SKV Burners

For economic and

environment-conscious
combustion of all liquid
and gaseous fuels,
i.e. even super-heavy
oils.

Combustion and Energy Systems

The SAACKE Rotary Cup Ato
Where the combustion of liquid and
gaseous fuels makes high demands on
economy, operational reliability, range of
control, environmental consciousness and
quality, SAACKE burners are first choice
products. The well-proved rotary atomizing
principle is the best condition for a perfect
combustion.
The basis of the SAACKE rotary cup burner
technology is the multi-stage rotation- and
air atomization with thermal support. The
result of this technology is a very fine oil
atomization with a narrow homogeneous
droplet spectrum and a constantly high
No other burner system is able to burn
super-heavy oils so efficiently.
quality throughout the entire wide control
range. The combustion process is optimally
controlled by the accurate distribution of the
combustion air as primary, secondary and
tertiary air.
The essential part of the rotary cup atomizer
is its rotating atomizing cup. The liquid fuel
is supplied into this cup almost without any
pressure. The centrifugal forces produced by
rotation draw a wafer-thin homogeneous
and closed film from the entering oil flow.
This film is then uniformly distributed on the
inside of the cup.
When the fuel film leaves the cup rim, the
existing surface tension makes that it is
widened up into an extremely fine film mist.
The primary air emerging with a high kinetic
energy concentrically around the cup rim
now carries out the final and essential part of
the atomization.
The result: optimum combustion.
omizer
The Sectional View shows the principle
of the multi-stage rotation- and
air atomization of the SAACKE rotary
cup atomizer.
The SKV-Low NOx Technolog
With its modular design, the SKV burner which is composed of
optimally matched components offers not only an operator-
friendly concept but also easy service and maintenance and
represents the actual state-of-the-art in firing technology.
- The product range includes SKV oil burners, SG gas burners and combined
burners of type SKVG
- Capacity range 0.5 - 45 MW
- Universally applicable for flame/smoke tube boilers, water tube boilers,
thermal oil boilers, combustors and process engineering plants
- Well-proved in land- and marine installations
- Reliable, long-life SAACKE quality made in Germany
- The modular design allows quick retrofitting for any other liquid or gaseous
fuel. SAACKE burners are, therefore, a future-oriented investment allowing
the operator to feel free and independent from supply- and price
fluctuations on the fuel market.
Windbox / Gas ring burner / Secondary air distributing and feeding
system with directional vane ring / Internal flue gas recirculation /
Tertiary air distributing and feeding system / Outer air annulus ring
- The combustion air guiding system based on many years of experience and
recent research results obtained in the SAACKE fluidics lab allow easy and
individual adaptation to any required plant operating conditions.
- The precise air guiding and distribution system provides for controlled
combustion in staged air streams and guarantees low values of NOx
and solids content.
- The adjustable air register consists of heat resistant CrNi-steel. It can
be swung open thus allowing the access to the boiler.
- The gas ring burner technology realizes cross-flow mixing with fuel-rich and
fuel-poor zones on a large outlet diameter (low energy density). The result: a
low-noise combustion well adapted to the boiler with very low NOx emissions.
y

Burner swing-out assembly / Rotary atomizing cup and primary air SAACKE Compound regulation system /Actuating of rotary oil
fan with the common drive / Gas-electric or light oil-electric ignition valve, gas control damper, primary- and secondary air dampers

