Inspection and Adjustment of Combustion in Boilers Abstract The combustion of fuel is routinely used as a source of heat energy.

This energy is utilized in the incineration of materials, the production of steam, etc. In this case study, exhaust gas from a boiler was analyzed and excess oxygen levels were found, indicating unnecessary energy consumption [1]. Efficient combustion conserves natural resources, reduces manufacturing costs, as well as minimizes emissions. Oxygen trim systems that automatically adjust the combustion to changing conditions provide the best performance. However, the expense of a trim system on each boiler in a plant may not be justified [1]. Therefore, a portable flue gas analyzer is used in a rigorous program of weekly boiler inspections and adjustments [1]. For combustion in a 300 Hp natural gas fired boiler, at a stack temperature of 400 F, reducing excess O2 levels from 6.2% to the optimum 2.0% can realize a fuel savings of 3% which translates into a cost savings of $732/yr. For combustion in an oil fired boiler, at the same stack temperature, reducing excess O2 levels from 8.5% to the optimum 3.7% can realize a fuel savings of nearly 4% and a cost savings of $426/yr [1]. With the use of a portable flue gas analyzer, these savings can be realized with a minimum investment. Process Description Stoichiometric Combustion is the ideal combustion process during which a fuel is burned completely. If there are unburned components in the exhaust gas the combustion process is not completed. The stoichiometric air to fuel ratio is the mixing proportion of fuel and air, that when burned, all of the fuel is consumed without excess air left over. Process heating equipment is rarely run that way. If an insufficient amount of air is supplied to the burner, unburned fuel, and carbon monoxide exhaust from the boiler results in lower combustion efficiency. To avoid this, boilers are normally operated at excess air levels. Even "on-ratio" combustion used in boilers incorporates excess air of about 10 to 20% beyond what is needed to insure complete combustion. Some level of combustibles will always appear in the flue gas even when the boiler is operated with excess air. This is due to poor mixing of fuel and air at the burner or other burner conditions. Combustion detectors are used to measure NOx, CO, and O2 in flue gases. This measurement allows the boiler to be tuned so that it maintains high combustion efficiency. Since combustibles decrease and flue gas heat loss increase with an increase in excess air, total combustion efficiency is maximized only when the amount of excess air supplied minimizes the sum of the unburned fuel loss and the flue gas heat loss.

Portable combustion analyzers range in price from about $1000 for a simple analyzer with an O sensor to roughly $20,000 for sophisticated units with NOx, CO, 2 SO2, VOC, and O2 sensors [2]. Combustion efficiency testing and boiler tune-up is often the most practical way to maximize boiler efficiency. Before costly capital improvements are undertaken, combustion efficiency should be maximized. Combustion efficiency can be maximized by simultaneously measuring oxygen and combustible levels in flue gases. The annual fuel cost savings due to combustion efficiency testing can be substantial and easily exceed the cost of testing. For combustion in a 300 Hp natural gas fired boiler, at a stack temperature of 400 F, reducing excess O2 levels from 6.2% to the optimum 2.0% can realize a fuel savings of 3% which translates into a cost savings of $732/yr. For combustion in an oil fired boiler, at the same stack temperature, reducing excess O2 levels from 8.5% to the optimum 3.7% can realize a fuel savings of nearly 4% and a cost savings of $426/yr. With the use of a portable flue gas analyzer, these savings can be realized with a minimum investment. Combustion Analyzer Products AMETEK/Thermox Nova Analytical Systems Inc. Literature Cited 1. Guide to Industrial Assessments for Pollution Prevention and Energy Efficiency, EPA/625/R-99/003, pp. E3-E4 (June 2001). 2. New Mexico Environment Department, Monitoring Protocol Gas-Fired Heaters, Furnaces and Boilers at New Mexico Title V Sources, http://www.nmenv.state.nm.us/aqb/forms/Gas-Fired-Heaters-Furnaces-Boilers5.31.2002.pdf (May 2002). http://www.thermox.com http://www.nova-gas.com

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