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A NEW DIMENSION IN CERAMAT GAS BURNERS MEDIA

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CERAMIC FIBERSGAS BURNERCeramat Gas Burners activity started in 2006. Backed by proven know-how and dedicated manufacturing facilities, Orkli focuses on the development and production of highly specialized Gas Burner Media.

Orkli presents a highly permeable, high-performance burner medium for gas-fired residential and industrial applications. The major innovation in Ceramat Gas Burner is found in its interior: ceramic fibers are formed into a mat structure, coated with silicon carbide in a CVD process, and welded at points of contact. The result: a burner surface with outstanding characteristics.

Orkli burners provide a lot of advantages, not only for Gas Boilers and Heaters, but also for other applications like Fireplaces, Oil boilers, Industrial processes or Cooking systems.

Welded together to form a rigid structure. Fibers under an electron microscope.

Ceramic fiber with a silicon carbide coating.

13 µm

ca. 25 µm

TWO VERSIONS FOR OPTIMAL PERFORMANCE

For gas heating systems and water heaters.

• For industrial furnaces and dryers.

• For gas fireplaces with lively yellow flames.

Ceramat Gas Burner FP (perforated)

Ceramat Gas Burner FN (non perforated)

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THREE OPERATION MODES

Radiation

Blue flame

Yellow flame

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Type of combustion Premix, fan assisted or atmospheric

Application Gas boilers, water heaters, room heaters

Dimensions Max.: 500 x 250 mm (19.7 x 9.8 inches) or according to customer specification

Perforation Variable perforation according to customer specification

Geometry Variable flat geometry according to customer specification

Thickness 3.2 +/- 0.5 mm (0.126 +/- 0.02 inches)

Gas types All gas types according to EN 437, ANSI Z21.1 ff. (natural gas, propane, town gas)

Specific load Min.: 1 Kw/dm2 (31,700 BTU/hr/ft2) / Max.: 30 Kw/dm2 (951,000 BTU/hr/ft2)

Radiation range 1 - 7.5 Kw/dm2 (31,700 - 237,750 BTU/hr/ft2)

Modulation range 1:30

Pressure drop < 5 Pa at 1.5 Kw/dm2 / < 45 Pa at 35 Kw/dm2 / (< 0.000725 PSI at 47,550 BTU/hr/ft2)(< 0.006525 PSI at 1,109,500 BTU/hr/ft2)

Maximum surface temperature 1.000 ºC (1,850 ºF)

Maximum temperature difference on the surfa-ce and between upper and lower side

800 ºC

Colour Anthracite black

TECHNICAL DATA

CHARACTERISTICS

MAXIMUM OUTPUT, MINIMAL SPACE

• High specific load: the combination of a highly permeable burner material and perforations supports specific loads of up to 30 Kw/dm2 with a perfectly stable flame for all the limit gases. This makes it possible to design small, compact burners and systems.

• Wide modulation range: the material’s flame stability and temperature resistance support a modulation range of 1:30. Star-stop emissions due to frequent on-off cycles can be substantially reduced, resulting in low emissions and easily modulated

water temperature for combination boilers.

• Electrical conductivity: SiC coating makes Ceramat burner conductive. Electricity can pass through the material, being this a great advantage for the control of the flame detection. The ionization signal is very good, similar to a metal burner.

• Wide radiation range: this ensures low NOx emissions at low flame temperatures.

• Stable combustion: with all common gas types and limit gases, burners ignite

CERAMAT GAS BURNER FPFOR GAS-FIRED BOILERS AND WATER HEATERS

Ceramat Gas Burner FP is a highly efficient burner medium made of silicon carbide coated ceramic fibers solidly welded together to form a self-supporting mat structure. This highly permeable, homogeneous, perforated burner mat is ideally suited for use in radiant and blue-flame gas burners in heating boilers. Its main advantages are high performance, a wide modulation range and low emissions. In addition, it allows compact burner design.

and operate safely with Ceramat Gas Burner FP.

• Load-bearing, self-supporting mat with thermal expansion: Ceramat Gas Burner FP makes it possible to design simple, cost-efficient burners.

• Variable geometry: for optimal heat transfer, the flat burner surface can be fully adapted to the heating system.

• Variable perforation: the perforation pattern of the burner surface is customizable and determined as a function of system requirements.

Please follow mounting instructions. Complete burner modules also available.