- Optimum combustion with low excess air and small emission of solids due to a - By means of precise mechanics, the SAACKE compound regulator
particularly fine and homogeneous rotary- and air atomization with thermal guarantees the reproducible, safe and almost hysteresis-free metering
support = saving fuel costs and reducing the needs of boiler cleaning. of fuel and combustion air or other additional
- Constant low excess air, even at boiler loads of less than 20 %, technically flows.
possible by using the primary air as component of the combustion air with high - All fuel and air flows can be set
mixing energy = increase of the boiler efficiency especially in partial loads independently and modulating over the
- The rotary cup burner’s ability to fire any fuel of variable quality, viscosity and entire control range.
contamination = increase of reliability in operation. - Power transmission is made via solid
- Low pressure fuel supply, the central fuel feed to several burner plants through linkages and high-quality hinged
only one pump and strainer unit, the insignificant wear as well as easy access to bearings. This assures longtime
the most important burner components when swinging the rotary cup atomizer constancy of the settings and
open = reduction of maintenance cost to a minimum. highest liability of operation.
- By its separate and monitored flame, the ignition burner for gas or light oil - The electric servomotor
ensures absolutely safe, pressure-shock free ignition of the main flame. (maintenance-free synchronous
motor) with robust gear can be
equipped with max. 4 limit switches
and 4 signaling potentiometers for external
functions.
 Water injection system for the reduction of solids
- In order to achieve an even higher burn-out of the heating medium
“heavy fuel oil” and a reduction of the content of solids in the flue gases,
water is added to the oil via nozzles before the oil enters the rotary cup
atomizer.
- The water finely distributed in the oil evaporates in the hot combustion zone
immediately downstream of the outlet of the rotary cup which acts as an
emulsifier.
- The expanding water vapor makes that the atomized oil droplets are dispersed
even finer so that the fuel oil - due to the larger surface - is burnt optimally and
the content of combustible solids in the flue gas is reduced to a minimum.
- This effect is further optimized by a chemical reaction, the “water-gas-reaction”
which supports the burn-out of otherwise hardly combustible fuel components.

Gas ring burner

- The gas ring burner technology realizes cross-flow mixing with fuel-rich and
fuel-poor zones on a large outlet diameter (low energy density). The result: a
low-noise combustion well adapted to the boiler with very low NOx emissions.
Advantages of the
rotary atomizing
technology

Economic

* The large range of control minimizes standstill losses

and extends the service life of the boiler.
* Finest homogeneous atomization results in optimum
combustion and reduces boiler fouling.
* The constant low excess air, even at boiler loads down
to 20 %, increases the efficiency of the boiler.
* The speed control system (option) reduces the electric
service costs.
* The O2 control system (option) optimizes the efficiency
of combustion.

Reliable in operation

* For safe “starts from cold”, it is only necessary to

provide for electric current as auxiliary energy.
* The burner’s ability to fire on any fuel of differing
quality, grade, pressure, viscosity, temperature or
degree of contamination assures continuous
readiness for operation.
* The absolutely safe and pressure-shock free ignition
(at low burner load) is always ensured by a separate
and monitored ignition flame.

