Heavy-Duty Industrial Gas Burners
Rapidflame combustion systems for furnaces, kilns, high-temperature process plant, and heavy industry applications.
Rapidflame designs and manufactures heavy-duty industrial gas burners and complete combustion systems for demanding, direct-fired heating applications where high temperature, stable combustion and precise process control matter.
Our principal range for furnace and heavy duty applications covers 105 kW to 5,300 kW, with turndown ratios up to 50:1, maximum chamber temperatures up to 1,540°C and high-velocity configurations producing flame velocities up to 150 m/s. Medium-velocity versions are also available where lower combustion-air pressure or a longer flame profile is preferred.
Rapidflame high temperature industrial burners can be supplied individually or as part of a complete engineered combustion system, incorporating combustion air, gas controls, ignition, flame supervision, modulation and plant-control interfaces.
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Heavy-duty burner range at a glance
Combustion systems for heavy industry
Rapidflame's heavy-duty burners are designed for medium- and high-temperature process applications across
metals, glass, ceramics, environmental plant and other heat-intensive industries. The Tecflame burner range uses
nozzle-mixing technology: gas and combustion air mix at the burner head to produce a stable, controllable flame
across a wide operating range.
Typical applications include:
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Ceramic shuttle kilns and industrial kilns
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Glass tempering furnaces
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Heat-treatment furnaces
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Annealing, tempering and quenching furnaces
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Preheating and drying furnaces
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Thermal oxidisers and regenerative thermal oxidisers (RTOs)
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Waste-gas incineration plant
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New OEM furnace equipment
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Furnace burner retrofit and replacement projects
Every application is reviewed against its required heat duty, chamber temperature, furnace pressure, available fuel
and air pressures, flame geometry, control philosophy and emissions objectives.
High turndown for accurate process-temperature control
A burner sized only for peak duty can become difficult to control when process demand falls. Tecflame
configurations can provide turndown ratios of up to 50:1, allowing heat input to reduce substantially while
maintaining a stable flame.
This wide operating range is particularly useful for batch furnaces, kilns and heat-treatment processes that must
move from rapid heat-up to tightly controlled soak conditions. The precise achievable turndown depends on burner
size, fuel, pressure conditions, control method and the complete combustion-system design.
Complete package burner and combustion-control systems
Rapidflame can supply more than the burner head. A Tecflame system can be engineered with:
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Combustion-air fan and air-pressure monitoring
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Gas train, filtration and pressure regulation
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Safety shut-off valves and valve proving, where required
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Automatic ignition and flame supervision
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Ratio control and burner modulation
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Local burner-management controls
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PLC or main plant-control interface
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Pipework, wiring and mounting arrangements within the agreed scope
Supplying the principal combustion components as a coordinated package helps ensure that the burner, air supply,
fuel controls and safety functions are selected to work together.
Medium- or high-velocity furnace firing
Tecflame burners are available with combustion chambers and refractory tiles selected for medium- or
high-velocity operation.
High-velocity configurations generate strong recirculation within the chamber. This can improve convective heat
transfer and temperature uniformity, making them well suited to processes where close temperature control is
critical.
Medium-velocity configurations provide a longer flame profile and typically require less combustion-air pressure.
They may offer the better system-level choice where the furnace geometry and uniformity requirement do not
demand maximum flame velocity.
Rapidflame engineers select the burner velocity and flame shape around the process rather than applying a single
configuration to every furnace.
Multi-megawatt burners for demanding industrial duties
With capacities extending to 5.3 MW per burner, the Tecflame range supports both distributed multi-burner furnace
layouts and high-duty individual firing positions. Burner quantity and size can be selected to suit zone control,
temperature uniformity, available installation space and required redundancy.
For larger systems, Rapidflame can coordinate the burner with combustion-air fans, gas trains, pressure
regulation, safety shut-off valves, ignition, flame detection, modulation and PLC interfaces.
Combustion performance and emissions
Tecflame burners are designed for complete, stable combustion with low CO and NOx performance. Actual
emissions are application-specific and depend on factors including furnace temperature, excess air, fuel
composition, burner loading, air preheat, chamber geometry and control strategy.
