Ceramic

Ceramic

Thanks also to its proximity to the Italian ceramic district (the “triangle” Sassuolo, Modena, Faenza), ESA has developed a unique competence in the sector, serving for over 40 years all the major Italian brands, companies that have made the history of the sector by bringing it to top technological and quality standards.
The accumulated experience allows today to provide highly efficient combustion solutions as well as specially developed products for kilns, tiles, bricks, extruded products, frits,furnaces, technical ceramics ovens and more .

EXTRUDED CERAMICS AND TILES
For extrusions and sanitaryware, the most commonly used ovens are tunnel ovens or chamber furnaces, while for tiles, roller ovens are now the reference standard thanks to their productivity and versatility.
For these types of ovens we offer two main families of high/medium speed burners:

ESA high velocity burners EMB SIK in sanitaryware Tunnell Furnace

ESA high velocity burners EMB SIK in sanitaryware Tunnell Furnace

1. The EMB range 
Characterized by extreme reliability, flexibility, robustness, EMBs generate a medium / high speed flame capable of operating in excess air up to 400%, ensuring high homogeneity in the atmosphere and in the oven temperature, critical elements in an oven tunnel, given its size.

EMB Burners family:  Metallic flame tube (EMB);  SIC  tube (EMB SIK), Double Air (EMB SIC DA), Staged recuperated Air (EMB Nxt))

EMB Burners family: Metallic flame tube (EMB); SIC tube (EMB SIK), Double Air (EMB SIC DA), Staged recuperated Air (EMB Nxt))

The EMBs also ensure the greatest turndown (1:10) in the category, thus being able to be used in all areas of the oven and for different recipes and cooking cycles. This represents an advantage, as the products can differ considerably from the point of view of the chemical composition, size, shape, grain size …. elements that require extreme precision in following the cooking cycles, in order not to incur possible defects in production.
With SIC or metal flame tube, the EMBs are supplied in 8 capacities, from 20 to 900 KW, which allows maximum freedom in correctly sizing the number of burners according to their power, and distributing them in the various areas of the oven.

The EMB / EMB-SIK work with cold air, while the EMB-SIK-NxT version works with preheated air: in this case the burner incorporates a two-stage combustion system, in order to reduce NOx. Double air burners are also available for special uses.

ESA EMB High Speed Burners for Sanitary Tunnel Furnaces

ESA EMB High Speed Burners for Sanitary Tunnel Furnaces

2. Self-recuperative high-speed burners REKO-SIK-NxT
This is another fundamental family of burners, now in the third generation for ESA. REKOs integrate a heat exchanger that uses hot fumes to pre-heat the combustion air, reducing consumption and emissions by up to 30% compared to traditional cold air burners. Today the new REKO-SIK-NxT has been completely redesigned and is sold in three versions: Free Flame (REKO-SIK-NxT-FF), Flat Flame (REKO-SIK-NxT-SW) and for radiant tubes (REKO-SIK -NxT-RT).
REKO ™ is covered by a worldwide patent and guarantees lower consumption and emissions than previous versions; today it is also made up entirely of cast iron parts, ensuring greater strength, construction speed and lower external temperatures thanks to the body internally covered with insulating fiber.

ESA Self recuperative burners Free Flame for Tiles Roller Furnaces

ESA Self recuperative burners Free Flame for Tiles Roller Furnaces

REKO ™ are the ideal solution for roller ovens, since in this type of oven, the temperatures are kept high to set faster and more productive cooking cycles, thus multiplying the heat recovery effect.
REKO ™, in the version for radiant tubes, are also used in drying roller ovens

ESA Self Recuperative Burners REKO Radiant Tubes for tiles driers

ESA Self Recuperative Burners REKO Radiant Tubes for tiles driers

The use of REKO-SIK-NxT-FF is also optimal for Chamber Furnaces , where the significant heat losses require more performing burners.

ESA Self Recuperative Burners Reko FF for Chamber Whiteware Furnaces

ESA Self Recuperative Burners Reko FF for Chamber Whiteware Furnaces

BRICKS In brick kilns, we offer the EMB-SIK-X burners, which are provided of a metal extension to adapt the burner to the high thicknesses of the insulating material typical of these kilns. It is also possible to customize the burner for those kilns in which the air ducts are drowned in the refractory..

ESA High Speed EMB SIC Burner with extension for brick furnaces

ESA High Speed EMB SIK X Burner with extension for brick furnaces

 FRITS AND ENAMELLING FURNACES

Another field of expertise of ESA, which offers two types of solutions:

 1. Low NOx long flame burners “ENM Nxt”

ESA ENM long flame burner for frites and enamelling furnaces

ESA ENM long flame burner for frites and enamelling furnaces

2. Complete Oxy fuel solutions
Today Oxy fuel systems are most used for these kind of kilns since they are quicker to reach the very high temperatures required by the process, thus insuring lower energy consmptions and reduced emissions.
ESA supplies for these kind of furnaces oxy fuel high turbulence burner “HT”, also in different customized versions,  and of course skid and automation.

ESA Oxy fuel solutions for Frites furnaces

ESA Oxy fuel solutions for Frites furnaces

ELECTRONIC  BCU CONTROLS

Further products specifically produced by ESA for the ceramic market can be found between our microprocessor flame controls and our pressure regulators.
In particular our flame control ESA GENIO has been developed as a simplified version of the ESA ESTRO , our BCU with a serial communication system.
Today, ESA GENIO, in the PRS version, can be equipped with an air pressure indicator, so that the operator, when he physically passes to ascertain the status of the burners, can also have this important general information.
If instead ESA ESTRO is used, it also becomes possible to use our PULSE FIRING system, which with the PULSE board and the touch-screen, allows you to do without an expensive PLC

http://www.esapyronics.com/wp-content/uploads/2014/04/ESA-Electronic-contols Genio, Estro, -and-pulse-firing-system-Pulse for-ceramic

http://www.esapyronics.com/wp-content/uploads/2014/04/ESA-Electronic-contols Genio, Estro, -and-pulse-firing-system-Pulse for-ceramic

Finally, a revolutionary product to revamp roller ovens that operate with fixed air and modulated gas, guaranteeing considerable energy savings, is the AR-REG-II pressure regulator, which allows to modulate the air according to the gas pressure, in particular during stationary or product changeover phases.
It is basically a traditional zero-governor like the BZR-REG-II but which works in the opposite direction, modulating the combustion air according to the gas pressure to the burner, ensuring combustion stoichiometry.

 Air Regulator ESA AR for ceramic roller furnaces.

Air Regulator ESA AR for ceramic roller furnaces.

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