NOx emissions are a direct result of combustion processes, and controlling these emissions starts with optimising burner design. Burners that operate at high temperatures, especially in industries like steel, cement, and petrochemicals, naturally produce nitrogen oxides (NOx)—gases such as nitric oxide (NO) and nitrogen dioxide (NO2)—as by-products of burning fuels in air. These pollutants contribute significantly to smog, respiratory issues, and environmental degradation. To meet stricter environmental standards set by regulations like the Industrial Emissions Directive (IED) in Europe and the Clean Air Act in the U.S., industries need advanced combustion technologies to limit NOx without compromising production efficiency.
ETC’s burner control systems offer the flexibility required to meet these challenges. Our controls are designed to optimise combustion across a variety of fuels and allow for precise management of air dampers and flue gas recirculation (FGR) dampers. FGR, a proven method for reducing NOx, works by recirculating a portion of the exhaust gases back into the combustion chamber, effectively lowering the flame temperature and thus reducing NOx formation. With ETC controls, burners can be easily augmented for FGR, adapting to the specific needs of each process.
Our technology provides a tailored approach to combustion management, offering industries the ability to maintain necessary high temperatures while mitigating NOx emissions. By integrating advanced control over air and fuel ratios, as well as leveraging FGR, ETC ensures that industries can comply with tightening emissions standards, avoid regulatory penalties, and continue their operations without compromising on efficiency or safety.
In a world where emissions regulations are only getting tougher, the ability to control and optimise combustion has become critical. ETC’s burner control systems offer the necessary tools to meet both environmental and operational demands.
Understanding the importance of NOx emission reduction
NOx gases, primarily nitric oxide (NO) and nitrogen dioxide (NO2), are by-products of combustion processes involving air at high temperatures. These gases contribute to the formation of ground-level ozone and particulate matter, which can lead to respiratory problems, smog, and even damage to ecosystems. Given the severe environmental and health implications, governments around the world are tightening NOx emissions standards.
In Europe, for instance, the Industrial Emissions Directive (IED) sets out clear guidelines for reducing industrial emissions, including NOx. Similarly, in the United States, the Environmental Protection Agency (EPA) mandates strict emissions limits under the Clean Air Act. Non-compliance can result in hefty fines, damage to a company’s reputation, and operational shutdowns, making it imperative for industries to adopt cleaner technologies.
However, the challenge lies in balancing the reduction of emissions with maintaining the high-temperature processes required for production, especially in energy-intensive sectors like steel, cement, and petrochemicals. Many of these processes demand temperatures above 1,300°C, where the formation of NOx becomes almost inevitable. As a result, the need for innovative combustion control technologies has never been greater.
How ETC’s accurate combustion technologies help
At ETC, we specialise in providing advanced control systems to help industries meet these regulatory demands without sacrificing efficiency or profitability. Our solutions enable businesses to control their combustion processes in real-time, minimising the formation of NOx while optimising operational performance.
Without ETC Controls there is No ‘Ox’ for the NOx
Here are two key technologies we offer:
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ETC Electronic Burner Controls
Our 6000 Series of Electronic Burner Controls are designed to provide precise management of the fuel-to-air ratio in industrial burners. One of the primary causes of excessive NOx formation is the occurrence of high-temperature combustion peaks. These peaks often result from inefficient fuel and air mixtures, where too much fuel or insufficient air leads to incomplete combustion at higher temperatures, encouraging NOx formation.
ETC’s Electronic Burner Controls address this issue by ensuring that the air-to-fuel ratio is consistently optimised. This dynamic adjustment of the fuel and air mix not only prevents temperature spikes but also improves the overall efficiency of the combustion process. By keeping combustion temperatures in check, manufacturers can significantly reduce NOx emissions while maximising the fuel economy of their operations.
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Oxygen Trim Systems
While controlling the fuel-to-air ratio is essential, maintaining real-time efficiency throughout varying operational conditions is equally critical. Our Oxygen Trim Systems are designed to make real-time adjustments to the combustion process by continuously monitoring the oxygen levels in the flue gas. These systems adjust the air-to-fuel ratio based on the current operating conditions, ensuring that combustion remains efficient without introducing excess oxygen.
Why is this important? Excess oxygen can contribute to higher NOx emissions. By keeping oxygen levels within a specified range, our Oxygen Trim Systems help avoid this issue while maintaining the efficiency and stability of the combustion process. This technology becomes particularly valuable in industries where fuel composition, load demands, or external conditions fluctuate regularly.
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The Benefits of Retrofitting Existing Systems
For many industrial operators, replacing entire combustion systems with new low-NOx technologies can be prohibitively expensive. This is where retrofitting comes in. Retrofitting existing burner systems with ETC’s Electronic Burner Controls and Oxygen Trim Systems offers a cost-effective solution that allows manufacturers to meet regulatory requirements without undergoing major capital investment.
By upgrading existing infrastructure with advanced burner management technologies, companies can strike a balance between achieving emissions compliance and maintaining profitability. Retrofitting not only extends the lifespan of existing equipment but also improves operational efficiency, reduces energy costs, and minimises the risk of regulatory penalties.
In addition, retrofitting supports long-term sustainability goals, enabling companies to reduce their environmental footprint without interrupting their production cycles. As industries continue to face increasing scrutiny over their environmental impact, adopting technologies that align with both compliance and sustainability objectives is crucial for long-term success.
Why choose ETC?
At ETC, we understand the unique challenges faced by industries like steel, cement, and petrochemicals. Our solutions are designed to provide tailored, effective pathways for reducing NOx emissions while improving operational efficiency. Whether you are looking to retrofit your existing systems or explore new combustion control technologies, ETC offers a range of products that help businesses achieve compliance without sacrificing performance.
Want to learn more? Our cutting-edge burner management systems are specifically developed to meet the evolving needs of modern industry.
Reach out to us today to find out how our low-NOx combustion technologies can benefit your business.