Where an emissions limit applies, provide the required reference conditions and units at enquiry stage. Rapidflame
can then assess burner selection and system design against the stated project target. No universal emissions
value should be assumed without an application review or test conditions.
Natural gas, LPG and engineered fuel configurations
Standard Tecflame configurations are available for natural gas and LPG. Other gaseous fuels may be possible
following review of calorific value, composition, supply pressure, flame characteristics and the applicable safety
requirements.
If future fuel flexibility is part of the project brief, tell us at the outset so it can be considered in burner, gas-train and
control-system selection.
Complete package burner and combustion-control systems
Rapidflame can supply more than the burner head. A Tecflame system can be engineered with:
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Combustion-air fan and air-pressure monitoring
-
Gas train, filtration and pressure regulation
-
Safety shut-off valves and valve proving, where required
-
Automatic ignition and flame supervision
-
Ratio control and burner modulation
-
Local burner-management controls
-
PLC or main plant-control interface
-
Pipework, wiring and mounting arrangements within the agreed scope
Supplying the principal combustion components as a coordinated package helps ensure that the burner, air supply,
fuel controls and safety functions are selected to work together.
New furnace projects and burner retrofits
For OEM and new-build furnace projects, Rapidflame can work from process duty, furnace drawings and control
requirements to define the firing arrangement.
For retrofit projects, we review the existing burner openings, furnace construction, available utilities, process duty,
control system and required shutdown window. The aim is to identify a practical replacement solution without
overlooking the wider combustion system that determines burner performance.
Useful information for an initial review includes:
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Process and furnace type
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Required maximum and minimum heat input
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Normal and maximum chamber temperature
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Fuel type, composition and available pressure
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Combustion-air conditions and any air preheat
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Furnace pressure and atmosphere
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Required flame length or velocity
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Applicable emissions limits and reference conditions
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Current burner details, drawings and photographs
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Electrical supply and control philosophy
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Installation country and applicable standards
Why specify Rapidflame?
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More than 50 years of industrial burner application experience
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UK combustion engineering and application support
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Burner-only, control-component and complete packaged-system options
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Medium- and high-velocity furnace burner configurations
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High-turndown solutions for demanding temperature-control duties
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ISO 9001:2015 quality management system
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Support for OEM, new plant and retrofit projects worldwide
Discuss your heavy-industry combustion system
Tell Rapidflame what you need to heat, the required duty and temperature, available fuel, operating range and any
emissions target. Our engineers will review the application and recommend an appropriate Tecflame burner and
combustion-system scope. Contact us.
Frequently asked questions
What is the capacity range of Tecflame industrial burners?
The Tecflame range covers heat inputs from 105 kW to 5,300 kW. The correct burner size depends on the process
duty, operating temperature, furnace conditions, fuel and required control range.
Can a Tecflame burner achieve 50:1 turndown?
Tecflame configurations can achieve turndown ratios of up to 50:1. Actual turndown depends on burner size, fuel,
available pressures, controls and operating conditions, so it should be confirmed during application engineering.
What is the maximum furnace temperature?
Tecflame configurations are available for chamber temperatures up to 1,540°C when used with the appropriate
refractory combustion chamber or tile. Final selection must consider the furnace construction and operating cycle.
What is the difference between medium- and high-velocity burners?
High-velocity burners use a faster jet to promote chamber circulation, convective heat transfer and temperature
uniformity. Medium-velocity burners generally provide a longer flame and use less combustion-air pressure.
Selection depends on furnace geometry and process objectives.
Can Tecflame burners be supplied as a complete package?
Yes. Rapidflame can supply a Tecflame burner with coordinated combustion-air, gas-control, ignition, flame-safety,
modulation and plant-interface equipment. The exact scope is engineered for the project.
Are Tecflame burners low-NOx?
Tecflame burners are designed for low CO and NOx performance, but emissions depend on the complete
application and test conditions. Any guaranteed limit must be reviewed against the fuel, temperature, excess air,
chamber design, burner loading and stated reference conditions.