofit, difficult to incorporate in smaller furnaces,
and often more impactful is the amount of additional maintenance that is required. Recuperation is
simply using a heat exchanger in the waste gas stream. The combustion air passes through the
heat exchanger (recuperator), allowing the combustion air to preheat. Recuperation is very simple,
less expensive, smaller footprint, easier to meet temperature uniformity at lower temperatures,
easy to incorporate in a retrofit, and often will provide a fuel reduction of 30%.”
According to Roberts, the Eclipse SER V5 recuperative radiant tube burners from Honeywell
Thermal Solutions are well suited to retrofit burners and external recuperators in existing furnaces.
The SER V5 can be mounted in horizontal or vertical configurations and is suitable for either
continuous or batch type furnaces with a variety of atmospheres. For the direct fired side of heat
treating, Roberts said, the Eclipse TJSR V5 is a direct fired, self-recuperative burner with a space
saving, integral eductor that pulls the furnace exhaust through an internal ceramic recuperator. The
recuperator preheats the incoming combustion air to very high levels, which improves furnace
operating efficiency to reduce fuel usage by as much as 50% over typical ambient air burners.
Cochran says, “While the physical burner hardware (rightly) receives quite a bit of attention, Bloom
is making important contributions to the control of the system. One of our most innovative recent
developments has been to reinvent the control of a regenerative system. By fundamentally
changing some of the key components (physical and conceptual) in regenerative system control,
we have been able to increase fuel efficiency, boost productivity, and cut yield loss. We have
always been at the forefront of emissions reduction research, and many of our burner products
make use of technologies to reduce NOX emissions. In particular, our line of radiant tube products,
regenerative burners, and high thermal release (flat-flame) burners are some of the most advanced
in terms of emissions mitigations.”
In the most general of terms, industrial heat-treating chambers, which can be furnaces, ovens, or
kilns, there are two types: batch and continuous. Cochran explains the differences: “Batch furnaces
take a stationary load of material and put it through a thermal cycle. A continuous process takes a
load and physically moves it through a heating cycle. In the broadest terms, often batch processes,
such as aluminum melting furnaces, and forge furnaces, are good candidates for regenerative
systems. However, recuperative systems are common for many continuous operations, such as
steel reheat furnaces. In actual application, the distinction is not so clear-cut. Most applications,
Controlling burner operation
Controlling burners is actually done by controlling the ratio of fuel and air to them. While a thorough
definition of burner control can be extensive, Cochran provides a brief explanation: “A burner control
system provides the proper amounts of air and fuel for good combustion. Fundamentally, there are
two main ways, (with many variations) of controlling the air and fuel flows. First, a technique
generally called pressure balance modulates the flow of air, and then uses a pressure regulator to
permit a corresponding flow of fuel. The fuel flow always follows the air flow. The other major type of
system allows for independent control of air and fuel flows. This system uses an algorithm to
determine the flows of each, meaning that they can function somewhat independently of one
another. The flexibility of such a system means that it is more versatile and can handle a wide range
of process requirements.”
Last adds that recuperative and regenerative burners can be controlled in any manner that cold air
burners are controlled. As with cold air burners, the control style is determined by the application.
Last offers the following control application examples:
•Tight temperature uniformity, large temperature control ranges, and narrow firing lanes are some
reasons to consider pulse firing. Note that pulse firing consists of either high/low or on/off firing. The
decision between those two is primarily determined by the operating temperature range.
•Lower temperatures or incineration requirements are some reasons to consider fuel-only control.
•Higher temperatures are typically on-ratio. Very efficient and simple air primary control via a
modulated valve on the air with cross-connected regulators on the gas work well. Additionally,
single-zone applications often can incorporate variable frequency drives (VFDs) on the combustion
blower removing the valve/actuator setup and adding another level of efficiency.
•Tube fired burners would be high/low, on/off, and possibly pulse fired.