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Messer Hardware

Oxipyr-technology for oxy-fuel combustion, Oxijet-technology for injection and enrichment

In heating-, melting-, refining-, purging- and calcination processes carried out in many different kind of furnaces, for the production of non-ferrous- and ferrous metals, glass, ceramic, mineral materials and many other purposes, it is often useful to inject oxygen or other gases or to use oxy-fuel combustion. Under the brand name Oxipyr and Oxijet, Messer has developed two equipment families for injection and combustion processes respectively units, aiming at a wide range of applications. The strengths of the Oxipyr- and Oxijet technology are high capacity, low downtimes, low emissions and flexible adaptation to different existing heating-, melting-, refining-, purging- and calcination processes.

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Oxipyr Burner Technology

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Oxipyr - F

For almost all combustion applications with gaseous or liquid fuels related to melting and heating processes

Power:                

50kW-5MW (turn down ratio > 1 : 10)

Feature:             

  • oxy-fuel, flameless (diluted) combustion,
  • high in-furnace off-gas recirculation
  • low flame peak temperatures, low NOx
  • homogenization of the furnace temperature
  • flame adjustable by manual change of natural gas nozzle

Fuel:                    

  • gaseous (natural gas, propane, butane, coke oven gas, …)
  • liquid (light oil, heavy oil, oil residues, …)

Oxidizer:            

oxygen

Applications:    

  • ferrous / non-ferrous industry for melting / heating
  • glass / refractory industry for melting / heating

Design tailor made for each costumer application:

  • free shaft length
  • connections
  • shaft protection
  • mounting fix / movable
  • with / without burner brick
  • ignition with integrated electrode /  separate pilot burner max 300kW
  • flame control by UV-cell
  • self-cooled / water-cooled / comp. air-cooled

        

Example of different Oxipyr-F burners

Oxipyr - F micro

For heating applications with gaseous fuels of troughs, channels and feeders

Power:                

2kW-100kW (turn down ratio > 1 : 10)

Feature:             

  • oxy-fuel, flameless (diluted) combustion,
  • high internal off-gas recirculation
  • low flame peak temperatures, low NOx
  • homogenization of the channel temperature

Fuel:                    

gaseous (natural gas, propane, butane, coke oven gas, …)

Oxidizer:            

oxygen

Applications:    

  • ferrous / non-ferrous industry for channel heating
  • glass for feeder heating

Design tailor made for each costumer application:

  • free shaft length
  • connections
  • shaft protection
  • with / without burner brick
  • flame control by UV-cell
  • self-cooled / water-cooled / comp. air-cooled

        

Example of Oxipyr-F micro burner for heating of various channels

Oxipyr - Flat

For melting and heating processes with gaseous fuels and flat-wide-flame requirement

Power:                

50kW-1MW (turn down ratio > 1 : 5)

Feature:             

  • oxy-fuel, flameless (diluted) combustion,
  • high in-furnace off-gas recirculation
  • low flame peak temperatures, low NOx
  • homogenization of the furnace temperature
  • flat flame due to arrangement of nozzles

Fuel:                    

gaseous (natural gas, propane, butane, coke oven gas, …)

Oxidizer:            

oxygen

Applications:    

glass for melting

Design tailor made for each costumer application:

  • connections
  • mounting fix with burner brick
  • with / without flame control by UV-cell
  • self-cooled / comp. air-cooled

  

Example of an  Oxipyr-Flat burner

Oxipyr - Flex

For almost all combustion applications related to melting and heating processes with gaseous or liquid fuels and flame adjustment requirements

Power:                

100kW-25MW (turn down ratio > 1 : 10)

Feature:             

  • oxy-fuel, flameless (diluted) combustion,
  • high in-furnace off-gas recirculation
  • low flame peak temperatures, low NOx
  • homogenization of the furnace temperature
  • flame automatically adjustable by cone movement

Fuel:                            

  • gaseous (natural gas, propane, butane, coke oven gas, …)
  • liquid (light oil, heavy oil, oil residues, …)

