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Dual-Fuel Burners

1. Introduction

Dual-fuel burners are designed to operate with two different fuel sources, usually gas and liquid fuel (e.g., natural gas + fuel oil).

These systems provide maximum flexibility, allowing continuous operation even if one fuel supply is unavailable.

In industries where fuel cost, supply security, or emission limits change frequently, dual-fuel systems are essential for maintaining reliable and efficient performance.

2. Operating Principle

A dual-fuel burner incorporates two independent combustion systems integrated into one body:

  • Gas circuit with nozzles, gas valves, and modulating air control.

  • Oil circuit with a fuel pump, pre-heater, and atomizing nozzles.

The burner can operate in:

  1. Single-fuel mode (gas only or oil only), or

  2. Dual-fuel mode with automated switching.

Transition between fuels can be manual, semi-automatic, or fully automatic, depending on the control system.

3. Key Components

  • Gas train: Includes pressure regulators, filters, valves, and safety shut-offs.

  • Oil train: Comprises fuel pump, pre-heater (80–120°C), filters, and solenoid valves.

  • Air fan & servo system: Supplies combustion air and adjusts flow based on selected fuel.

  • Control unit: Manages ignition, flame detection, and fuel switching sequence.

  • Atomization system: Uses steam, compressed air, or mechanical pressure to ensure fine droplet formation for oil combustion.

4. Advantages of Dual-Fuel Systems

  • Fuel flexibility: Operates with either gas or liquid fuel depending on availability.

  • Cost optimization: Switch to the cheaper fuel when prices fluctuate.

  • Reliability: Maintains operation during fuel-supply interruptions.

  • Adaptability: Meets emission regulations and changing environmental policies.

  • Efficiency: Modern systems maintain consistent air-fuel ratio control across both fuels.

5. Challenges and Considerations

  • Complex design: Two combustion circuits increase system complexity.

  • Maintenance: Oil system requires regular cleaning and filter replacement.

  • Combustion tuning: Different flame characteristics between fuels demand precise calibration.

  • Safety: Additional sensors and interlocks are necessary for smooth switching.

6. Applications

  • Industrial steam and hot-water boilers

  • Process heating in food, textile, and petrochemical industries

  • Power generation backup systems

  • Energy plants in regions with unstable gas supply

7. Conclusion

Dual-fuel burners represent the next step in energy flexibility.

They allow industries to adapt instantly to fuel price changes, supply interruptions, or environmental restrictions, without sacrificing efficiency or safety.

At InnoBurn, our dual-fuel systems are engineered with precise control, high combustion stability, and robust mechanical construction — ensuring continuous performance and maximum operational independence.