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Type of combustion Atmospheric

Application Gas fireplaces and stoves with yellow flame

Dimensions Max.:1.200 x 300 mm (47.2 x 11.8 inches)or according to customer specification

Geometry Variable flat geometry according to customer specification

Thickness 3.5 +/- 0.7 mm (0.138 +/- 0.028 inches)

Gas types All gas types according to EN 437ANSI Z21.1 ff. (natural gas, propane, town gas)

Specific load Min.:1 Kw/dm2 (31,700 BTU/hr/ft2)Max.: 2.5 Kw/dm2 (79,250 BTU/hr/ft2)

Modulation range 1:3

Pressure drop < 7 Pa at 1.5 Kw/dm2

(< 0.001015 PSI at 47,550 BTU/hr/ft2)

Maximum surface temperature 1.000 ºC (1,850 ºF)

Maximum temperature difference on the surface and between upper and lower side

800 ºC

Colour Anthracite black

Type of combustion Premix, fan assisted

Application Industrial furnaces and dryers with radiant gas heaters

Dimensions Max.: 1.200 x 300 mm (47.2 x 11.8 inches) or according to customer specification.Individual Ceramat Gas Burner can be combined to form larger burner surfaces

Geometry Variable flat geometry according to customer specifications

Thickness 3.5 +/- 0.7 mm (0.138 +/- 0.028 inches)

Gas types All gas types according to EN 437, ANSI Z21.1 ff. (natural gas, propane, town gas)

Radiation range 1 - 6 Kw/dm2 (31,700 - 190,200 BTU/hr/ft2)

Modulation range 1:6

Pressure drop < 7 Pa at 1.5 Kw/dm2

< 15 Pa at 6 Kw/dm2

(< 0.001015 PSI at 47,550 BTU/hr/ft2

< 0.002175 PSI at 190,200 BTU/hr/ft2)

Maximum surface temperature 1.000 °C (1,850 °F)

Maximum temperature difference on the surface and between upper and lower side

800 ºC

Colour Anthracite black

Please follow mounting instructions. Complete burner modules also available. Please follow mounting instructions. Complete burner modules also available.

TECHNICAL DATA TECHNICAL DATA

CHARACTERISTICS CHARACTERISTICS

LIVELY FLAMES, REAL LOG FIRE INSTANT REACTIVITY, OPTIMIZED PRODUCTION

• Realistic flame pattern: Ceramat Gas Burner FN is extremely porous so that the gas flows through its entire surface to create lively flames with changing heights and positions, just like a real log fire. This effect is also obtained in closed, room-air independent systems.

• Glow for an even more natural look: Ceramat Gas Burner FN not only makes it possible to bring artificial logs and embers to a radiant glow, but it can also glow itself. And since the mat supports temperatures up

• Instant reaction: full radiation is obtained within three seconds after ignition. And the radiation stops when the burner is shut off. The temperature of Ceramat Gas Burner FN surface immediately drops to a point where it can be safely touched. By effectively preventing residual heat and avoiding long pre-heating periods, this fast reaction provides optimal system control.

• Homogeneous mat structure: Ceramat Gas Burner FN ensures uniform radiation.

to 1.000 °C, the 950 °C glowing temperature poses absolutely no problem.

• The neutral colour of Ceramat Gas Burner FN blends perfectly with the logs and fire, unlike shiny stainless steel, for example.

• Stable combustion: with all common gas types and limit gases, burners ignite and operate safely with Ceramat Gas Burner FN.

• Simple, cost- and space-efficient burner design due to the rigid, self-supporting structure of the mat and its minimal thermal expansion.

• Clean surface combustion: very low NOx and CO emissions reduce the environmental impact.

• High efficiency: a properly matched system with Ceramat Gas Burner FN saves energy costs, especially when compared to electric heating systems.

• Wide modulation range: the desired temperature can be precisely set and is easily adjustable when required.

CERAMAT GAS BURNER FNFOR GAS FIREPLACES

CERAMAT GAS BURNER FPFOR INDUSTRIAL FURNACES AND DRYERS

Ceramat Gas Burner FN is a highly efficient burner medium made of silicon carbide coated ceramic fibers solidly welded together to form a self-supporting mat structure. This highly permeable, homogeneous burner mat is ideal for gas fireplaces, ensuring a lively flame pattern that looks like a real log fire.

Ceramat Gas Burner FN is a highly efficient burner medium made of silicon carbide coated ceramic fibers solidly welded together to form a self-supporting mat structure. This highly permeable, homogeneous burner mat is ideal for radiant gas burners in industrial furnaces and drying installations.

• High flexibility: the mat can be supplied in any flat shape and size. Thus, Ceramat Gas Burner FN makes it possible to adapt the output of the burner to the customer’s individual requirements.

• Modulation potential for variable flames: even with very low flames, stable combustion maintains a natural-looking flame pattern.

• Low emission values: properly matched complete systems meet the strictest exhaust gas and efficiency standards.