Oxidizer:    

oxygen

Applications:            

  • ferrous / non-ferrous industry for melting / heating
  • glass / refractory industry for melting / heating

Design tailor made for each costumer application:

  • free shaft length
  • connections
  • shaft protection
  • mounting fix / movable
  • with / without burner brick
  • gaseous-liquid fuel combination possible
  • ignition with integrated electrode /  separate pilot burner max 300kW
  • flame control by UV-cell
  • self-cooled / water-cooled / comp. air-cooled

  

    

Examples for Oxipyr-Flex burners

Oxipyr - Flex3

For almost all combustion applications related to melting and heating processes with gaseous or liquid fuels and flame adjustment requirements

Power:                

50kW-5MW (turn down ratio > 1 : 10)

Feature:             

  • oxy-fuel, flameless (diluted) combustion,
  • high in-furnace off-gas recirculation
  • low flame peak temperatures, low NOx
  • homogenization of the furnace temperature
  • flame automatically adjustable by ratio inner/outer oxygen

Fuel:                            

  • gaseous (natural gas, propane, butane, coke oven gas, …)
  • liquid (light oil, heavy oil, oil residues, …)

Oxidizer:    

oxygen

Applications:            

  • ferrous / non-ferrous industry for melting / heating
  • glass / refractory industry for melting / heating

Design tailor made for each costumer application:

  • free shaft length
  • connections
  • shaft protection
  • mounting fix / movable
  • with / without burner brick
  • ignition with integrated electrode /  separate pilot burner max 300kW
  • flame control by UV-cell
  • self-cooled / water-cooled / comp. air-cooled

     

   

Examples for Oxipyr -Flex3 burner

Oxipyr - P / P LON

For almost all combustion applications related to melting and heating processes with gaseous or liquid fuels and soft flame requirements

Power:                

10kW-5MW (turn down ratio > 1 : 5)

Feature:     

  • oxy-fuel with parallel flow
  • low impulse, low off-gas recirculation
  • flame long and soft at nominal power

Fuel:                            

  • gaseous (natural gas, propane, butane, coke oven gas, …)
  • liquid (light oil, heavy oil, oil residues, …)

Oxidizer:    

oxygen

Applications:            

  • ferrous / non-ferrous industry for melting / heating
  • glass / refractory industry for melting / heating

Design tailor made for each costumer application:

  • free shaft length
  • connections
  • shaft protection
  • mounting fix / movable
  • with / without burner brick
  • ignition with integrated electrode /  separate pilot burner max 300kW
  • flame control by UV-cell
  • self-cooled / water-cooled / comp. air-cooled

        

Example for Oxipyr-P LON and Oxipyr-P burner

Oxipyr - Air

For all combustion applications related to melting and heating processes with gaseous or liquid fuels and low temperature process section requirements

Power:                

100kW-25MW (turn down ratio > 1 : 10)

Feature:     

  • oxy-fuel, flameless (diluted) combustion,
  • high in-furnace off-gas recirculation
  • low flame peak temperatures, low NOx
  • homogenization of the furnace temperature
  • flame automatically adjustable by cone movement

Fuel:                            

  • gaseous (natural gas, propane, butane, coke oven gas, …)
  • liquid (light oil, heavy oil, oil residues, …)

Oxidizer:    

oxygen-air-mixture (O2-content >25%)

Applications:            

ferrous / non-ferrous industry for melting / heating

Design tailor made for each costumer application:

  • free shaft length
  • connections
  • shaft protection
  • mounting fix / movable
  • with / without burner brick
  • ignition with integrated electrode /  separate pilot burner max 300kW
  • flame control by UV-cell

   

Examples for Oxipyr-Air burners

Oxipyr - SVNR

For almost all combustion applications related to melting and heating processes with gaseous or liquid fuels and long-soft-flame requirements

Power:                       

100kW-15MW (turn down ratio > 1 : 5)

Feature:     

  • oxy-fuel, staged combustion,
  • middle in-furnace off-gas recirculation
  • low flame peak temperatures, low NOx
  • homogenization of the furnace temperature
  • under-part of the flame under stoichiometric

