Thank you for your attendance of the presentation of Sunflame and

Thank you for your attendance of the presentation of Sunflame and its products. This page shows you our latest office and the factory.
Our contact number and web site are also shown here.
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We are located in Kyoto, an ancient capital of Japan, and our city, Uji City is famous in the production of green tea leaves.
This year we have celebrated 40 years of company operation since 1968.
We are rather small company of 65 people including factory staff, and annual turnover of about Thirty Million US$. in 2007.
We have only two core products, Oil burner for marine aux. boiler and incinerator using rotary cup burner.
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This indicates main principle and structure how oil receives centrifugal power at the cup inside and make thin oil film. On the right hand side there are three photos, the upper‐most shows you how water is fed to the cup inside and is given a centrifugal power, under low cup rotation to give you easier understanding. In the middle, oil is fed and thin oil film is formed, but no primary air is given yet. This also try to give you easier understanding how we make thin oil film.
The lowest one shows atomization of the oil, after making thin oil film using primary air from the cup circumference. Once putting fire to this, flame comes out. The size of oil mist is the most important for good atomization. Rotary cup burner can provide this fine oil mist for any grade of oil, very good low viscosity oil to the worst one such as sludge oil.
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For boiler burner, we have achieved direct driven rotary cup burner upto 22ton boiler. There are two important things such as high speed rotation of rotary cup and high pressure air for oil atomization.
For 1st generation burner, it is very difficult to secure these two things due to following structure.
Alfa laval and Saacke burner is 1st generation type
As you can see, the burner unit is rotating by motor with belt and also there is a big atomization fan in the shaft, which means too much stress goes to belt, fan and shaft at every burner start and stop.
Therefore if the balance of fan goes wrong, combustion become worse due to unstable atomization air.
Their fan is very huge so this imbalanced fan causes shaft and motor damaged with some vibration from fan.
Also if the tension of belt becomes loosen, rotary cup rotation speed changes and this leads to bad combustion.
As a result this burner needs more maintenance, adjustment and consumable parts.
SUNFLAME 3rd gen type (DIRECT DRIVE ROTARY CUP BURNER)
Our burner is direct drive type, motor and shaft are connected without belt.
Also there is no fan in the shaft and the load on the shaft is much lighter therefore cup rotation speed is stable.
Atomization fan is separately installed and this makes atomization air secured.
As a result, 3rd generation burner doesn’t need many maintenance and trouble 4
possibility is much lower.
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Rotary cup burner can handle MGO and HFO without modification and also no adjustment is required because of low oil pressure.
However Pressure jet burner, high oil press 20‐30 kg/hr, needs some adjustment such as oil pressure, oil volume and oil temperature.
For example when changing MGO from HFO, oil pressure drips and atomization changes worse and then it is necessary to adjust oil pressure, oil volume and oil temperature.
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There is no modification required for rotary cup burner to burn HFO and MGO. However for Pressure jet burner and Steam atomizing burner some modification are necessary.
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For Tanker use boiler plants, the boiler flue gas is used for IGS plants which require oxygen content max. 5%, meaning it is natural for engineers to pay attention to the O2 content.
However, for dry cargo ships, the crew tends to supply more air than it is needed to the furnace just to avoid black smoke. This results less effective combustion. Too much excess air means cooling down the furnace, and in other words it means bigger heat loss. Although, not many engineers pay attention to the O2 content for small boiler, we should study this for it brings benefits to the users.
As you see here, if the O2 content is high in the flue gas, it results bigger heat loss, increase of the NOx & SOx, and the deterioration of the combustion efficiency.
If the O2 content is too low, it results bad combustion such as black smoking and energy loss. Therefore, to select which area of the oxygen range and combustion efficiency in the graph should be important for better burner combustion. Such being the situation, we should aim the best combustion with good air ratio.
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According to our data, for pressure jet burners, the oxygen content in the flue gas could be around 7 to 10 %, say in average 8.5%, and with our rotary cup burner it is abt. 3 to 5%, say 4% in average. In the calculation formula, 10.5Nm3/kg is a theoretical air volume for combustion, 0.33 is a specific heat of boiler flue gas, difference of excess air ratio of two burner combustion cases, and flue gas outlet temperature minus fresh air inlet temp. are also influencing.
