Combustion Control for Boilers

C lic k to e d it M a s te r s u b title s ty le

Contents
1. 2. 3. 4. 5.

Introduction Basic type of boilers. Why need boiler controls? Combustion control for boilers. Oxygen gas analyzer.

Introduction
How does a boiler works?

A boiler is a water containing vessel which transfers heat from a fuel source (oil, gas or coal) into steam which is piped to a point where it can be used to run production equipment, to sterilize, to provide heat, to

. Why need boiler controls?

Boiler efficiency relates the boilers energy output to the boilers energy input and can be expressed as:Boiler efficiency (%) = Heat exported by fluid/Heat provided by fuel
An accurate control of the amount of air is essential to the boiler

Why need boiler controls?

1. 2. 3. 4.

Increase uptime and availability Reduce flue gas emissions Maintain boiler safety Control operating costs

Why need boiler controls?

1.

Increase uptime and availability

The primary objective of most boilers operation is maintaining the uptime and availability. It is essential to maintain and upgrade the boiler control systems to assure steam availability. Modern controls are more reliable and can be readily adjusts to load swings caused by varying plant operations.

. Why need boiler controls?

2.

Reduce flue gas emissions

Failure to comply with the current emissions regulations can be as costly as loss of utilities. Government mandates are enforced by fines, threat of closure, or imprisonment will provide sufficient incentives for plants to comply with the regulations; thus, modernize controls are necessary. Improved in combustion efficiency

Why need boiler controls

3.

Maintain boiler safety

Modernize control system will have tight integration with flame safety or burner management system to improve safety. Accessing field data, diagnostics functions and alarms can be achieved by coupling modern electronic controls. Password security of the configuration software also assures no unintended changes can be done which can

Why need boiler controls?

4.
a) b)

Control operating costs

Reduction in fuel consumption Reduction in engineering, installation and startup costs Reduction maintenance costs associated with older equipment Reduction manpower with automatic responds

c)

d)

Principles of Combustion

Combustion: rapid oxidation of a fuel Complete combustion: total oxidation of fuel (adequate supply of oxygen needed) Air: 20.9% oxygen, 79% nitrogen and other Nitrogen: (a) reduces the combustion efficiency (b) forms NOx at high temperatures

Principles of Combustion

Control the 3 Ts to optimize combustion: 1T) Temperature 2T) Turbulence 3T) Time Water vapor is a by-product of burning fuel that contains hydrogen and this robs heat from the flue gases

Principle of Combustion

Principle of Combustion

Stochiometric calculation of air required

Stochiometric air needed for combustion of furnace oil Theoretical CO2 content in the flue gases Actual CO2 content and % excess air Constituents of flue gas with excess air Theoretical CO2 and O2 in dry flue gas by volume

Concept of Excess Air

Concept of Excess Air

Concept of Excess Air

Concept of Excess Air

Excess air (%)

Residual oxygen (%)

Combustion control for boilers.

Burner combustion control generally includes one or a combination of the following methods: Excess air regulation Oxygen trim Burner modulation Air/Fuel cross-limiting Total heat control

Combustion control for boilers.

1.

Excess air regulation In actual practice, gas , oil, coal burning and other systems do not do a a perfect job of mixing the fuel and air even under the best achievable conditions. Additionally, complete mixing may be a lengthy process. To ensure complete combustion and reduce heat loss, excess air has to be kept within suitable range. The regulation of excess air provides:-

Combustion control for boilers.

Excess air regulation

. Combustion control for boilers.

2.

Oxygen trim When a measurement of oxygen in the flue gas is available, the combustion control mechanism can be vastly improved (since the percentage of oxygen in flue is closely related to the amount of excess air) by adding an oxygen trim control module, allowing Tighter control of excess air to oxygen setpoint for better efficiency

Combustion control for boilers

Oxygen trim

Combustion control for boilers

3.

Burner modulation Modulating control is a basic improvement in controlling combustion. A continuous control signal is generated by a controller monitoring the steam or hot water line. Reductions in steam pressure or hot water temperature lead to an increase in firing rate. The advantages of introducing burner modulation in combustion control include.

Combustion control for boilers

4.

Air/Fuel cross-limiting A cross limiting combustion control strategy ensures that there can never be a dangerous ration of air and fuel within a combustion process. This is implemented by always raising the air flow before allowing the fuel flow to increase or by lowering the fuel flow before allowing the air flow to drop. Cross-limiting combustion control is highly effective and can easily provide

. Combustion control for boilers.

Air/Fuel cross-limiting

Oxygen gas analyzer.

Accurate O2 Measurement is Essential for Energy Saving!
The oxygen analyzer consists of a compact zirconia detector that can be inserted directly in wall of the flowing sample gas. The detector measures the oxygen content in the flowing sample gas and transmits the signal to the converter. The converter will then trigger the ON-OFF alarm based on the preset oxygen concentration and give control signal to other devices. In Boiler A,B & D on line oxygen monitoring

oxygen gas analyzer.

Excess air coefficient and energy loss ratio

Excess Air Coefficient 1.1 1.2 1.3 1.4 1.6

Exhaust Oxygen, O2 (%) 1.9 3.5 4.8 6.0 7.9

Energy Loss Ratio, Exhaust Gas (%) 9.4 10.3 11.1 12.0 13.7

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