Direct Fired Air Heaters

Direct Hot Air Boiler Advantages;

• The initial installation cost is much less than other industrial heating systems,
• With activation, heating is provided within 10-15 seconds and there is no waiting time,
• Since no liquid is used as a heat conductor, there is no danger of purification, waste liquid, freezing and leakage,
• Designed in a horizontal or vertical position, it is suitable for almost any position.
• It requires very little maintenance, minimum inspection and service. Since it does not work with water, there is no rusting and corrosion problem,
• Pressureless and closed circuit operation - lossless system
• Front boiler cover at touch temperature.
• Allows heat input up to 20:1 with modulating regulation.
• It can operate upstream or downstream of the process air blower under positive or negative pressure.
• Generous combustion chamber suitable for working with heavy oils.
• Custom design according to customer requirements.
• Many years of experience in industrial/commercial boiler technology
• H2 ready
• Low maintenance and service costs
• Easy user interface with Tsb Energy control system.
• Flow monitoring systems integrated into the heater design and included in all our devices ensure smooth and reliable operation.
• High process reliability, remote control is available.
• Optionally, to further increase the operating efficiency without affecting emissions, the combustion air is heated by the exhaust gas using a recovery unit (recuperator).
• Low NOx emissions are available.
• CO2 emissions are reduced by burning up to 100 per cent hydrogen.
• Customer-specific software revision specific to your company with our expert staff.
• The boiler can be optionally equipped with a PLC with different communication protocols such as Modbus, Profibus, etc. and thus boiler integration into any industrial process can be provided.

Our HGP Direct Hot Air Boilers are supplied with a fully compatible burner for gas or oil firing and an optional recuperator for very high efficiency operation. The drive fan assisted system works in conjunction with the modulating burner to provide full proportional control of the process air outlet temperature.

Compared to conventional indirect heating methods, our HGP devices simplify and reduce the total cost of installation and operation of the plant. Especially when planning new installations, the reduced space demand and ease of operation greatly reduces overhead costs and normal operational maintenance demand.

Direct Hot Air Boiler Working Principle;

Our direct hot air boilers, which are designed in a horizontal or vertical construction, take the heat load on the combustion chamber by passing the turbulent air coming from the air supply fan through the air breaker and air diverters on the combustion chamber without creating a stationary area. Afterwards, these heated gases are combined with flame-smoke gases at the combustion chamber outlet and delivered to the process as direct-hot air.

Different gases can be utilised to meet specific process heating requirements, making our direct hot air boilers a very flexible system.

The fresh air blower is specifically dimensioned to the flow rate and back pressure requirements of each application, maintaining a safe film temperature on the surfaces. The burner modulation and the fresh air fan drive are controlled by PID control according to the process requirement. Thus, the required heat input is provided proportionally.

Design:  Direct hot air boilers are designed and manufactured in accordance with AD 2000, Loyd's Rules, TRD, DIN, EN and ASME Section VIII Div 1 in a horizontal or vertical construction where flame-smoke gases and air are in contact. All electrical components are UL labelled and wired in accordance with applicable National Electrical Code requirements.

The boiler is delivered ready for operation as a compact unit on a single chassis. All that is required is to connect the direct hot air generator to the electricity supply and to the devices that use hot air.

The HGP is fitted with inspection and cleaning covers, condensate drains and water resistant gaskets where required by the process and no dead spots are left on the appliance to obstruct the air flow to reduce the risk of particle accumulation on the heating surface.

TSB ENERGY Hot air boiler is designed for you to earn while using, not buying.

Ease of Use and Maintenance: It is easily maintained due to its simple structure and lack of control equipment.
Since clean air or gases are used as heat transfer medium, users do not encounter known problems such as pressure, scale formation, corrosion, freezing and explosion risk.

User-friendly controls and easy access to components simplify operation and maintenance, minimising downtime and operating costs. Thanks to a control panel with one-button start-up, self-checking of the device to stop the system against possible faults, and summary maintenance instructions with warnings according to the duration of use, boiler operation has become very reliable and understandable for the boiler operator.

All security devices are monitored by PLC. Necessary safety measures are taken in case of alarm. Boiler control is carried out by the boiler operator via HMI. Active alarms and past alarms are monitored via the same HMI. Alarm and running information is transmitted to other systems via digital contacts (dry contact). Remote data collection and boiler status information are available via ModBus, Modbus TCP/IP and Profinet protocols.