Fuel:                            

  • gaseous (natural gas, propane, butane, coke oven gas, …)
  • liquid (light oil, heavy oil, oil residues, …)

Oxidizer:    

oxygen

Applications:            

ferrous / non-ferrous industry for melting / heating

Design tailor made for each costumer application:

  • free shaft length
  • connections
  • shaft protection
  • mounting fix / movable
  • with / without burner brick
  • gaseous-liquid fuel combination possible
  • ignition with integrated electrode /  separate pilot burner max 300kW
  • flame control by UV-cell
  • self-cooled / comp. air-cooled

  

Example for an Oxipyr-SVNR burner

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Oxipyr Regulation

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Oxipyr - Advanced regulation

Infinitely variable control unit for Oxipyr-burner systems

Range:                        

to fulfil requirements (turn down ratio > 1 : 10)

Fuel:                            

  • gaseous (natural gas, propane, butane, coke oven gas, …)
  • liquid (light oil, heavy oil, oil residues, …)

Oxidizer:    

oxygen-air-mixture

Feature:     

  • design customized (dimensions, connections)
  • ratio controlled regulation with thermal mass flow meter
  • fuel as reference value
  • operation mode manual / automatic (temperature, recipe)
  • failsafe electric control unit Simatic S7 300 with/without ignition, flame control
  • compressed air as instrumental air and for cooling
  • combustion air controlled by frequency converter
  • data exchange via interface

Accordance:             

  • with EC-Directive 2006/42/EC, 97/23/EC, 2006/95/EC, 2004/108/EC
  • with harmonized standards EN ISO 12100-1/-2, DIN EN 60947, DIN EN 729-3, DIN EN 746-2, DIN EN 50156

     

Oxipyr – Advanced Regulation for liquid and gaseous fuels

Oxipyr - Basic+, Basic regulation

Progressive 3 stage control unit for Oxipyr-burner systems

Range:                        

to fulfil requirements (turn down ratio > 1 : 10)

Fuel:                            

gaseous (natural gas, propane, butane, coke oven gas, …)

Oxidizer:    

oxygen

Feature:     

  • design customized (dimensions, connections)
  • ratio controlled regulation with thermal mass flow meter for Basic+
  • fuel as reference value for Basic+
  • operation mode manual / automatic (temperature, recipe) for Basic+
  • electric control unit Simatic S7 1200 with/without ignition, flame control for Basic+
  • compressed air as instrumental air and for cooling
  • data exchange via interface for Basic+

Accordance:             

  • with EC-Directive 2006/42/EC, 97/23/EC, 2006/95/EC, 2004/108/EC
  • with harmonized standards EN ISO 12100-1/-2, DIN EN 60947, DIN EN 729-3, DIN EN 746-2, DIN EN 50156

     

Oxipyr – basic+; 3 stage regulation

Oxipyr - 400 regulation

Infinitely variable control unit for Oxipyr-burner systems

Range:                        

up to 400kW (turn down ratio > 1 : 10)

Fuel:                            

gaseous (natural gas, propane, butane)

Oxidizer:    

oxygen

Feature:     

  • ratio controlled regulation with MFC (mass flow controller)
  • fuel as reference value
  • operation mode manual / automatic
  • electric control unit Simatic S7 1200 with/without ignition, flame control
  • no compressed air
  • data exchange via interface

Accordance:             

  • with EC-Directive 2006/42/EC, 97/23/EC, 2006/95/EC, 2004/108/EC
  • with harmonized standards EN ISO 12100-1/-2, DIN EN 60947, DIN EN 729-3, DIN EN 746-2, DIN EN 50156

        

Oxipyr – 400; regulation unit with MFC

Oxipyr - Direct regulation

Infinitely variable control unit for Oxipyr- burner group systems

Range:                        

to fulfil requirements (turn down ratio > 1 : 10)

Fuel:                            

gaseous (natural gas, propane, butane, coke oven gas, …)

Oxidizer:    

oxygen

Feature:     

