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SAACKE burners for industry

Emission limit values for industry are falling while demands on sophisticated technical solutions increase – and this worldwide. For example, this is demonstrated by the Chinese guidelines, which prescribe a strict NOx limit value of 30 mg/m³ based on 3% dry O2 in urban areas, such as Beijing, for new power station and energy generation plant projects since 2017. SAACKE constantly adapts and aligns to changing conditions with its ongoing research and development activities.

SAACKE offers standardized burners for a wide range of fuels, from conventional to special, such as BPA (a liquid by-product of the plastic production process) or animal fat.

SAACKE burners with their typical large control range and minimum air excess are especially efficient and provide high availability.

The SAACKE TEMINOX burner combines all the benefits of a modern combustion plant for industrial heat and steam generation. The burner is available in monoblock or duoblock design and for gas or light oil operation with unrivaled burner capacities up to 28 MW.

  • Lowest emission values in accordance with or reliably below country-specific emission regulations, e.g. BImSchV (German Federal Ordinance on Exposure Control)
  • High efficiency due to low residual oxygen in the exhaust gas, even under high emission requirements
  • Extremely efficient, sound absorbing fan (monoblock) with low current consumption
  • Complies with CE directives, type-tested
  • Durable, modular design
  • Straightforward mounting, commissioning and maintenance
  • Suitable for various heat generators
  • Available as a natural gas, light oil or dual fuel burner with the option of simultaneous operation of two fuels and combustion of special fuels
  • Design for air preheating (optional)
  • Integrated combustion management system (optional)
  • Further modular system extensions possible (optional)
  • Capacity range 3-28 MW (gas and oil operation)
  • Fuels: Natural gas, liquefied gas, light oil, special gases
  • Applications: Shell boilers, water-tube boilers, thermal oil boilers, thermal processing plants, new construction and modernization of industrial plants

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NOx reduction measures of many competitors often lead to a high amount of excess O2 or a high level of CO. Significant reductions in the released nitrogen oxide can often only be achieved using expensive, catalytic (SCR) or non-catalytic (e.g. SNCR) processes. However, all of these options increase fuel consumption, material costs and the use of necessary additives at the operator’s expense. By contrast, the SAACKE LONOX UCC (Ultra Clean Combustion) System is based on established technology that has been tried and tested in practice. The burner fires all standard gaseous fuels cost-effectively and efficiently in compliance with the limit value of 30 mg/m³ NOx based on 3% dry O2 – all with a low flue gas recirculation rate of < 25% and without further secondary measures. The burner draft loss of the combustion air is lower than 30 mbar (depending on the burner design). Compliance with the statutory emission limits is possible thanks to a special, swirled flame geometry as well as a specially-engineered flame control. The SAACKE LONOX UCC System can be customized to the respective customer requirements and plant infrastructure.

  • Extremely low NOx emissions (< 30 mg/m³) based on 3% O2, dry
  • Control range up to 1:7
  • Highly efficient fuel use by very low excess air ratio of only 10% at full load
  • Also suitable for extremely short furnaces
  • Suitable for shell boilers and water-tube boilers
  • Reduced operating costs due to high-efficiency combustion technology and low auxiliary power requirement
  • Less maintenance time and exceptionally long life
  • Conforms with European and Chinese guidelines

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SAACKE GmbH has been supplying versatile and customer-specific solutions in the field of sulfur combustion for more than 50 years. We offer solutions for sulfur combustion in sulfuric acid plants and sulfur dioxide (SO2) generation plants and various combustion technologies.

Due to its compact design and optimal atomization mechanisms, the rotary atomizer has advantages for use in sulfuric acid and SO2 generation plants.

Due to its highly turbulent flow, the SAACKE swirl burner ensures an intensive mixing of fuel and combustion air at the beginning of combustion. This burner system is ideally suited for hydrogen sulfide (H2S) combustion, e.g. in Claus plants and it can also be combined with atomizer lances for liquid sulfur.

In addition, SAACKE also offers solutions for the thermal purification of back acids (split acid plants) and combustion chambers in which the contaminated acid is freed from the organic components by thermal oxidation. After heat extraction in a steam boiler, the SO2 gas is available for the next process steps.

When it comes to safely and efficiently converting heavy oil into heat, the first choice is rotary cup atomizer burners. Monoblock burners such as the SKVJ-M are especially suitable for this purpose in the low and medium capacity range. This series features robust rotary cup atomizer technology with a perfectly coordinated fan, an electronically controlled preheater and a precise oil pressure controller, all combined in the casing. The fuel pressure and temperature upstream from the burner can also be low in this case, which reduces operating costs considerably.

However, the SKVJ-M combusts not only heavy oil, but also bio oil and other high-viscosity liquids. With optionally available water injection, the dust content of the flue gas for fuels with high asphalt content can be reduced still further.