• Variable geometry: the burner medium makes it possible to precisely adapt the burner surface to the requirements of the installation.

• Rigid, self-supporting structure: very low thermal expansion and low pressure drop simplify burner design.

• High temperature resistance: despite high specific loads the burner surface has a long life expectancy.

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Ceramat Gas Burner has an open porosity of approximately 95%, making it highly permeable. The gas or gas/air mixture passing through it can easily permeate the entire surface and burns off in the form of a flame carpet. The flames remain on the surface and do not lift off. This offers the advantages of stable combustion, a wide range of modulation and high specific load, which allow compact burner design.

The silicon carbide coating gives rigidity to the fibers. This coating bonds the fibers together at their interfaces to form a rigid structure. Thus Ceramat Gas Burner is self-supporting and will not significantly sag, even on larger burner surfaces and when exposed to fan pressure. No additional support is required.

Ceramat Gas Burner can also be used as a radiant burner. The burner surface is resistant up to 1.000 °C and only glows to a depth of 1 mm, while the temperature on the underside remains at approximately 150 °C. The material also resists thermal shock. With its high resistance to heat and changing temperatures, it can be used under unusually difficult combustion conditions.

The simple adaptability of Ceramat Gas Burner to a specific heating system and its wide radiation range ensure very low CO and NOx values without reducing the performance and flame stability of the burner.

SiC coating makes Ceramat burner conductive. Electricity can pass through the material, being this a great advantage for the control of the flame detection. The ionization signal is very good, similar to a metal burner.

Ceramat Gas Burner is suitable for use in both blue-flame and radiant modes and offers a correspondingly wide modulation range, as well as the possibility of precise, continuous adjustment.

Ceramat Gas Burner is extremely thin and ultra-light. Its low thermal mass results in very fast burner responsiveness during heating and cooling. Upon ignition, a bright radiation is produced, signaling immediate heat. When the flame is extinguished, Ceramat Gas Burner cools within seconds so that its surface can be safely touched. It is ideal for burners and installations that need to be frequently turned on and off in short cycles.

HIGH SPECIFIC LOAD, STABLE COMBUSTION

RIGID, SELF-SUPPORTING STRUCTUREEVEN RADIATION

LOW EMISSIONS

ELECTRICAL CONDUCTIVITY

WIDE MODULATION RANGE

FAST REACTION

OUTSTANDING ADVANTAGES

Extremely thin and highly resistant to heat and thermal shock: from 950 °C to 150 °C in just 3.2 mm.

Perforated Ceramat Gas Burner: the flames stabilize each other.

High surface temperatures are not transmitted to lower layers. When used as a radiant burner, this allows for a temperature differential of up to 800 ºC between the topside and the underside. There is no danger of flashback and the temperature of the burner housing remains very low, even without additional cooling. This means that even compact burners can be safely operated with high output.

LOW THERMAL CONDUCTIVITY

Since the material practically does not expand when heated, the shape remains virtually unchanged during operation. This makes it possible to use simple frame and burner designs and ensures uniform, stable combustion.

At approximately 25 to 30 μm, the diameter of the silicon carbide coated fibers is much greater than the maximum 3μm range considered critical for human health conditions. In addition, the fibers are solidly welded together. If they should break off, they are heavy enough to fall to the ground instead of being inhaled, a fact that has been confirmed by independent studies. Therefore, Ceramat Gas Burner installation and operation does not generate health hazards.

LOW HEAT EXPANSION

NO HEALTH HAZARDS

The self-supporting structure simplifies frame design and construction.

QUALITY THROUGH AND THROUGH

SUCCESSFUL TOGETHER

QUALITY ANDINNOVATION

Ceramat Gas Burner is a high quality product that offers many advantages. Its exceptional characteristics make new applications possible with great enhancement for existing burner systems. Orkli R&D&i department, composed of combustion experts, is supported by two Research Institutes, Ikerlan (Mondragon Group), that focuses on new applications and CEIT, a Technology Center that focuses on materials. Looking for performances, efficiency and safety, Ceramat Gas Burner guarantees outstanding quality.

With our customized burner solutions we at Orkli are committed to contributing to our customers’ success through close cooperation. Backed by the know-how of a leading industrial group, this is what we strive for in our ongoing research and development. Our mission is to create successful products based on new ideas, a challenge we look forward to meeting in collaboration with you.

High Efficiency.High specific load, stable combustion.Wide modulation range.Low emission.Electrical conductivity.Even radiation.Fast reaction.Low thermal conductivity.Low heat expansion.Rigid, self-supporting structure.No health hazards.

CERAMAT GAS

BURNER

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