Environmental conscious

* Emission values which are even lower than those

specified by the stringent German emission
regulations make proof of highest combustion
quality.
Oil operation:
Low NOx and low solids content as a result of multi-
stage rotation- and air atomization with thermal
support.
Gas operation:
Low NOx as a result of gas ring burner technology
with fuel-rich and fuel-poor zones on a large outlet
diameter.
* Emission minimizing measures can be integrated
without problems.
* A water injection system reduces the content of
solids in the flue gas further without the need of
an additional emulsifier.
The Technical Performances
The rotary cup atomizer
The high-precision atomizer has been
designed on the basis of our latest researches
and is manufactured with the highest possible
accuracy. Its most characteristic features are:
Rotary atomizing cup
• computer-calculated geometry
• optimally shaped cup rim
• integrated pre-distributor
• finest hard-chrome plated surface
• inner air guiding
• vibration-free running due to alignment to
VDI 2060 Q 2,5
• uniform film formation and finest
atomization are even assured for a long
operation time when firing contaminated oil
Primary air fan, shaft and drive
• integrated high-performance fan
• pressurized primary air, high pulse for
optimum combustion
• precision-type shaft with ball- and roller
bearings
• long time lubrication even in standard
design, small maintenance needs
• in case of re-lubrication: over-greasing
impossible
• high-tech Poly-V drive with high efficiency
(low heating), slip-free and long service life
• maintenance-free three-phase a.c. motor
which can be sized for all voltages and
frequencies
• the high-pressurized primary air in
connection with the characteristics of the
rotary atomizing cup results in high
combustion quality even when firing super-
heavy fuel oils otherwise never achieved
Oil guiding system, oil valves
• heated up to the oil outlet thus assuring safe
start from cold
• oil circulation up to the compound regulator,
even in case of burner standstill
• low-pressure system, only low oil pressure
and low pre-heating temperature required
• no hoses, only solid pipings
• burner can be swung in open position
without disconnecting the oil system, clean
handling
• labyrinth packing ring avoids surplus flow of
oil
• only one oil meter (low-pressure) required in
the supply piping
• oil valves TÜV-approved in compliance with
DIN-EN regulations
• robust, compact design of SAACKE valves of
type ESV (optional), directly actuated, axial
sealing, without control drillings
• high pull-up capacity, no holding capacity,
safe even in case of voltage drop down to
85 %
• can be heated electrically
The SAACKE know-how systematically
developed and collected during decades
makes proof especially in certain details which
are not considered in other burner makes. The
consequent attention given to all relevant facts
ensures that SKV plants are firing systems with
highest possible availability and reliability.
Compound regulator
The compound regulator is a SAACKE
invention that is well-known since decades
and is continuously optimized:
• made of fluid- and wear-resistant special cast
• oil flows for full load and small load can be
set independently from each other
• the oil flow for full load can be set individually
by axial setting of the rotary valve when
making full use of the setting angle thus
making the compound regulator a valve with
variable nominal bore !
• multilayer cam strips made of CrV-spring
steel, cam blocks made of precision-fine cast
• cam followers with needle bearings,
clearance- and maintenance-free
• radial adjustment of the cam followers to the
cam strip by rotary seat, no mechanical
overload
• can be disconnected from the servomotor for
commissioning purposes, with locking device
• equipment with up to 3 cams of same design,
e.g. for 2 air dampers and 1 gas damper
Gas burner
• possibility to burn gas of almost all grades,
such as natural gas, propane or butane gas
and even process gases and waste gases, etc.
• combustion of gases having a very low heat
value, furthermore co-combustion of waste
gases is possible when main firing is assured
with liquid fuel
• simultaneous combustion of 2 gases
• designed for large control range
• absolutely flashback-proof thanks to the
special design of the gas nozzles
• requires only low gas pressure; operation,
however, also possible with high gas pressure
• design and equipment to German regulations
DIN and DVGW
• suitable for normal boiler brickwork, small
mounting depth
• gas ring made of steel of special resistance,
cooled by the combustion air
• front part lined with refractory material,
Al2O3- content > 70 %, thus protected against
flame radiation
Gas train
• variably adapted compact gas trains, mounted
ready for operation
• in compliance with German Standards DIN
and DVGW
• assuring high safety: 2 safety shut-off valves
• installation of the gas train adaptable to the
local space conditions at and near the boiler
• quality-assured, approved components
• leak test system in connection with the
SAACKE automatic sequence control system
• design also possible for compatibility with
automatic control systems of other
manufacturers
Fan, windbox
Fan
• precise energy-saving design of volume and
pressure in relation to the individual capacity
requirements of the plant
• efficiency of even more than 80 %
• optimized course of characteristic curves
adapted for large control ranges
• stable, low-vibration design
• reduction of vibrations by burner mounting
on vibration dampers and vibration de-
coupling by means of separately delivered
elastic connections to the windbox
• selected special fan impellers and casings
with well adapted design allow direct fitting
to various windbox types
• variable constructive types make it possible to
assure the most favorable location in the
plant, e.g. on the boiler, underfloor, separate
installation place or room
• compact, price-efficient design with disk-type
sound absorber
• corresponding to the most stringent noise
reduction regulations
• available with sound cabins or suction- or
discharge-side sound absorbers (optional)
• adaptation to all control-engineering
variations such as swirl controller or speed