Safety: Safety and standards are our top priority. Our boilers are equipped with advanced safety features, such as air flow-proofing, outlet temperature protection, surface safety temperature monitoring and emergency boiler shutdown mechanisms.

Since other heating systems are pressurised vessels, they require extreme safety systems, failures that may occur in these systems are dangerous and can cause major damage. Since direct type hot air boilers are non-pressurised, there is no such destruction.

Material: The envelopes and covers of our indirect hot air boilers are made of P355GH boiler sheet in accordance with EN 10028-2 or AISI304 quality stainless steel sheet in accordance with EN 10028-8, and the ashtray is made of AISI310S and AISI253 stainless high temperature sheet.

Efficiency: It produces hot air within 10-15 seconds as soon as it is switched on, and when the system stops, it stops heating, so there are no storage and preheating as in boilers, there are no waiting losses, there are no unnecessary heat losses.

With the studies of our R&D department, the air baffles placed on the combustion chamber of direct type hot air boilers have been redesigned with the support of analysis programmes and the velocities of the air on the combustion chamber in full turbulent flow have been increased. Thus, combustion chamber film temperatures and air back pressure have been reduced. In this way, both electrical energy is saved by using electric motors with lower power (KW) compared to standard boilers, and fuel is saved by producing less NOx gas and high boiler efficiency is achieved.

There are three rows of insulation system on the front door of our direct type hot air boilers. The first row is Hycast SS alumina doped fired concrete which traps the high heat in the inner wall, then ceramic fibre blanket prevents the heat load coming from the concrete from passing to the boiler door, and finally ceramic paper is adhered to the door to keep the door at touch temperature.

100mm thick high density outer wall insulation provides low heat loss from radiation. The thermal insulation is covered with galvanised and painted DKP sheet with low lambda value. All insulation has low conductivity and high density materials.

During chlorine production and similar chemical processes, most of the hydrogen gas is released into the atmosphere without being used. This waste and difficult to store hydrogen can be used in our boilers by using suitable burners.

Environmentally Friendly Design: Our aim is a cleaner environment and for this we try to minimise emissions, In a clean combustion, NOx emissions in our gas-fired boilers: 70 mg/Nm3 in our gas fired boilers and 150 mg/Nm3 in our liquid fuelled boilers.

All of our TSB ENERGY industrial liquid-gas fuelled products can operate with 100% hydrogen by equipping them with a suitable burner that can operate with 100% hydrogen. Since the boiler structure and working principle are designed according to high-speed flame-smoke gases, NOx level remains far below the standards even in hydrogen fuel. At the same time, CO2 emissions are significantly reduced.

Customisation: We know that every manufacturing and process is unique to each business, and we customise our proven equipment based on hundreds of examples and analysis of your process to make it the most suitable and ideal for you. Designing and manufacturing our Svı-Gas fired boilers and more importantly providing the engineering support and personnel required for a successful installation requires exceptional expertise. You will not only buy a boiler from us, but also years of experience and know-how.

If you have any further questions, please do not hesitate to request an individual expert consultation.

Our customers are offered the following extensions for each boiler:

• Automation and control technology
• Fresh air fan
• Safety temperature sensors and flow sensors,
• Air ducts
• Very high efficiency.
• Simple and easy maintenance
• Dual and mixed fuel ignition options

What is Direct Hot Air Boiler?

Direct type hot air boilers are called closed unpressurised vessels in which the combustion chamber is cooled by the turbulent air coming from the air supply fan and the flame-smoke gases in the combustion chamber, which is specially designed according to the flame length and heat load, designed in diameter and length to absorb high temperature, are mixed with this air.

When to Use Direct Hot Air Boiler?

The TSB ENERGY direct hot air boiler - generator is suitable for the most demanding industrial environments, including heavy industry and dusty areas where long life and ease of use are essential.

Since hot air boilers are designed based on the principle of economical and fast movement of air, and the hot air outlet temperature can be kept clearly within the desired range with the automated control of the fan and burner, it provides economical and high quality production in industrial drying processes.

• In chemical plants and refineries,
• Drying of table salt and similar foodstuffs
• Drying of bricks, briquettes, tiles and similar building elements
• Drying of ceramic products
• Drying of mine ore, fire soil and similar granular materials
• In the manufacture of insulation materials
• In artificial fertiliser production
• Drying of timber, paper and similar products
• Drying of soft products such as wool, cotton
• Drying of powder detergent and similar powder or granular chemical products
• Drying of dyed products

Drying of grain, wood dust, gum arabic and coal dust