HTS Hauck – MegaStar MS Multi-Fuel Burner

Overview

The Hauck MegaStar® MS is a packaged, high-efficiency multi-fuel burner engineered for aggregate drying and asphalt plant rotary drum applications. Designed to be easy to light, reliable, and efficient, the MegaStar supports a wide variety of liquid and gaseous fuels—including natural gas, propane, light and heavy fuel oils, and waste/recycled oil—providing operational flexibility for optimizing fuel costs.

Available in six nominal sizes ranging from 25 to 150 million Btu/hr (7,327 to 43,960 kW), the MegaStar employs variable frequency drive (VFD) technology for precise air flow control across its entire operating range. Combined with real-time fuel flow measurement, this delivers maximum combustion efficiency and measurable energy savings. The burner package is compact, easy to install, and designed for minimal maintenance. Custom lengths are available for warm-mix applications, and the unit is designed for use up to 1,500°F (815°C) process temperatures.

Features & Benefits

• Multi-fuel capability – Supports natural gas, vaporous propane, liquid propane, light fuel oil (No. 2), heavy fuel oils (No. 4/5/6), and waste/recycled oil for maximum fuel flexibility and cost optimization.
• Variable frequency drive (VFD) air flow control – Provides precise combustion air management over the full operating range, reducing electricity consumption and lowering utility demand charges through reduced motor starting current.
• Low NOX, CO, and VOC emissions – Proven combustion technologies minimize emissions; all combustion is completed within the recommended combustion zone to eliminate flame quenching from process materials.
• Wide flame shaping range – Adjustable flame geometry allows the burner to be adapted to specific drum configurations and process requirements.
• Low pressure and high pressure atomization – Low pressure atomization for light fuel oil or LP; high pressure compressed air atomization available for heavy fuel oils or high-elevation installations.
• Standard and longnose versions available – Provides installation flexibility for various drum configurations, including warm-mix applications with custom lengths.
• Simplified maintenance design – Reduced moving parts and elimination of linkages make the burner easy to maintain and adjust in the field.
• High power factor and lower KVA – VFD technology delivers high electrical efficiency, reducing operating costs and utility demand charges.
• Hauck BCS7000 panel integration – Paired with the Hauck BCS7000 control panel for complete flame management, process control, and efficiency optimization.
• Ideal for sand drying applications – Burner design and flame control characteristics are well-suited for sand and aggregate drying in addition to asphalt production.

Technical Specifications

• Burner type: Total air, packaged rotary dryer burner
• Nominal sizes: MS-25, MS-50, MS-75, MS-100, MS-125, MS-150
• Capacity range (gas): Up to approximately 166 MMBTU/hr (45.2 MW), model dependent
• Capacity range (oil): Up to approximately 153 MMBTU/hr (41.5 MW), model dependent
• Process temperature rating: Up to 1,500°F (815°C)
• Main air flow: Up to approximately 1,960,000 SCFH, model dependent
• Main air pressure: Model dependent, up to approximately 18.5 in. w.c.
• Air flow control: Variable frequency drive (VFD)
• Supported fuels: Natural gas, vaporous propane, liquid propane (LP), light fuel oil (No. 2), heavy fuel oil (No. 4/5/6), waste/recycled oil
• Atomization methods: Low pressure (light oil/LP); high pressure compressed air (heavy oil/high elevation)
• Mounting type: Drum centerline, same pitch as drum
• Approvals: Designed for NFPA-compliant fuel trains
• Custom lengths: Available for warm-mix applications

Applications

• Asphalt plant rotary drum dryers
• Aggregate and sand drying
• Warm-mix asphalt production (custom length configurations)
• High-elevation installations requiring high pressure atomization
• Multi-fuel operations requiring flexibility between gas and liquid fuels
• Applications requiring reduced NOX, CO, and VOC emissions

Models / Configurations

• MS-25 – 25 million Btu/hr nominal capacity; base model for smaller rotary drum configurations
• MS-50 – 50 million Btu/hr nominal capacity
• MS-75 – 75 million Btu/hr nominal capacity
• MS-100 – 100 million Btu/hr nominal capacity
• MS-125 – 125 million Btu/hr nominal capacity
• MS-150 – 150 million Btu/hr nominal capacity; highest output model for large rotary drum installations
• Longnose version – Extended nose configuration available across the MS series for specific drum and warm-mix installation requirements
• Custom lengths – Available to meet warm-mix asphalt application requirements

MegaStar Accessories

• Hauck BCS7000 Control Panel – Dedicated burner management and process control panel providing complete flame management, process monitoring, and combustion efficiency optimization; recommended system pairing for the MegaStar.

Documentation