All variants are delivered ready to be connected and are easy to mount and place in operation. Because it is greatly standardized across all sizes, the SKVJ-M is also especially affordable with quick delivery times.

  • Sturdy monoblock design based on rotary cup atomizer technology proven thousands of times over
  • Affordable burners with a short delivery time and long service life
  • Large control range
  • Integrated fan optimally adapted to the burner
  • Optionally available with water injection for especially low-dust combustion
  • High efficiency, low maintenance costs and long service life
  • Fast, uncomplicated planning, mounting and commissioning
  • In compliance with European directives and requirements of ship classification societies

With the SKVG rotary cup atomizer series, SAACKE offers a burner concept with performance capabilities and variability that far exceed comparable solutions of other manufacturers. This series covers the range of high load ranges, high control ranges and the heaviest fuels, which place extreme requirements on a combustion plant, yet still offers high availability and safety. The rotary cup atomizer technology  offers maximum reliability with optimal burnout, very low emission values and an extremely long service life.

The burner is available for use with light and heavy fuel oil and in variants for standard gases or as a combined gas and oil burner. If required, it can burn different gases and liquids simultaneously with simultaneous firing, in a wide range of combinations. The duoblock burner design with a separate fan increases firing flexibility considerably and allows for applications with air preheating or the use of unusually high furnace pressures.

  • Burner concept with unmatched flexibility
  • Produces energy reliably from even the heaviest fuels and wastes with low emissions
  • Suitable for virtually all heat generators and furnace geometries
  • Sturdy rotary cup atomizer design based on technology proven thousands of times over
  • Simultaneous combustion of multiple gases and oils
  • Very large control range for liquid and gaseous fuels
  • Low fuel supply pressure and low preheating temperature requirement
  • High efficiency, low maintenance costs and long service life
  • In compliance with European directives and requirements of ship classification societies

The SKVG-A rotary cup atomizer series combines proven rotary cup atomizer technology with the advantages of a compact burner. The burners and fans are optimally adapted to each other ex works. Each unit is fully mounted and ready on delivery. This reduces installation planning and mounting to a minimum. The burners of this series are suitable for all commonly used furnaces and can also be used with problematic fuels with outstanding results. Of course the emission values fall below even the strictest limits.

All oil components are heated and designed for operation with super-heavy fuel oils. Even unpurified oils and biogenic fuels are no problem for the SKVG-A, underscoring the strength of its sturdy design.

The gas variant is equally versatile and sturdy. It is based on the parallel flow principle and offers fuel gradation with two gas flows for an especially wide control range. If necessary, the SKVG-A can also utilize biogas cleanly and efficiently.

In the dual fuel version, the SKVG-A can combust either gas or oil with identical control ranges, which makes firing especially flexible.

  • Sturdy, modular design based on rotary cup atomizer technology proven thousands of times over
  • Even super-heavy oil can be combusted with no problems
  • Very large control range for liquid and gaseous fuels
  • Reliable compliance with strict emission limit values due to low NOx technology
  • Optionally available with water injection for especially low-dust combustion
  • Integrated fan optimally adapted to the burner
  • High efficiency, low maintenance costs and long service life
  • Standardized design ensures short planning and delivery times
  • Uncomplicated mounting and commissioning
  • In compliance with European directives and requirements of ship classification societies

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The innovative DDZG steam pressure atomizer series sets new standards in terms of emissions, and is revolutionizing the steam pressure atomizer market as an innovative further development. The secret is simple: It is essentially not just a burner, but also a variable, modular building block system from which burners can be individually configured. That is what makes the DDZG highly flexible – while also delivering low NOx emissions that no competitor can match.

As the core of process firing, the DDZG can burn even unconventional gases (e.g. with a high hydrogen content) safely and with low emissions. If required, it can burn different gases and liquids simultaneously with simultaneous firing, in a wide range of combinations.

The new process concept keeps operating costs very low while at the same time delivering extremely low emissions. Low pressure losses minimize the power consumption of the fan. The DDZG also sets new standards in terms of environmental protection, reliably conforming to very stringent limits. In typical applications, emission limit requirements between 50 and 80 mg NOx/m³ (at STP) for operation with natural gas and 100 to 150 mg NOx/m³ (at STP) for fuel oil have already been met. Under the right conditions even lower emissions can be achieved.

  • Flexible burner concept
  • Simultaneous combustion of multiple gases, also in combination with various liquid fuels
  • Air preheating can be used up to 300°C
  • Extremely low emissions
  • Large control range
  • Low operating cost thanks to high-efficiency combustion technology and low auxiliary power requirement
  • Short planning phase thanks to modular design concepts
  • Numerous pre-designed solutions as the basis for custom engineering
  • In compliance with European Directives

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Potentials of combined heat and power (CHP) in the high temperature range can now be used with a total efficiency of over 90%. The SAACKE LONOX DTEG gas duct burner increases system efficiency by reducing the residual oxygen content in the exhaust gas while improving the emission balance. It is used in water-tube boilers, in insulated or water-cooled combustion chambers in front of shell boilers, thermal oil heaters and waste heat boilers without their own combustion chamber and in drying plants.

