Riello RS120 Gas Burner Upgrade for a 4 t/h Food Processing Steam Boiler

One of our food processing customers needed to upgrade the combustion system of a 4 t/h gas-fired steam boiler used for soybean product cooking and sterilization.

The existing burner had become unstable after long-term operation, causing fluctuations in steam pressure and affecting temperature stability during sterilization. Aging gas valve components were also leading to more frequent ignition and flame-out faults, increasing maintenance requirements.

In addition, the customer needed the boiler to support continuous 24-hour production while meeting the applicable local NOx emission requirements.

After reviewing the boiler capacity and operating conditions, we selected a Riello RS120 gas burner for the upgrade. The burner was configured with a Dungs MB-DLE 415/1 gas valve train, Siemens LME burner controller, and flame detection components to form a complete combustion control system.

The Riello RS120 provided modulating control, allowing burner output to adjust according to changes in boiler load. The Dungs gas valve train provided gas shut-off and valve leak-checking protection, while the Siemens controller handled ignition sequencing, flame monitoring, and safety interlocks.

During on-site commissioning, we adjusted the air-fuel ratio according to the boiler's actual operating conditions and optimized the combustion settings to meet the customer's low-NOx requirements.

After commissioning, the boiler maintained more stable steam pressure, helping the cooking and sterilization processes operate with more consistent temperatures. According to the project record, ignition success was close to 100%, while flame-out faults were significantly reduced and routine maintenance requirements decreased.

Following air-fuel ratio optimization, gas consumption was approximately 8–12% lower than with the previous burner system. The upgraded system also met the applicable local NOx emission limit and passed the required environmental inspection.

The upgraded industrial gas burner system now provides the stable steam output required for the customer's continuous food processing operation, with improved ignition reliability and reduced maintenance frequency.