Modernising Burner Controls for Efficiency and Reliability in the Fertiliser Industry

A client in the fertiliser industry reached out to JBC to address performance and reliability issues with their direct fired rotary dryer. The system was running on outdated burner technology and controls that made it increasingly difficult to manage temperature stability and fault diagnostics. As a key part of their production line, any inefficiencies in the dryer’s performance were directly impacting operating costs and product consistency. The client was looking for a long-term solution that would not only replace obsolete components but also improve energy efficiency, reduce downtime, and support consistent product quality.

After an on-site assessment, our engineering team proposed a targeted upgrade that would modernise the system without requiring a complete overhaul. We replaced two ageing Maxon burners with high-performance Rapid Flame burners, offering improved flame stability and responsiveness. To complement this, we integrated Siemens LMV51 burner management controls, a reliable solution that supports precise diagnostics and simplifies fault-finding. We also enhanced the burner ratio control and upgraded the temperature control system, helping to create a more consistent and efficient drying process overall.

The impact of the upgrade was immediate. Gas consumption was significantly reduced, contributing to lower operational costs and better energy performance. Warm-up times were faster, and with improved diagnostics and control, unplanned downtime was minimised. Most importantly, the temperature stability of the dryer improved noticeably, leading to better product consistency, a key requirement in the fertiliser industry.

This project is a great example of how updating legacy systems with modern burner and control technology can drive long-term operational benefits. By focusing on practical engineering and reliable solutions, JBC helped the client achieve greater efficiency, lower costs, and enhanced process control without the need for a full system replacement.