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Fuel Types (Including Dense & Residual Fuels)

1. Introduction

The choice of fuel is one of the most decisive factors in combustion system design.

Each fuel type — gaseous, liquid, dense, or renewable — has unique chemical, physical, and environmental characteristics that directly influence burner efficiency, maintenance frequency, and emission levels.

At InnoBurn, we analyze the combustion behavior of every fuel type and design burners capable of operating safely and efficiently under a wide range of conditions.

2. Main Fuel Categories

a) Natural Gas

  • The most common and cleanest industrial fuel.

  • Delivers stable combustion, high controllability, and low CO₂ and NOₓ emissions.

  • Ideal for premix and postmix burner systems with precise air–fuel control.

b) LPG (Liquefied Petroleum Gas – Propane/Butane mixture)

  • High calorific value, suitable for small and medium industrial systems.

  • Portable and easy to store, but requires very accurate air–fuel ratio adjustment.

  • Commonly used where natural gas is unavailable.

c) Fuel Oil & Heavy Fuel Oil

  • Widely used in large boilers, dryers, and process heating.

  • Requires pre-heating to 80–120 °C for proper atomization.

  • Can be supplied through low-pressure (5–8 bar) or high-pressure (25 bar) pumping systems.

  • Atomization is performed via steam or compressed air to ensure complete combustion.

  • Regular filtration and viscosity control are essential for long equipment life 

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d) Animal Fat Fuels

  • Derived from meat, fish, poultry, or rendering industries.

  • Require feed-line temperatures above 50 °C for proper flow.

  • Some types are acidic or corrosive; therefore, stainless-steel components are recommended 

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e) Vegetable Oil Fuels

  • Produced from palm, rapeseed, sugar-cane molasses, or recycled cooking oils.

  • Renewable but viscous — pre-heating and filtration are mandatory.

  • Suitable for plants aiming at partial substitution of fossil fuels.

f) Waste Oil Fuels

  • Recovered from food processing, automotive, or chemical industries.

  • Require temperatures of 60–80 °C and high-efficiency filtration.

  • Provide an eco-friendly and cost-effective energy-recovery option 

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g) Alcohol and Methanol Derivatives

  • By-products from breweries, wineries, and chemical plants.

  • Highly volatile and low-viscosity fuels.

  • Require compressed-air atomization (steam or air) for stable combustion 

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h) Dense and Residual Oils

  • Extremely viscous and energy-dense fuels derived from refining residues.

  • Need continuous heating, often above 120 °C, and a viscosity-control loop.

  • Burner designs for these fuels include steam-jacketed pumps, heated nozzles, and recirculation lines.

  • Offer excellent energy yield but demand precise maintenance and filtration.

i) Biogas and Hydrogen

  • Renewable, low-carbon alternatives for sustainable energy.

  • Require advanced air–fuel control and modulation systems.

  • Hydrogen combustion produces only water vapor — no CO₂ — but needs materials resistant to high flame speeds and temperatures.

3. Fuel Selection Criteria

When determining the appropriate fuel for a combustion system, consider:

  • Energy cost and availability

  • Emission regulations and local standards

  • Process heat requirements

  • Burner type and control strategy

  • Maintenance and filtration infrastructure

4. Fuel–Burner Compatibility

Each fuel type requires a specific burner design and operating strategy:

  • Heavy fuels → steam pre-heating and atomization

  • Light oils and alcohols → air atomization

  • Waste oils and animal fats → filtration and stainless components

  • Biogas and hydrogen → adaptive modulation and oxygen sensors

Proper matching ensures high thermal efficiency, low emissions, and safe operation.

5. Conclusion

Energy diversity is essential for modern industry.

Understanding each fuel’s characteristics allows engineers to optimize performance, reduce operational costs, and minimize environmental impact.

At InnoBurn, our mission is to deliver versatile burner systems that operate efficiently with all fuel categories — from natural gas to dense oils — achieving maximum efficiency and minimal emissions.