control (optional)
• for light oil/gas burners with flue gas
recirculation for NOx reduction
• flue gas recirculation fans in space-saving
design with heat- and sound insulation
• recirculation fans designed for highest
thermal loads
Windbox
• windbox for most favorable air directing with
flow optimization
• configurable for all plant specific requirements
• durable surface protection by powder
coating with well-defined coat thickness
• integrated air dampers, both-side precisely
supported without clearance, with optimum
characteristic curve
Automatic sequence control system,
control cabinet
• oil-, gas- or combined oil/gas operation
• approval to DIN EN 230 and DIN EN 298,
CE approval no. to “Gas Appliances
Guideline”
• 72-hour operation without attendance
according to TRD 604, Sheets 1 and 2,
Section 5.4
• ignition by means of an ignition burner or
direct ignition with ignition spark monitoring
possible with suitable burner design
• separately integrated safety circuits with
connection terminals for safety elements
“General”, “Oil” and “Gas”
• integrated testing of the combustion air
pressure monitor
• integrated program- and start-up time
monitoring
• adjustable purge time
• fully automatic control of the servodrive
during the purge period
• selectable running time of the servodrive
• memory of collective trouble
• integrated automatic leak testing system for
the gas valves
• interlock by external fault signal possible
• self-monitoring
• thanks to the constructive design of the
control system and various setting
possibilities, the automatic sequence control
system is suitable for almost all applications
• plug-connections
Flame detection
• type-certified flame detector, self-monitoring
• high safety and long service life
• 100 % inspected, especially for SAACKE
• option: intensity indicator
Ancillary products, options
Oil supply equipment
Pumps and strainer group
• low-pressure design, low noise, economic
due to small current consumption and long
service life
• screw-type pump with integrated safety valve
• compact unit with strainer or change-over
strainer and valves and fittings
• maintenance-free three-phase a.c. motor
Preheater
• efficient heat transmission to the counterflow
principle
• electric heating element (option) provides for
a safe start of the burner plant if no steam or
hot water are available as heating medium
• TÜV-certified quality for highest operational
reliability and service life
• completely equipped with valves and fittings
and control devices
• extremely low power consumption thanks to
the SAACKE rotary atomizing principle
Pressure controller
• available as inlet pressure controller (spill flow
controller) or outlet pressure controller
(pressure reducer), i.e. optimum design for
the individual plant conditions
• good control accuracy, low hysteresis
• oil-hydraulically calculated special shaping of
the control valves for large control ranges
Water - fuel mixing system for solids-poor
combustion MEF
When firing “heavy” fuel oil, the injection of a
maximum of 10 % water upstream of the
burner inlet provides for a higher burn-out. At
the same time, the content of solids in the flue
gases is considerably reduced.
The water finely distributed in the oil
evaporates in the hot combustion zone
immediately behind the outlet of the rotary
cup.
By the expansion of the water vapor, the oil
droplets are decomposed even finer. The
heavy fuel oil burns optimally due to the
developed larger surface so that the content of
combustible solids in the flue gases is reduced
to a minimum.
In most cases, MEF replaces cost-extensive
filtering equipment thus representing the more
cost-effective and maintenance-friendly
solution.
Further advantages are:
• unrestricted use of heavy fuel oils
• injection of the water immediately upstream
of the burner, controlled via 4 magnetic
valves in dependence of the load demand
• simple and reliable mode of operation
• easy retro-fitting in existing plants possible
• no costly emulsifiers required
• simple commissioning, maintenance-friendly
Separate water feed unit with pressure vessel
and water centrifugal pump, completely piped
on a base plate together with all necessary
valves and fittings, with double protection
against a possible return of fuel oil into the
water supply system.
Electric control plants
• land installations
• marine installations
• SAACKE-own manufacture of electric control
plants
• own final inspection facilities
• development and realization of user-defined
solutions in electric and control engineering
Options
• Wiring of the burners on a common terminal
box with high-temperature resistant cable
Integrated Management System IMS
(Initial value signalling system for burner
control systems)
• freely configurable inputs 230 V a.c. for initial
value-, fault- and operational messages as
well as operating mode presettings
• relay outputs for control-, pushbutton- and
special functions (e.g. collective fault output)
• all message texts are freely configurable
• instructive texts (What to do ?) and
measuring point designations (KKS standard
or similar) can be allocated to the text of
each message
• freely configurable time display for every
message (actual time, instant, timer function,
without time)
• the messages can also be issued, in parallel
with the clear text display, to a PC, printer or
via modem
• the last 250 messages are stored
• freely user-configurable LEDs as “flashing”,
“continuous light” or “off”
• control and diagnostic functions can be
selected via convenient software menus
• the inputs can be projected in operating
current or closed-circuit current mode
• initial value messages are acknowledged via
the control keyboard or optionally via inputs -
also automatically
• remote data transmission of the messages via
modem is possible
Burner control with a fail-safe
Programmable Logic Control (PLC)
Type HIMA / Siemens
• oil-, gas- or combined oil/gas operation
• operation of up to 4 burners
• one- or two-burner parallel operation
• hardware inspected by TÜV
(Class 1-6 to DIN V 19250)
• software in compliance with the binding
regulations to DIN, TRD and VDE
• integrated evaluation of initial value fault
messages
• initial values monitored on IMS display