  • design customized (dimensions, connections)
  • ratio controlled regulation with redundant orifice meter
  • fuel as reference value
  • operation mode automatically per group, each burner manual adjustable
  • failsafe electric control unit Simatic S7 300
  • compressed air as instrumental air and for cooling
  • data exchange via interface

Accordance:             

  • with EC-Directive 2006/42/EC, 97/23/EC, 2006/95/EC, 2004/108/EC
  • with harmonized standards EN ISO 12100-1/-2, DIN EN 60947, DIN EN 729-3, DIN EN 746-2, DIN EN 50156

    

Oxipyr – direct; regulation for burner groups

Optional

Oxipyr- IPC: Internal post combustion

If volatile organic compounds (VOC) and/or CO are present in the exhaust gas, the combustion ratio is changed by reducing the amount of fuel and regulated depending on exhaust gas parameters. This means that high-quality fuels can be relieved. Oxygen is always supplied via Oxipyr burners; Oxijet lances are also used for certain types of furnaces.

Advantages:

  • Less fuel consumption
  • Relief of post-combustion
  • reduction of production costs

Oxipyr-DOC: dynamic oxygen control

The system can be used in reheating-, hearth- and rotary drum furnaces in combination with an Oxipyr Air burner or with oxygen lances. The level of O2 enrichment depends on the power input.

Advantages:

  • No additional hardware
  • Oxygen savings at low loads
  • enrichment regulates itself automatically

Oxipyr-DLC: dynamic λ control

The system can be installed in all furnaces. The furnace is equipped with an oxygen measurement in the exhaust gas. The combustion ratio is regulated depending on the oxygen content in the exhaust gas.

Advantage:

  • Constant oxygen content in the exhaust gas

Oxipyr-furnace control

In addition to the burner system, other furnace functions such as hydraulics, doors, tilting and rotating movements, etc. are operated by the PLC.

Advantages:

  • Turnkey solution for all types of furnaces
  • Conversion or new construction

Oxipyr-off gas duct

This system has been developed to control the furnace pressure and to cool exhaust gas, especially during the implementation of oxipyr burners to adapt the exhaust system. An apparatus enables cooling of the exhaust gas and pressure control in the furnace.

Advantages:

  • Stable furnace pressure
  • No fan for cooling air
  • No flaps
  • Fast response time

Oxipyr data

All existing process data are stored and are available to other systems for further processing.

Oxipyr level control

Non-contact level measurement of the melting bath by radar.

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Oxijet Lance

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Oxijet - Basic

Purpose: 

Subsonic open jet injection of oxygen for purging-, refining- and enrichment applications

Flow rate:          

corresponding to requirements

Feature:             

  • design customized
  • for one / different gas types
  • for shrouded gas / gas mixture

Applications:    

  • Chemical industry
  • Ferrous / non-ferrous industry
  • Glass industry
  • Cement / lime / refractory industry
  • Waste incineration plants

Design tailor made for each costumer application:

  • Nominal outlet speed, momentum
  • Free shaft length
  • Connections
  • Shaft protection
  • Mounting fix / movable
  • Self-cooled / water-cooled / compressed air-cooled

       

            

Different constructions and installations of Oxijet-basic lancing

 

 

Oxijet - Supersonic

Purpose:            

Supersonic injection of gases for pulsating Oxijet and other applications

Flow rate:          

corresponding to requirements

Feature:             

  • Design customized
  • Outlet speed > 2 Mach
  • Supersonic speed by laval nozzles
  • Implementation in existing burners and tuyere

Applications:    

  • Chemical industry
  • Cement / refractory industry
  • Waste incineration plants
  • Iron-steel foundries with Cupola

Design tailor made for each costumer application:

  • Free shaft length
  • Connections
  • Shaft protection
  • Mounting fix / movable
  • Self-cooled / water-cooled / comp. air-cooled

        

Different constructions and installations of Oxijet-Supersonic lancing

Oxijet - Atomizing

Purpose:            

atomizing of low calorific alternative fuels with oxygen

Flow rate:          

corresponding to requirements

Feature:             

