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Can effective combustion control reduce emissions by 10% each year?

April 23, 20192:41 pm
At Energy Technology & Control we’re confident that effective combustion control can reduce emissions by up to 10% each year, saving industrial burner operators thousands in energy costs. Our combustion control specialists explain how… The facts Typically, combustion of 1m3 of Natural gas in an industrial boiler produces 2.03kg of C02, and 1 kWh of electricity generated in a gas fired power station produces 0.420kg of C02. It is not unusual for an industrial burner/boiler to use in excess of 130,000 pounds of fuel per annum, directly emitting up to 15,700 tonnes of C02. If we add to that figure, the electricity used to power the burner fan, then the total C02 emissions caused by a single burner of this size can exceed 15,750 tonnes per annum. From an environmental perspective it obviously makes sense to aim for a reduction in CO2 emissions, there is however also a business case for this as reduced CO2 is usually a result of improved efficiency and fuel consumption. The solution Electronic controllers ETC’s electronic combustion controllers are usually customised for each burner manufacturer. This ensures that the unique design features of each burner are fully realised. Integration of burner and boiler control into a small electronic controller removes the need for large cabinets or housing; this lowers capital cost and in turn improves space utilisation. When using an electronic controller, the low fire point can be set lower than the ignition point meaning that the turn-down ratio can be increased and burner on/off cycles and their associated cold air purges reduced. Savings of 5% have been reported on a burner that prior to conversion had an on/off frequency of approximately once every 10 minutes. If a plant does not run continuously then a second modulation control setpoint can be used to switch the boiler to a lower steam pressure or hot water temperature during periods of reduced activity. Oxygen trim When oxygen trim is employed oxygen levels can be trimmed to their optimum level. This process automatically and continuously compensates for the variables that affect efficient combustion. An adaptive trim system will contribute energy savings of approximately 3% per annum. Air dampers Unfortunately air dampers can leak and even when fully closed the air flow can be significant. However combustion efficiency can be improved at low fire if the fan speed is reduced. By simply adding fan speed control, burner turn-down can be…

Celebrating 30 years of worldwide success

February 7, 20192:49 pm
Energy Technology & Control has been a global leader in the design and development of combustion controls and burner control technology for an impressive 30 years. To mark the occasion, ETC has created an infographic outlining some of the most notable dates in the company’s history. It is fitting that the first date of interest should be the date of the management buyout in 1988. The next decade was a busy one as ETC started to build its reputation and gain traction in the electronic burner controls market, firstly securing European approval for the ETC3000 electronic air fuel ratio controller, before launching it in the UK market a year later. In 1998 the ETC3000 electronic air fuel ratio controller received USA, UL and FM approval allowing ETC to enter the US market represented by Fireye Inc. In the same year the company were thrilled to receive the highest official UK award for British business – the Queen’s Award for Environmental Achievement – for the combined combustion of base and waste fuels offered by the ETC3900 burner control. The 90s ended on a high with approval received for ETC’s first fully integrated burner control system, the ETC1200, in 1999. The millennium saw ETC set its sights on the world stage; in 2000 the ETC3000 burner control received Australian AGA approval, allowing ETC to market its products on the other side of the world. In 2006 the ETC6000 burner management system was launched – quickly receiving European approval – and leading to ETC’s first project with HP-Consulting in Germany in the following year. In 2008 the ETC6000 series burner management system received UL, FM and AGA approval. This led to partnerships being established with; Italian company General Bruciatori in 2008, Spanish company E&M Combustion and Czech company PBS Power Equipment in 2009, the following year ETC agreed partnerships with Hamworthy Combustion in France and Gastech-Energi in Denmark, finishing 2010 in a strong position with its burner controls and burner management systems being fitted throughout Europe and beyond. In 2011 ETC strengthened its position in Italy securing a second partnership with Italian OEM Bono Energia. The company also added two new models – the ETC6008 and ETC6009 – to the established ETC6000 series burner management system range of combustion controls. The ETC6008 & ETC6009 are designed to address applications where bio and waste fuels are being used. The year closed on a high…