Fuel Capacity range 0.455 0.57 0.57 0.68 0.74 1.13 1.13 1.36 1.81 2.26 2.60 2.83 3.62 3.96 4.53
왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔 왔
(MW) 1.7 2.26 3.39 4.53 5.66 6.79 9.055 11.32 16.98 20.4 22.6 28.3 33.9 39.6 45.3
Burner size 15 20 30 40 50 60 80 100 150 180 200 250 300 350 400
Burner type

Heavy oil SKV

Light oil SKV

Gas SG

Heavy oil/gas SKVG

Light oil/gas SKVG

2 gases SGD

Heavy oil/2 gases SKVGD

Light oil/2 gases SKVGD

The SKV is able
to burn any
liquid or
gaseous fuel

Oil burner SKV

Safe investments
by modular
design The SAACKE SKV burner represents a
future-oriented investment because
even the standard burner can be
applied universally and adapted to
various individual operating conditions.
Its modular design further allows quick
conversion to any other liquid or gaseous
fuel: even liquid or gaseous waste fuels or
other problematic fuels can be burnt.

The burner’s ability to fire on any fuel of

differing quality, viscosity or contamination
assures operational reliability at any time.

In addition, SAACKE rotary cup burners

give you the possibility to burn different
liquid and gaseous fuels simultaneously.

It is also possible to provide for operation

with preheated combustion air thus
reducing service costs considerably.
Gas burner SG

The SAACKE SKV makes you

independent from fuel supply
problems or abrupt changes of
the energy markets.
Count on this Service

SAACKE production sites and service stations in 22 countries

worldwide, additional 70 international SAACKE contact
offices, supply of spare parts in 24-hour service, repair
and replacement around the clock...
We help competently and immediately – wherever you
need us.

Diagnostics via thight-knit, worldwide Tele Support & Service and

extensive capacities in maintenance, repair and spare parts
logistics enable us to ensure your burners‘ trouble-free operations
long after assembly and commissioning at site.
Tele Support & Service
replaces external
SAACKE‘s customers worldwide can rely on fast availability
servicing in many cases.
regarding repair and replacement of all SAACKE burners.
SAACKE‘s service partnership includes at the same time –
depending on the individual agreement – maintenance and
operational optimisation of your burners, training of boiler
room personnel, safety inspections according to TRD or complete
boiler room management by our specialists.

In line with our burner systems, we offer a wide choice of

services to choose from at any time, according to your special
requirements.

Our service is geared to on aim: to secure the functioning of

your burners for many years – economic, eco-friendly, reliable!