  • design customized
  • alternative fuels can be pasty pumpable substances, contaminated with solid particle
  • implementation in existing burners

Applications:    

  • Chemical industry
  • Cement industry
  • Waste incineration plants

Design tailor made for each costumer application:

  • free shaft length
  • connections
  • shaft protection
  • mounting fix / movable
  • Self-cooled / water-cooled / comp. air-cooled

     

Different constructions and installations of Oxijet-Atomizing lancing

Oxijet - Swirl

Purpose:            

injection of gases with spherical diffusion

Flow rate:          

corresponding to requirements

Feature:             

  • design customized
  • spherical diffusion in contrast to open jet

Applications:    

  • Chemical industry
  • Ferrous / non-ferrous industry
  • Glass industry
  • Cement / lime / refractory industry
  • Waste incineration plants

Design tailor made for each costumer application:

  • free shaft length
  • connections
  • shaft protection
  • mounting fix / movable
  • self-cooled / water-cooled / comp. air-cooled

  

Different constructions and installations of Oxijet-Swirl lancing

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Oxijet Regulation

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Oxijet - Enriched regulation

Infinitely variable control unit for gases

Range:                

to fulfil requirements (turn down ratio > 1 : 10)

Media:                                

gaseous (oxygen, nitrogen, …)

Feature:             

  • design customized (dimensions, connections)
  • flow control with thermal mass flow meter
  • flow regulation with pneumatic valves
  • operation mode manual / automatic
  • failsafe electric control unit Simatic S7 300
  • compressed air as instrumental air and for cooling
  • data exchange via interface

Accordance:     

  • with EC-Directive 2006/42/EC, 97/23/EC, 2006/95/EC, 2004/108/EC
  • with harmonized standards EN ISO 12100-1/-2, DIN EN 60947, DIN EN 729-3, DIN EN 746-2, DIN EN 50156

Optional:

Oxijet-DOC: dynamic oxygen control

The system can be installed in all furnaces. The level of O2 enrichment depends on the desired O2 content and the amount of combustion air available.

Advantage:

  • No additional hardware
  • enrichment automatically regulated

Oxijet-DLC: dynamic λ - control

The system can be installed in all furnaces with oxygen enriched combustion air. The furnace is equipped with an oxygen measurement in the exhaust gas. The combustion ratio is regulated depending on the oxygen content in the exhaust gas.

Advantage:

  • Constant oxygen content in the exhaust gas

     

Regulation for enrichment or injection of gases

Oxijet - Puls regulation

Regulation system to control supersonic, pulsating injection of gases

Range:                

to fulfil requirements (turn down ratio > 1 : 10)

Media:                                

gaseous (oxygen, nitrogen, …)

Feature:             

  • design customized (dimensions, connections)
  • flow control with thermal mass flow meter
  • flow regulation by pulsating cycle
  • operation mode manual / automatic
  • electric control unit Simatic S7 1200
  • exchange of data via interface

Accordance:     

  • with EC-Directive 2006/42/EC, 97/23/EC, 2006/95/EC, 2004/108/EC
  • with harmonized standards EN ISO 12100-1/-2, DIN EN 60947, DIN EN 729-3, DIN EN 746-2, DIN EN 50156

     

Regulation for pulsating supersonic injection of gases

Oxijet - Refined regulation

Regulation system to control injection of gases up to 80 Nm³/h

Range:                

max. 80 Nm³/h (turn down ratio > 1 : 10)

Media:                                

gaseous (oxygen, nitrogen, …)

Feature:             

  • design customized (dimensions, connections)
  • flow control and regulation with mass flow controller
  • operation mode manual / automatic 
  • electric control unit with temperature controller

Accordance:     

  • with EC-Directive 2006/42/EC, 97/23/EC, 2006/95/EC, 2004/108/EC
  • with harmonized standards EN ISO 12100-1/-2, DIN EN 60947, DIN EN 729-3, DIN EN 746-2, DIN EN 50156

    

Regulation for two gases up to 80 Nm³/h