An additional benefit lies in its modular concept: individual ramps are available as required.

  • Capacity range 1.5 - 150 MW, can be designed for turbine exhaust gas quantities from gas turbines with up to 100 MW of electric power
  • Fuels:  Natural gas, refinery gas, biogas
  • Applications: Use of turbine exhaust gas as combustion air to maximize the efficiency of downstream heat generation in combined heat and power (CHP) plants. For hot gas generation with fresh air as combustion air, e.g. for drying processes.

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If furnaces are limited in the high load range, it's time for the SSB swirl burner series. It is based on SAACKE steam pressure atomizers, to which a tangential air supply has been added. This causes the combustion air to be intensively swirled and allows for an especially short and stable flame.

The swirl can be finely adjusted with a swirl slide in the burner, so that the length of the flame can be specifically adapted to local conditions. Gas and oil are directed into the furnace with a fuel gun. This makes firing especially flexible because the burner can be changed over to other fuels within a very short time.

Regardless of the fuel, all basic variants already have the equipment features that are needed for hard operation in process combustion systems. That includes for example a solid built-in heat protection shield that protects the entire burner from heat radiated back out of the furnace. Also included is a gun retract mechanism that reliably prevents oil from cracking in the fuel gun. The modular design of the burner makes additions or conversions easy. With a second fuel gun, firing with two liquids, two gases and a pulverized fuel is even possible.

With all these details, the SSB is still an especially robust and reliable component for operating combustion chambers, waste incineration plants or special solutions based on thermal process.

  • Sturdy design adapted to process combustion systems
  • Unmatched stable and short flame
  • Low emissions, even under difficult conditions
  • Ideal as a startup and support burner
  • Suitable for sub and superstoichiometric combustion with lambda 0.3 - 4

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The SSB-LCG swirl burner series converts even lean gases with extremely low heat values into a valuable source of energy. Even though the technology of the SSB-LCG is simple in principle: A special muffle is installed downstream from a swirl burner (SSB) in which the supercritically swirled lean gas flame burns stably. This process developed by SAACKE works without a support fuel and achieves astonishingly low NOx emission values less than 20 mg/m³.

An SSB is used as the basic burner. To heat up the muffle, it is operated for a short time when it starts with a standard fuel. The SSB-LCG is equally suitable for combustion chambers, water-tube boiler and flame tube boilers.

Because the gas does not flow in until downstream from the actual burner, the gas pressure can also be pleasantly low, thereby reducing plant expenses even before commissioning. Air preheating up to 300°C can make operation significantly more economical. Special designs can utilize up to four gases and one liquid fuel. Firing with the SSB-LCG is not at all inflexible during operation. On the contrary, it can be easily and reliably controlled just as with a conventional burner. The control range for every application is astonishingly wide, with extremely low emission values at each firing rate.

  • Ideal for furnace gas and almost all inert waste gases (for example formalin gas)
  • Unmatched low emission values
  • Very low gas inlet pressure possible
  • Absolutely stable flame with a wide control range
  • Very short amortization time
  • Air preheating to 300°C further increases efficiency

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The SSB-D swirl burner series offers economical firing in combustion chamber operation with optimum burnout and low flue gas values.

As soon as the heat generator has warmed up in gas firing operation mode, the dust can provide the required heat: After brief simultaneous firing mode with gas and dust, the dust flame burns absolutely stably – without any support fuel. In dust mode, the heat generator responds like a conventional combustion system, offering a control range of 1:3 or better. Dust burnout is outstanding at every firing rate and the NOx and CO emission values are reliably below all limit values. NOx emissions are also especially low on water-tube boilers in combination with a muffle and multistage combustion air supply, often making secondary measures for reducing NOx (for example SNCR) superfluous.

Even if the equipment overhead for a dust combustion system requires higher investment costs for the silo and dust transport, deriving heat from carbon dust, wood dust or petroleum coke quickly pays for itself. The amortization times are even shorter if by-products can be utilized which would otherwise have to be disposed of in expensive processes. In principle, all pulverized fuels with a particle size < 0.5 mm can be used for this purpose. In actual practice, fuels include post-extraction canola meal, soy husks, coffee husks or wood sanding dust.

Because the SSB-D is part of the swirl burner product family, it offers all the advantages of that flexible series. Additional fuels can also be added, including variants that fire oil, two gases and dust, if necessary even simultaneously. The specific variant or size and the type of dust that is used do not play a significant role.

  • Makes it possible to use dust as an inexpensive fuel
  • Can replace valuable standard fuels
  • Extremely low emission values at all firing rates
  • Very short, stable flame which can be controlled well
  • No support fuel required
  • Short amortization time