Industrial burner controls

February 7, 20192:43 pm
How using electronic burner controls can significantly reduce costs Energy costs in many of the industries that employ process heating are considerable. Negotiating a good fuel and electricity price can help to keep energy costs under control. But is your burner controls set up working as hard as it should be? Our industrial burner control experts examine the money saving solutions available in the UK. Control is key Controls for industrial burners have changed significantly in recent years; mechanical cam fuel:air ratio control has been replaced by self-checking fuel:air ratio electronic control. Oxygen trim has been added with flue gas re-circulation working to reduce emissions. Performance has been improved by increasing turn down ratios through more flexible control strategies and fan speed control, as well as by improved matching of load and demand from embedded 3 term PID systems. Software options such as boiler lead/lag control can improve burner utilisation and communications software can greatly enhance information flow. Most of the improvements to industrial burner controls have been introduced in the last few years. These controls can be specified on new burners or retrofitted to existing plant. It is now possible to reduce energy costs to lower emissions and to obtain trending information for management decisions. Self-checking controls with automatic logging and dial-out can release boiler house manpower for other process applications. If you haven’t reviewed your industrial burner controls in the past five years, make 2019 the year that you take action. Mechanical cams and linkages – is your boiler really as efficient as you think? Consider a typical industrial boiler with mechanical cam control and let us assume that the burner has recently been serviced. At high fire, the oxygen level in the flue gas would have been set at a safe level – slightly above optimum – to allow for changes in conditions that affect combustion. When burning oil, viscosity, calorific value and filter condition will all cause variations in combustion and when firing on gas the supply pressure and calorific value of the gas will both cause variations in combustion. The burner engineer will make allowances for any backlash in the linkages associated with the cam and will set the cam to ensure that the oxygen cannot fall too low. After all, if the oxygen level in the flue gas is too low the risk of explosion is increased. In addition the risk of emissions containing…

ETC launches responsive new website

January 14, 20192:50 pm
Energy Technology & Control, a global leader in the design and development of combustion controls and technology, is proud to launch a sophisticated new responsive website. With more than 30 years’ experience designing and manufacturing innovative electronic burner controls for industrial applications that cut energy costs and emissions, Energy Technology & Control decided now was the time for its online presence to more closely match its technological prowess. Worldwide reputation The company – which prides itself on supporting British industry by ensuring all of its products are made in Britain – always strives to be at the forefront of research and development; it’s unique and sought after ability to label combustion control products with its clients own branding has allowed them to gain a worldwide reputation for delivering trusted products. The combustion control products produced by Energy Technology & Control form the cornerstone for its customers businesses, many of whom have confidently built their own reputation based upon this close and very productive working relationship. Responsive website The newly launched responsive website allows the company to strengthen its online presence and extend its reach into new markets and new countries. Managing Director Martin Thirsk said: “As a company, we pride ourselves on our solid customer relationships – tailoring products to meet our customers’ applications – and strong emphasis on R&D as such all of our burner control products are approved to international standards. “We are confident our new website will give us a solid foundation online with which to break into new markets and further extend our global reach, we are keen to forge links with new clients in new countries helping to support their industrial growth. We are also pleased to be able to consolidate our offering for our existing clients.” Contact the team to find out more about the company’s range of burner control products.

ETC Launches Range of EX Actuators

August 22, 20182:51 pm
Energy Technology & Control Ltd has expanded it’s range of servos to include EX actuators (servo motors), these are approved for hazardous area operation. They are variants of the ETC6023 and 6024 CANbus type, with 20Nm and 40Nm actuation force respectively. Compatibility They are marked as ETC6023-Ex and ETC6024-Ex and are compatible with all OEM variants of ETC6000 series controllers. Ex type marking – EX logo ll 3 G Ex nR llC T5 Gc Evaluated and certified by ExVeritas

New ETC6075 Hi Resolution Touchscreen Launched

August 21, 20183:09 pm
The ever popular ETC6075 Touchscreen HMI has been upgraded to an 800 x 600 pixel resolution display. Existing users will immediately notice the crispiness of the graphics and text as well as increased performance of the touch panel itself. Product facelift ETC has also taken the opportunity to give the product a facelift which includes a new boiler mimic graphic and a built-in help facility that allows the operator to call up relevant sections of the Operator’s Manual during normal operation and when commissioning the burner. The memory card slot previously used for firmware updates has now been replaced with a USB port and all ETC6075 displays will now be supplied Ethernet ready allowing local communications using customers’ own Ethernet networks or remotely using the built-in web server.