From these factors, we can obtain difference on the air/gas side calories by two different burners’ combustion, and divide it with the Low Calorific Value of the fuel oil, resulting 5.8% fuel saving by our rotary cup burner. 10
By applying this calculation to a boiler plant of 1.5t/h, if the boiler spends 2,000lit/day, runs 125 days a year, and if the MGO price is at US$850/ton, 5.8% fuel saving results saving US$12,325.‐/year.
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Sunflame has developed control system for two boiler operation intended to tanker, Afra
size to VLCC.
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Boiler water level fluctuation can be solved now by our new idea and device in our new control system.
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Conventional burner for tanker is steam atomized burner but rotary cup burner offer you many advantages.
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We mix oil and water and make emulsion fuel.
This is the photo of emulsion fuel. White dot is water particles in the fuel.
Once this fuel goes into boiler furnace, micro explosion happens.
Combustion of emulsion fuel is better than normal HFO combustion and then excess air can be reduced much more due to much better combustion.
Not only fuel saving, these factor can be reduced thanks to emulsion combustion.
This value changes depends of boiler type and working conditions.
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One chemical tanker installs 1 set of 15 t/h aux. boiler and has spent abt 1,500 tons of fuel in a year acc to one of user.
Price of large type ECS, ECS‐1500, is 5,500,000 JPY (abt 55,000USD) If saving rate of 7.4% is applied to this case, 111t fuel can be saved per year.
And price of this amount oil is 600$/t x 100JPY/$ ＝ 6,660,000JPY (66,600USD)
Return of Investment can be less than 1 year.
Sunflame rotary cup burner price is not included in this calculation
Now 30 vessels are running with this system and another 20 vessels will deliver with this system.
Please consider our fuel saving system with this ECS.
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Today this is our first time ever to present our new rotary cup burner.
There is a movement that the bunker slightly tend to change gas from oil because of regulation, environmental friendly and price of gas as the gas has been discovered all over the world.
Some vessels are presently running with gas bunker, it’s very eco friendly. In order to meet the trend of marine industry, we have developed dual fuel rotary cup burner.
Fuel oil burring case, oil comes out of rotary cup burner and atomized by centrifugal power and atomizing air.
Gas burring case, the gas comes out of nozzle header, and air is atomized inside and outside of gas header therefore gas and air is nicely mixed and combustion is very nice.
We achieved, Low NOx and O2, the flame is adjustable, one burner can handle HFO 700cSt,MGO 1.5cSt & GAS, Gas fuel is economical as you know.
Ofcouse there’re many thing we need to discus such as infrastructure, bunker tank and safety system etc. but probably this would be one of tendency we are heading.
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The most important point is that thanks for the rotary cup burner we can burn waste oil itself without help from diesel oil combustion, and user can save DO consumption very much. Although our initial cost is higher due to adoption of rotary cup burner, we can offer you much lower running cost by eliminating DO consumption while burning sludge oil. This is a message to the owner/user, not much for the ship buildiers.
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Difference of rotary burner & pressure jet burner in the marine boiler use, can be summarized in these points. You can read one by one from the Pressure jet burner point, then to Rotary cup burner. Each item is in comparison with each other. 19
One of big advantage is diesel oil consumption. Sunflame rotary cup burner can burn sludge itself without using diesel oil burner. However other maker’s incinerator using pressure jet burner needs diesel oil assist burner for sludge burning.
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In 2013 Marpol regulation was revised to control garbage disposal into the sea.
This garbage feeder makes it possible to burn the garbage while incinerator operation. Ship staff are not exposed to the flame from the furnace.
You can burn more garbage by incinerator.
Another good thing is even shipstaff can easily replace the door with garbage feeder at the same position of existing door.
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Refractory falling down.
This is one of typical trouble of incinerator,all the incinerator, not only sunflame but also other makers. This trouble happens because Less maintenance, Heaviness of material itself, Poor repair work and Low quality material.
The process of refractory falling apart are 1st stage, accumulation of incombustible material and secondly starting of corrosion, finally refractory falls down and worst case the casing gets damaged.
This is big headache to the user because the repair cost is too much and it is tough job to the crews.
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This is the material we have developed recently.
Actually this ceramic material was used for garbage feeder first, and then we have reflected this idea on this ceramic board.
Less crack expansion and easy replacement, just bolts and nuts.
This board can be applied for new building and existing vessels as optional.
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We have world‐wide service net work, working with service partners at these major ports in the world. So far no written agreement is made yet with this service partner, we cannot ask customer to contact them directly yet. Therefore for the time being, please contact us for any help. 24